Submerged arc furnace front robot control system

Abstract

The present invention discloses a robot control system for a submerged arc furnace, and relates to the technical field of data processing, including a data acquisition device, a control device, a robot unit, and a burner unit with a graphite electrode; the data acquisition device is used to obtain three-dimensional image data of the furnace eye contour of the submerged arc furnace, and obtain temperature data of the furnace eye and the graphite electrode; the three-dimensional image data and the temperature data are sent to the control device; the control device is used to determine a motion trajectory according to the three-dimensional model at each moment included in the three-dimensional image data and the temperature value at each moment included in the temperature data; generate a control instruction for the determined motion trajectory; send the control instruction to the robot unit; the robot unit is used to control the burner unit to perform a burn-through operation along the motion trajectory according to the control instruction. The solution provided by the embodiment of the present invention can realize an automated burn-through operation.

Description

Technical Field

[0001] The invention relates to the technical field of data processing, and in particular to a robot control system in front of an electric arc furnace. Background Art

[0002] The ore-fired furnace is a type of electric arc furnace. Its smelting products include ferrosilicon, silicon-manganese alloy, ferroalloy, yellow phosphorus, calcium carbide, corundum, etc. Its core smelting theory is: by ionizing the air to form a directional high-temperature ion flow-arc, the electrical energy is converted into thermal energy to provide a sufficiently high temperature field for the reduction reaction.

[0003] During the smelting process, as the smelting procedures are gradually carried out, the liquid level of the molten pool or slag surface of the furnace bottom product continues to rise. When the products in the furnace gather to a certain amount, it is necessary to open a hole parallel to the plane of the furnace bottom, that is, open the furnace eye, so that the products can flow out. After the products have flowed out, the opened hole is blocked with mud. Then repeat the next smelting process.

[0004] The furnace eye opening process requires a burner. The working principle of the burner is mainly based on the arc thermal energy effect to melt the mud ball in the furnace eye to open the eye. There is a graphite electrode at the front end of the burner. When the front end of the graphite electrode is close to the furnace eye, an arc will be formed. The high temperature of the arc melts the mud ball that seals the furnace eye, thereby opening the furnace eye. The traditional ore furnace burner is mainly operated manually. The manual eye burning process is that the operator holds the burner and aligns the graphite electrode head at the front end of the burner with the furnace eye, and constantly adjusts the up and down, left and right angles and the front and back positions of the burner. The high temperature arc generated by the graphite electrode head at the front end of the burner is used to melt the mud ball to open the eye. In actual operation, it is necessary to control the current and the distance between the graphite electrode and the furnace eye to ensure the burn-through effect. The operator mainly relies on his own experience to judge the discharge current of the burner and the position of the graphite electrode. Inexperienced operators have low efficiency in burning eyes and are prone to burning graphite electrodes. Summary of the invention

[0005] The present invention aims to solve one of the technical problems in the related art at least to a certain extent. To this end, one object of the present invention is to provide a robot control system for a submerged arc furnace to realize an automated burn-through operation.

[0006] An embodiment of the present invention provides a robot control system for a submerged arc furnace, the system comprising: a data acquisition device, a control device, a robot unit, and a burner unit with a graphite electrode;

[0007] The data acquisition device is used to obtain three-dimensional image data of the furnace eye contour of the ore furnace, and obtain temperature data of the furnace eye and the graphite electrode; and send the three-dimensional image data and the temperature data to the control device;

[0008] The control device is used to determine a motion trajectory according to the three-dimensional model at each moment included in the three-dimensional image data and the temperature value at each moment included in the temperature data; generate a control instruction for the determined motion trajectory; and send the control instruction to the robot unit;

[0009] The robot unit is used to control the burn-through unit to perform a burn-through operation along the motion trajectory according to the control instruction.

[0010] Optionally, the control device determines the motion trajectory according to the three-dimensional model at each moment included in the three-dimensional image data and the temperature value at each moment included in the temperature data, including:

[0011] Determine a starting point position based on the three-dimensional model at the first moment included in the three-dimensional image data and the temperature value at the first moment included in the temperature data, and generate a first motion trajectory according to the starting point position and the furnace eye position in the three-dimensional model at the first moment;

[0012] In a case where the motion trajectory is a first motion trajectory, the robot unit is used to control the burn-through unit to perform a burn-through operation along the first motion trajectory according to the control instruction.

[0013] Optionally, the data acquisition device further includes a pressure measuring device;

[0014] The pressure measuring device is used to obtain pressure data of the action pressure of the robot unit; and send the pressure data to the control device;

[0015] The control device generates a control instruction for the determined motion trajectory, including:

[0016] generating a first control instruction for controlling the moving direction of the burn-through device on the first motion trajectory according to a comparison result between the pressure value at the second moment in the pressure data and a preset pressure threshold;

[0017] The second moment is located after the first moment.

[0018] Optionally, the data acquisition device further includes a current measuring device;

[0019] The current measuring device is used to obtain current data of the discharge current of the burn-through unit; and send the current data to the control device;

[0020] The control device generates a control instruction for the determined motion trajectory, including:

[0021] generating a second control instruction for controlling the moving direction of the burn-through device on the first motion trajectory according to a comparison result between the current value at a third moment in the current data and a preset current threshold value;

[0022] The third moment is located after the first moment.

[0023] Optionally, the data acquisition device further includes a sound acquisition unit;

[0024] The sound collection unit is used to measure the sound data of the graphite electrode; and send the sound data to the control device;

[0025] The control device generates a control instruction for the determined motion trajectory, including:

[0026] generating a fifth control instruction for controlling the moving direction of the burn-through device on the second motion trajectory according to a comparison result between the vibration frequency at the fourth moment in the sound data and a preset frequency threshold;

[0027] The fourth moment is located after the first moment.

[0028] Optionally, the control device determines the motion trajectory according to the three-dimensional model at each moment included in the three-dimensional image data and the temperature value at each moment included in the temperature data, including:

[0029] After the first motion trajectory is generated, in response to reaching the end condition of the burn-through operation, a preset furnace eye shape is compared with the furnace eye shape in the three-dimensional model at the fifth moment included in the three-dimensional image data, and a second motion trajectory is generated according to the comparison result;

[0030] In a case where the motion trajectory is a second motion trajectory, the robot unit is used to control the burn-through unit to perform a burn-through operation along the second motion trajectory according to the control instruction.

[0031] Optionally, the end condition of the burn-through operation includes:

[0032] The temperature value at any time in the temperature data reaches a preset temperature threshold.

[0033] Optionally, the data acquisition device includes a three-dimensional image scanning unit and a temperature detection unit;

[0034] The three-dimensional image scanning unit is used to obtain three-dimensional image data of the furnace eye contour of the ore furnace; and send the three-dimensional image data to the control device;

[0035] The temperature detection unit is used to obtain the temperature data of the furnace eye and the graphite electrode, and send the temperature data to the control device.

[0036] Optionally, the data acquisition device is also used to measure the sound data of the graphite electrode and the current data of the discharge current of the burn-through unit;

[0037] The control device comprises: a fuzzy control unit, a fuzzy processing unit, and an execution unit;

[0038] The fuzzy control unit is used to receive the temperature data, the sound data and the current data sent by the data acquisition device; perform fuzzy processing on the temperature data, the sound data and the current data to obtain a fuzzy signal; and send the fuzzy signal to the fuzzy processing unit;

[0039] The fuzzy processing unit is used to generate a PID parameter corresponding to the fuzzy signal according to a preset fuzzy rule; and send the PID parameter to the execution unit;

[0040] The execution unit is used to generate a control instruction including an expected position of the motion trajectory of the burn-through device based on the PID parameters.

[0041] Optionally, the data acquisition device further includes a video acquisition unit;

[0042] The video acquisition unit is used to shoot and acquire video data of the robot unit.

[0043] In the solution provided by the embodiment of the present invention, three-dimensional image data and temperature data are obtained by data acquisition equipment. In this way, the furnace eye contour can be automatically identified based on the three-dimensional image data; and the burn eye path can be independently planned according to the temperature data. Moreover, after the motion trajectory is determined according to the three-dimensional image data and the temperature data, the robot controls the burner to move along the motion trajectory to realize the control of the burner, avoid manual contact with the burner for operation, and realize fully automated burn-through operation.

[0044] Additional aspects and advantages of the present invention will be given in part in the following description and in part will be obvious from the following description, or will be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 It is a structural schematic diagram of a first submerged arc furnace front robot control system provided by an embodiment of the present invention;

[0046] Figure 2 1 is a schematic diagram of the structure of a second submerged arc furnace front robot control system provided by an embodiment of the present invention;

[0047] Figure 3 It is a flowchart of a data processing method provided by an embodiment of the present invention;

[0048] Figure 4 It is a structural schematic diagram of a submerged arc furnace provided by an embodiment of the present invention;

[0049] Figure 5 It is a structural schematic diagram of a control algorithm unit provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0050] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be construed as limiting the present invention.

[0051] In one embodiment of the present invention, see Figure 1 , a submerged arc furnace front robot control system is provided, the system comprises: a data acquisition device 101, a control device 102, a robot unit 103, and a burner unit 104 with a graphite electrode;

[0052] The data acquisition device 101 is used to obtain the three-dimensional image data of the furnace eye contour of the ore furnace, and obtain the temperature data of the furnace eye and the graphite electrode; and send the three-dimensional image data and the temperature data to the control device;

[0053] The control device 102 is used to determine the motion trajectory according to the three-dimensional model at each moment included in the three-dimensional image data and the temperature value at each moment included in the temperature data; generate a control instruction for the determined motion trajectory; and send the control instruction to the robot unit;

[0054] The robot unit 103 is used to control the burn-through unit 104 to perform a burn-through operation along a motion trajectory according to a control instruction.

[0055] In one embodiment of the present invention, the data acquisition device includes a three-dimensional image scanning unit and a temperature detection unit;

[0056] A three-dimensional image scanning unit, used to obtain three-dimensional image data of the furnace eye contour of the ore-fired furnace; and send the three-dimensional image data to a control device;

[0057] The temperature detection unit is used to obtain the temperature data of the furnace eye and the graphite electrode, and send the temperature data to the control device.

[0058] The 3D image scanning unit may be a unit composed of a 3D image scanner or a visual camera. In this way, the 3D image scanning unit can photograph the ore-fired furnace and the burn-through device to obtain 3D image data, and the 3D image data represents the 3D model of the furnace eye through the values ​​of height, width and depth. Specifically, image recognition can be performed on the photographed 3D image data to obtain the furnace eye contour.

[0059] The image recognition method may be statistical pattern recognition, structural pattern recognition, fuzzy pattern recognition, etc. Alternatively, the recognition may be performed by training a neural network model such as YOLOV5, which is not limited in the embodiment of the present invention.

[0060] In another embodiment, the three-dimensional image scanning unit can obtain three-dimensional image data, and the data processing unit in the following embodiment performs image recognition.

[0061] The three-dimensional image data can be sent to the robot unit based on a preset communication protocol, such as HTTPS (Hypertext Transfer Protocol Secure), etc. In the following embodiments, the temperature acquisition unit, the sound acquisition unit, and the current measurement device send data to the robot unit in a similar manner.

[0062] The temperature acquisition unit can be an infrared temperature sensor or a temperature measuring camera, which can detect the temperature of the graphite electrode and obtain temperature data for recording the temperature.

[0063] The sound collection unit may be a spectrum analyzer.

[0064] During the burn-through operation, the graphite electrode will vibrate, and the vibration has different frequencies during arc discharge and contact discharge. The frequency of the vibration of the graphite electrode is recorded in the sound data. In addition, the different amplitudes of the graphite electrode during arc discharge and contact discharge can also be recorded in the sound data. In addition, by measuring the frequency and amplitude range of the vibration of the graphite electrode under the condition of known arc discharge, and comparing it with the sound data, it can be determined whether the sound data indicates an arc discharge state.

[0065] The current measuring device may be an ammeter or a current sensor, etc.

[0066] The three-dimensional model and temperature values ​​at different times can be used to determine one or more motion trajectories, so that the burn-through device can perform a burn-through operation along each motion trajectory in a time sequence under the clamping of the robot. For details, please refer to the burn-through operation process of the first to thirteenth steps in the following embodiment.

[0067] In addition, the temperature data and the three-dimensional image data may only include a three-dimensional model and a temperature value at one moment. In this case, only one motion trajectory may be generated, ie, the first motion trajectory in the following embodiment.

[0068] The above control device can be an onboard control device or a remote control device.

[0069] In the solution provided by the embodiment of the present invention, three-dimensional image data and temperature data are obtained by data acquisition equipment. In this way, the furnace eye contour can be automatically identified based on the three-dimensional image data; and the burn eye path can be independently planned according to the temperature data. Moreover, after the motion trajectory is determined according to the three-dimensional image data and the temperature data, the robot controls the burner to move along the motion trajectory to realize the control of the burner, avoid manual contact with the burner for operation, and realize fully automated burn-through operation.

[0070] In one embodiment of the present invention, when the data acquisition device measures the sound data of the graphite electrode and the current data of the discharge current of the burner unit,

[0071] The control device includes: a fuzzy control unit, a fuzzy processing unit, and an execution unit;

[0072] A fuzzy control unit is used to receive the temperature data, sound data and current data sent by the data acquisition device; perform fuzzy processing on the temperature data, sound data and current data to obtain a fuzzy signal; and send the fuzzy signal to the fuzzy processing unit;

[0073] The fuzzy processing unit is used to generate PID parameters corresponding to the fuzzy signal according to preset fuzzy rules; and send the PID parameters to the execution unit;

[0074] The execution unit is used to generate a control instruction including an expected position of the motion trajectory of the burn-through device based on the PID parameters.

[0075] According to the preset fuzzy rules, PID parameters corresponding to the temperature data, sound data and current data are obtained, and control instructions are generated based on the PID parameters.

[0076] Fuzzy rules contain conclusions and premises, and specify that a conclusion can be drawn when the premise is met. For example, the premise can be defined as a temperature value, vibration frequency, current value such as current intensity or voltage, and the conclusion can be the output value of the PID parameter.

[0077] Additionally, the premise can be a value or a range of values.

[0078] In this way, the PID parameters associated with the temperature data, sound data and current data can be set through fuzzy rules. Through the association relationship, PID parameters with different values ​​can be output for control when in the arc discharge state or the contact discharge state.

[0079] The fuzzy rules can be determined by model training. In this embodiment, the fuzzy rules are represented based on the weight coefficients of the pre-trained neural network model;

[0080] The neural network model is a model that is trained based on the output sample PID parameters and is used to output PID parameters.

[0081] The training method can be: input sample temperature data, sample sound data, and sample current data with different values ​​into the neural network model, obtain the sample PID parameters output by the neural network model, and adjust the weight coefficient of the neural network model based on the loss of the sample PID parameters and the preset benchmark PID parameters, so as to improve the fuzzy rules represented by the neural network model.

[0082] Through training, the neural network has the ability to predict output based on input, and the predicted output is consistent with the benchmark PID parameters, which can provide the accuracy of PID parameters derived from fuzzy rules.

[0083] Specifically, a control instruction including an expected position can be generated according to the PID parameters;

[0084] The expected position is determined by the following formula:

[0085]

[0086] Among them, u(t) represents the expected position at time t, K P is the parameter representing the proportional gain, e(t) represents the error at time t, which is the difference between the actual position of the burn-through unit at time t and the target position of the motion trajectory, and K i It is expressed as the parameter representing the integral gain, e(τ) represents the error at time τ, τ is the integral variable, K d Denoted as a parameter representing the derivative gain.

[0087] The expected position is the position of the burner unit at different times when the burner unit moves along the motion trajectory; the robot unit controls the burner unit to move along the expected position at different times until it reaches the target position. The target position can be the end point of the motion trajectory.

[0088] t is an independent variable, and its value is different at different times.

[0089] In this way, by indicating the expected position, the burn-through tool can be controlled to maintain the current position or move at different times.

[0090] As above, the control instruction specifies the position of the movement and may specify the direction of the movement. When the control instruction is executed, the control instruction may be sent to the furnace discharge machine control system.

[0091] The tapping machine control system is used to generate decomposed actions corresponding to the control instructions, so that the joints of the robot move to form a movement in a specified direction.

[0092] Figure 5A control algorithm unit for generating the above control instructions is shown in the figure, which can be applied to a robot unit, including: a fuzzy control unit, a PID controller unit, a neural network NN unit, a controlled object unit, a measuring element unit, and a self-learning algorithm unit.

[0093] The controlled object unit is the actuator of each action of the robot unit. r(t) is the system reference input, indicating the current position of the burner, e(k) is the error, e(k) = r(t)-y(k), y(k) is the target position.

[0094] Kp, Ki, and Kd are respectively the proportional gain coefficient, the integral gain coefficient, and the differential gain coefficient of the PID controller, which are consistent with the above-mentioned embodiment.

[0095] The fuzzy control unit is used to fuzzify the real-time signal from the sensor to obtain a fuzzy vector to represent the above data respectively, and the format type of the fuzzy vector is in accordance with the input type specified by the fuzzy rule, so that the fuzzified signal can be used as the input of the fuzzy rule. The real-time signal includes the temperature data, sound data, and current data in the above embodiment.

[0096] The use of fuzzy control algorithm can passivate the time-varying and unpredictable characteristics of the discharge current of the graphite electrode, reduce the amplitude of the system step fluctuation, and make the control more stable.

[0097] The neural network unit, namely the NN (Neural Networks) unit in the figure, is used to represent fuzzy rules and output PID parameters, as in the aforementioned embodiment.

[0098] The NN unit receives multiple input signals, generates output signals through certain calculations, and transmits the output signals to other neurons. The composition formula of neurons can be expressed as:

[0099]

[0100] Among them, a represents the output of the neuron, g() represents the activation function, represents the i-th input signal, represents the weight of the i-th input signal, and b represents the bias.

[0101] The calculation of the arc current and arc radius inside the neuron is mainly based on the arc furnace model theory of energy balance. The corresponding differential equation of arc energy is:

[0102]

[0103] i is the arc current, r is the arc radius, k1, k2, k3, m, and n are variable parameters, and the variable parameters can be set according to the specifications of the ore-fired furnace and the type of smelted products.

[0104] The PID controller outputs u(k), which is the expected position at time k, to control the controlled object unit.

[0105] The measuring element is the aforementioned data acquisition device, and the measuring element inputs temperature data, sound data, and current data as sample inputs to the self-learning algorithm unit.

[0106] The self-learning algorithm is used to train the neural network, and the training process is as described in the above embodiment. In this way, through the training of the self-learning algorithm, the control device can predict the position where the arc discharge may occur after the burn-through device completes the movement based on the sound data, current data, etc., so as to achieve accurate control of the burn-through device.

[0107] In one embodiment of the present invention, the motion trajectory is determined in the following manner.

[0108] Determine a starting point position based on the three-dimensional model at the first moment included in the three-dimensional image data and the temperature value at the first moment included in the temperature data, and generate a first motion trajectory according to the starting point position and the furnace eye position in the three-dimensional model at the first moment;

[0109] When the motion trajectory is the first motion trajectory, the robot unit is used to control the burn-through unit to perform the burn-through operation along the first motion trajectory according to the control instruction.

[0110] The specific first moment can be specified manually. The data acquisition device can take pictures of the ore-fired furnace and the robot control system in front of the ore-fired furnace at different moments to obtain three-dimensional models at different moments, from which a certain moment is selected as the first moment.

[0111] The temperature data may include the temperature values ​​measured at different positions of the ore-arcing furnace, and the temperature values ​​are superimposed on the 3D model in the 3D image data according to the positions of the detected temperatures. In this way, the position corresponding to the temperature value closest to the target temperature on the 3D model can be compared with the preset target temperature, and the position corresponding to the temperature value closest to the target temperature on the 3D model can be selected as the starting position of the burn eye.

[0112] When the burner unit is controlled to move along the first motion trajectory, the burner can be moved in a preset direction and at a preset moving speed, or the moving direction of the burner can be adjusted according to data collected by the data collection device, see the subsequent embodiments.

[0113] In one embodiment of the present invention, the robot unit is further used to obtain a pressure value of an action pressure of the robot unit, and to obtain a current value of a discharge current of the burner unit from a current measuring device; a moving direction of the burner is determined based on a comparison result of the pressure value with a preset pressure threshold value and a comparison result of the current value with a preset current threshold value; and the burner is controlled to move in the determined moving direction until the graphite electrode reaches a target temperature;

[0114] The target temperature and current threshold are respectively the measured temperature and the measured current value when the graphite electrode performs arc discharge.

[0115] In the robot cell, pressure sensors are installed on each joint of the robot operating the burn-through device to obtain the pressure value of the action pressure;

[0116] For the specific control process, please refer to the sixth step in the process steps of the following burn-eye control algorithm.

[0117] The first step is to issue a command to start burning the eye. The command can be issued manually to the robot control system in front of the submerged arc furnace, so that the robot control system in front of the submerged arc furnace starts working.

[0118] The second step is to scan the furnace eye and the burner, collect the temperature data and 3D model data of the furnace eye and the burner, that is, the model of the furnace eye represented by the 3D image. Figure 4 shown.

[0119] Among them, 401 is the furnace eye, 402 is the molten pool, 403 is the solidified charge, and 404 is the refractory brick. The graphite electrode melts the solidified charge and mud balls from the outside of the furnace to the inside until the molten pool in the furnace.

[0120] According to the actual experience of burning eye, the ideal shape of the furnace eye is a slanted cone shape with a large outside and a small inside. This shape is convenient for the molten charge to flow out along the furnace eye. The effect of controlling the shape of the furnace eye can be achieved by setting the curved motion trajectory from the starting point of the burning eye to the target position according to the slanted cone shape.

[0121] The third step is to generate a first motion trajectory; the control device determines the starting position based on the three-dimensional model at the first moment included in the three-dimensional image data and the temperature value at the first moment included in the temperature data, and generates the first motion trajectory based on the starting position and the furnace eye position in the three-dimensional model at the first moment.

[0122] The moment when the third step is performed is the first moment.

[0123] In the subsequent ninth step, after the first motion trajectory is generated, in response to reaching the end condition of the burn-through operation, the preset furnace eye shape and the furnace eye shape in the three-dimensional model at the fifth moment included in the three-dimensional image data are compared, and a second motion trajectory is generated according to the comparison result;

[0124] When the motion trajectory is the second motion trajectory, the robot unit is used to control the burn-through unit to perform the burn-through operation along the second motion trajectory according to the control instruction.

[0125] By comparing the preset furnace eye shape with the furnace eye shape shown in the second three-dimensional image data, the difference from the preset furnace eye shape is determined, so as to obtain the terminal position that has not been burned through, and the second stage burning eye starting point close to the terminal position is selected from the three-dimensional model, and a straight line or curve motion trajectory can be formed between the terminal position and the second motion trajectory after update. In this way, all solid furnace materials and mud balls in the preset final furnace eye shape can be burned out.

[0126] In the fourth step, the burner moves along the first motion trajectory and reaches the starting position first.

[0127] During the movement, it is determined in real time whether the burn-through device has reached the starting point of the first stage burn-through. If yes, it proceeds to the next step, otherwise, it continues to the fourth step.

[0128] Step 5: Power on the burn-through device. A power-on device can be provided in the system to power on the burn-through device, see the subsequent embodiments.

[0129] Step 6: Start the first stage of eye burning.

[0130] In one embodiment of the present invention, the data acquisition device further comprises a pressure measuring device;

[0131] A pressure measuring device, used to obtain pressure data of the action pressure of the robot unit; and send the pressure data to the control device;

[0132] The control device generates a control instruction for the determined motion trajectory, including:

[0133] Generate a first control instruction for controlling the moving direction of the burn-through device on the first motion trajectory according to a comparison result between the pressure value at the second moment in the pressure data and a preset pressure threshold;

[0134] Among them, the second moment is located after the first moment.

[0135] The pressure measuring device can measure the action pressure of the robot at each moment and obtain the pressure value of the action pressure at each moment.

[0136] In the current embodiment, the time for implementing the sixth step is the second time, the time for implementing the third step is the first time, and the second time is after the first time.

[0137] During the burning process, the action pressure Fa is compared with the limit pressure Ft in real time. Fa is the pressure value at the second moment in the pressure data, and Ft is the preset pressure threshold.

[0138] Below is the comparison result graph in the above embodiments. Among them, Fa is the torque information of the real-time feedback of the actions of each joint of the robot, and Ft is the limiting torque of the actions of each joint, that is, the pressure threshold. If Fa < Ft, the first control instruction is to maintain the current moving direction and enter the eighth step. If Fa >= Ft, the first control instruction is to retreat along the motion trajectory to prevent the graphite electrode from breaking due to excessive force.

[0139] During the eye-burning process, the burn-through current Ia is compared with the target current It1 in real time, and during the movement along the first motion trajectory, the comparison of the current values and current thresholds at multiple different times can be carried out. In addition, in some embodiments, the comparison of the pressure value and the pressure threshold, and the comparison of the vibration frequency and the frequency threshold can also be carried out multiple times.

[0140] In an embodiment of the present invention, the data acquisition device further includes a current measuring device;

[0141] The current measuring device is used to obtain the current data of the discharge current of the burn-through unit; and send the current data to the control device;

[0142] The control device generates control instructions for the determined motion trajectory, including:

[0143] Generating a second control instruction for controlling the moving direction of the burn-through unit on the first motion trajectory according to the comparison result of the current value at the third moment in the current data and the preset current threshold;

[0144] Wherein, the third moment is after the first moment.

[0145] The embodiments of the present invention do not limit the timing sequence of the third moment and the above-mentioned second moment. In the above embodiments, the pressure value and the pressure threshold can be obtained for comparison first, and then the current value and the current threshold can be obtained for comparison; or the current value and the current threshold can be obtained for comparison first, and then the pressure value and the pressure threshold can be obtained for comparison.

[0146] The current measuring device can measure the burn-through unit at each moment to obtain the current values at each moment.

[0147] Ia is the current value at the third moment in the current data of the burn-through unit, It1 is the current threshold, and Iδ1 is the allowable current offset in the first stage. The comparison results include: if Ia <= It1 - Iδ1, the third control instruction is to move forward along the motion trajectory; if It1 - Iδ1 < Ia < It1 + Iδ1, the third control instruction is to maintain the current position; if Ia >= It1 + Iδ1, the third control instruction is to retreat along the motion trajectory.

[0148] In this way, by comparing with the current threshold, the burner can maintain a current value close to the target current during the movement along the first motion trajectory, so that arc discharge is more easily generated.

[0149] In one embodiment of the present invention, the data collection device further includes a sound collection unit;

[0150] A sound collection unit, used for measuring the sound data of the graphite electrode; and sending the sound data to the control device;

[0151] The control device generates a control instruction for the determined motion trajectory, including:

[0152] A fifth control instruction for controlling the moving direction of the burn-through device on the second motion trajectory is generated according to a comparison result between the vibration frequency at the fourth moment in the sound data and a preset frequency threshold.

[0153] The sound collection unit can measure the vibration frequency of the graphite electrode at each moment.

[0154] The process of controlling the moving direction according to the sound is similar to the tenth step described below, the only difference being that the vibration frequencies at different times are used.

[0155] Similarly, the fourth moment and the second moment and the third moment may have any sequence, which is not limited in the embodiment of the present invention.

[0156] During the burn-through process, it is also determined whether the graphite electrode temperature has reached the preset temperature threshold. After the graphite electrode generates arc discharge, the graphite electrode is rapidly preheated under the action of the current. When the temperature rises to the preset temperature threshold, the arc can be normally and quickly started in other low-temperature areas in the furnace eye. If the graphite electrode temperature reaches the preset temperature, the next step is entered, otherwise, the seventh step is continued. In other words, the end condition of the burn-through operation includes: the temperature value at any time in the temperature data reaches the preset temperature threshold.

[0157] After the graphite electrode starts arcing, it is quickly preheated under the action of the current. When the temperature rises to the preset temperature value, it can start arcing normally and quickly in other low-temperature areas in the furnace eye. If the graphite electrode temperature reaches the preset temperature, proceed to the next step, otherwise re-execute step 6.

[0158] Step 7. The burner exits.

[0159] That is, through the control device, for any moment, it can be determined whether the temperature value at that moment in the temperature data reaches a preset temperature threshold; if so, a control instruction indicating that the burn-through operation is stopped is sent to the robot unit;

[0160] The robot unit instructs the burn-through device unit to exit the motion trajectory according to the control instruction indicating to stop the burn-through operation.

[0161] During the process of the burner retracting, determine whether the burner has retracted to the predetermined position. If so, proceed to the next step; otherwise, execute step 7 again.

[0162] Step 8: Rescan the three-dimensional data of the furnace eye and the burner to obtain the three-dimensional model at the current moment.

[0163] Step 9: Regenerate the second movement trajectory. Refer to the above embodiments, and details are not described here again.

[0164] Step 10: The burner starts to move from the burner starting point of the second movement trajectory to perform the second-stage burner-eye process.

[0165] During the second-stage burner-eye process, it is carried out in real time. Re-obtain the pressure value Fa of the action pressure and compare it with the limit pressure Ft. If Fa < Ft, proceed to the next step; if Fa >= Ft, retreat along the movement trajectory.

[0166] Moreover, the current measuring device can also re-measure the obtained current value, and re-obtain the burner current Ia and compare it with the target current It2. It2 is the second current threshold. It2 can be the same as or different from the current value of It1.

[0167] Among them, Ia is the real-time burner current collected by the current measuring device 107, It2 is the set burner standard current value in the second stage, and Iδ2 is the allowable current offset in the second stage. If Ia <= It2 - Iδ2, the fourth control instruction is to advance along the updated movement trajectory; if It2 - Iδ2 < Ia < It2 + Iδ2, the fourth control instruction is to maintain the current position and proceed to the next step; if Ia >= It2 + Iδ2, the fourth control instruction is to retreat along the second movement trajectory.

[0168] The calculation process is similar to step 6, with the only differences being the different movement trajectories and the different stages of the burner-eye operation. Details are not described here again.

[0169] In addition, it is also possible to measure the vibration frequency Ha at the current moment in the sound data and compare it with the frequency threshold Ht. If Ha >= Ht, the fifth control instruction is to maintain the current position; if Ha < Ht, the fifth control instruction is to retreat along the movement trajectory.

[0170] It should be noted that in this embodiment, the sound acquisition unit is used to control the movement of the second movement trajectory. In the same way, the sound data collected by the sound acquisition unit can also be used to control the movement of the first movement trajectory, with the only difference being that different moments of sound data are used.

[0171] Similarly, the way in which the current data and the pressure data control the moving direction in the second motion trajectory is the same as the way in which the moving direction is controlled in the first motion trajectory, the only difference being that data at different times are used.

[0172] During this process, the three-dimensional image data can be updated in real time to determine whether the furnace eye is burned. If so, the burn-through device is controlled to return along the motion trajectory. If not, continue to execute the tenth step.

[0173] Alternatively, after updating the three-dimensional image data, a third motion trajectory may be generated again and the burner may be controlled to perform a burn-through operation based on the three-dimensional model in the updated three-dimensional image data and the updated temperature values ​​corresponding to different positions, or by comparing a preset furnace eye shape with the updated three-dimensional image data, so that the embodiment of the present invention may include more than two motion trajectories, and the embodiment of the present invention is not limited to this.

[0174] In addition, the position of the burn-through device can be obtained in real time to determine whether it has reached the end position. If so, the burn-through device is controlled to retreat along the motion trajectory. If not, the tenth step is continued.

[0175] Step 11, the burn-through device is retracted along the path;

[0176] During the return process, determine whether the burn-through device returns to the preset position. If yes, proceed to the next step, otherwise continue to execute "return along the path";

[0177] Step 12: Cut off the power supply of the burner;

[0178] Step 13: Finish burning the eyes.

[0179] The method of controlling the burn-through device is the PID control in the aforementioned embodiment, and the temperature data, sound data and current data can be updated by acquiring the data of the temperature acquisition unit, the sound acquisition unit and the current measuring device in real time, so as to obtain the updated PID parameters and calculate the new expected position.

[0180] By controlling the movement through control instructions generated by temperature data, sound data and current data, the working state of the burner can be detected more comprehensively and accurately by temperature data, sound data and current data, and the burner can be controlled to maintain the arc discharge working state during movement, thereby reducing contact discharge, reducing the thermal efficiency of the current during contact discharge, and reducing the situation in which most of the electric energy acts on the burner unit, causing the graphite electrode and the burner to rise sharply in temperature and cause damage.

[0181] In one embodiment of the present invention, the control device further includes a data storage unit and a data processing unit;

[0182] The data storage unit can store the three-dimensional image data and the temperature data; the data processing unit can obtain the three-dimensional image data and the temperature data from the data storage unit, and send the three-dimensional image data and the temperature data to the robot unit.

[0183] The data storage unit may be a preset database or a file system, which is not limited in the embodiment of the present invention.

[0184] The data storage unit may also record various control instructions executed by the robot unit during the burn-through operation, data collected by the above-mentioned sensors and collection units, and the like.

[0185] In the aforementioned embodiment, when the sound data and the current data are sent to the robot unit, the above data may also be stored in the data storage unit, and retrieved and forwarded by the data processing unit.

[0186] In this case, the data processing unit may include a temperature data processing module for acquiring temperature data from the data storage unit.

[0187] The data processing unit may include a sound data processing module for acquiring sound data from the data storage unit.

[0188] In addition, the data processing unit may include a furnace eye recognition algorithm building module for performing image recognition on the three-dimensional image data to obtain the furnace eye contour therein.

[0189] The data processing unit is used to forward the data, so that the image data of each time period and other data can be recorded by the data storage unit, thereby being able to record the complete burn-through operation process, which is convenient for subsequent review and analysis and training of the self-learning algorithm.

[0190] In one embodiment of the present invention, the data processing process is as follows Figure 3 The data acquired by the data acquisition device are stored in the database, and the data acquisition device includes the above-mentioned three-dimensional image scanning unit, temperature acquisition unit, sound acquisition unit, and current measurement device; accordingly, the data stored in the database includes three-dimensional image data, temperature data, sound data, and current data.

[0191] The furnace eye recognition algorithm building module, temperature data processing module, and sound data processing module obtain data from the database and output it to the execution device for execution control. And through the control device's burner control algorithm, the corresponding PID parameters are output, and control instructions are generated to achieve PID control of the robot.

[0192] The furnace tapping machine control system decomposes the control instructions into the robot's actions, so that the robot controls the burn-through unit to move along the motion trajectory, and the graphite electrode discharges to perform the burn-through operation. The data storage system can record the control instructions.

[0193] The client device can obtain temperature data, sound data, etc. from the database, and the client device can also input manually set control instructions by interacting with the I / O interface.

[0194] In one embodiment of the present invention, in addition to the graphite electrode, the burner unit further comprises: a burner, a graphite electrode holder

[0195] A burn-through device for connecting the graphite electrode holder and the preset power-on device;

[0196] Graphite electrode holder, used to hold graphite electrodes.

[0197] like Figure 2 As shown, the graphite electrode holder 203 is connected to the copper busbar 206, and one end of the copper busbar 206 is fixed on the burn-through device 202. The other end of the copper busbar 206 is connected to the automatic power-on copper busbar 212, and the power-on copper busbar 212 is automatically powered on and off through the power-on device 208.

[0198] Specifically, the data acquisition device also includes a video acquisition unit; the video acquisition unit is used to shoot and acquire video data of the robot unit.

[0199] The video acquisition unit may include one or more video recording devices for capturing video data, so as to facilitate manual monitoring of the burn-through operation progress without approaching the burn-through operation site during the automated burn-through operation.

[0200] Figure 2 The figure shows the connection mode of each component of the robot control system in front of the electric arc furnace. As shown in the figure, the robot unit 103 is connected to the burner unit, which includes a burner 202, a graphite electrode holder 203, a graphite electrode 204, and a copper busbar 206. The graphite electrode 204 is fixed to the front end of the burner through the graphite electrode holder 203, and the graphite electrode holder 203 is connected to the copper busbar 206, and the copper busbar 206 is fixed on the burner 202. The other end of the copper busbar 206 is connected to the power-on device 208, and the other end of the copper busbar 206 is connected to the automatic power-on copper busbar 212.

[0201] The power-on device includes a power-on copper bar 212, a power-on cylinder, and a current measuring device 207. The power-on cylinder is used to control the on and off of the power-on copper bar. The current measuring device performs current measurement as in the above-mentioned embodiment.

[0202] The power-on device may further include a power-on actuator and a power-on status signal acquisition device. The power-on actuator is used to connect the power supply, and the power-on status signal acquisition device is used to obtain the on / off status of the power-on cylinder.

[0203] In the figure, the copper busbar slide rail 205 is used to place the copper busbar 206.

[0204] The temperature collection unit 209 , the three-dimensional image scanning unit 210 , the sound collection unit 211 and the robot unit 201 may be connected by wireless communication.

[0205] It should be noted that the logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as a sequenced list of executable instructions for implementing logical functions, and can be specifically implemented in any computer-readable medium for use by an instruction execution system, device or apparatus (such as a computer-based system, a system including a processor, or other system that can fetch instructions from an instruction execution system, device or apparatus and execute instructions), or in combination with these instruction execution systems, devices or apparatuses. For the purposes of this specification, "computer-readable medium" can be any device that can contain, store, communicate, propagate or transmit a program for use by an instruction execution system, device or apparatus, or in combination with these instruction execution systems, devices or apparatuses. More specific examples of computer-readable media (a non-exhaustive list) include the following: an electrical connection portion with one or more wirings (electronic device), a portable computer disk box (magnetic device), a random access memory (RAM), a read-only memory (ROM), an erasable and programmable read-only memory (EPROM or flash memory), an optical fiber device, and a portable compact disk read-only memory (CDROM). In addition, the computer-readable medium may even be paper or other suitable medium on which the program is printed, since the program may be obtained electronically, for example, by optically scanning the paper or other medium and then editing, interpreting or processing in other suitable ways if necessary, and then stored in a computer memory.

[0206] It should be understood that the various parts of the present invention can be implemented by hardware, software, firmware or a combination thereof. In the above-mentioned embodiments, a plurality of steps or methods can be implemented by software or firmware stored in a memory and executed by a suitable instruction execution system. For example, if implemented by hardware, as in another embodiment, it can be implemented by any one of the following technologies known in the art or their combination: a discrete logic circuit having a logic gate circuit for implementing a logic function for a data signal, a dedicated integrated circuit having a suitable combination of logic gate circuits, a programmable gate array (PGA), a field programmable gate array (FPGA), etc.

[0207] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner.

[0208] In the description of the present invention, it is to be understood that the terms “center”, “longitudinal”, “lateral”, “length”, “width”, “thickness”, “up”, “down”, “front”, “back”, “left”, “right”, “vertical”, “horizontal”, “top”, “bottom”, “inside”, “outside”, “clockwise”, “counterclockwise”, “axial”, “radial”, “circumferential”, etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0209] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In the description of the present invention, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0210] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0211] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may mean that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, a first feature being "above", "above" or "above" a second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being "below", "below" or "below" a second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0212] Although the embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are exemplary and are not to be construed as limitations of the present invention. A person skilled in the art may change, modify, replace and vary the above embodiments within the scope of the present invention.

Claims

1. A robot control system for a submerged arc furnace, characterized in that: The system includes: a data acquisition device, a control device, a robot unit, and a burner unit with a graphite electrode; The data acquisition device is used to obtain three-dimensional image data of the furnace eye contour of the ore furnace, and obtain temperature data of the furnace eye and the graphite electrode; and send the three-dimensional image data and the temperature data to the control device; The control device is used to determine a motion trajectory according to the three-dimensional model at each moment included in the three-dimensional image data and the temperature value at each moment included in the temperature data; generate a control instruction for the determined motion trajectory; and send the control instruction to the robot unit; The robot unit is used to control the burn-through unit to perform a burn-through operation along the motion trajectory according to the control instruction; The control device determines the motion trajectory according to the three-dimensional model at each moment included in the three-dimensional image data and the temperature value at each moment included in the temperature data, including: Determine a starting point position based on the three-dimensional model at the first moment included in the three-dimensional image data and the temperature value at the first moment that is closest to the target temperature included in the temperature data, and generate a first motion trajectory according to the starting point position and the furnace eye position in the three-dimensional model at the first moment; In a case where the motion trajectory is a first motion trajectory, the robot unit is used to control the burn-through unit to perform a burn-through operation along the first motion trajectory according to the control instruction.

2. The system according to claim 1, characterized in that The data acquisition device also includes a pressure measuring device; The pressure measuring device is used to obtain pressure data of the action pressure of the robot unit; sending the pressure data to the control device; The control device generates a control instruction for the determined motion trajectory, including: generating a first control instruction for controlling the moving direction of the burn-through device on the first motion trajectory according to a comparison result between the pressure value at the second moment in the pressure data and a preset pressure threshold; The second moment is located after the first moment.

3. The system according to claim 1, characterized in that The data acquisition device also includes a current measuring device; The current measuring device is used to obtain current data of the discharge current of the burn-through unit; sending the current data to the control device; The control device generates a control instruction for the determined motion trajectory, including: generating a second control instruction for controlling the moving direction of the burn-through device on the first motion trajectory according to a comparison result between the current value at a third moment in the current data and a preset current threshold value; The third moment is located after the first moment.

4. The system according to claim 1, characterized in that The data acquisition device also includes a sound acquisition unit; The sound collection unit is used to measure the sound data of the graphite electrode; sending the sound data to the control device; The control device generates a control instruction for the determined motion trajectory, including: generating a fifth control instruction for controlling the moving direction of the burn-through device on the second motion trajectory according to a comparison result between the vibration frequency at the fourth moment in the sound data and a preset frequency threshold; The fourth moment is located after the first moment.

5. The system according to claim 1, characterized in that The control device determines the motion trajectory according to the three-dimensional model at each moment included in the three-dimensional image data and the temperature value at each moment included in the temperature data, including: After the first motion trajectory is generated, in response to reaching the end condition of the burn-through operation, a preset furnace eye shape is compared with the furnace eye shape in the three-dimensional model at the fifth moment included in the three-dimensional image data, and a second motion trajectory is generated according to the comparison result; In a case where the motion trajectory is a second motion trajectory, the robot unit is used to control the burn-through unit to perform a burn-through operation along the second motion trajectory according to the control instruction.

6. The system according to claim 1, characterized in that The termination conditions of the burn-through operation include: The temperature value at any time in the temperature data reaches a preset temperature threshold.

7. The system according to claim 1, characterized in that The data acquisition device includes a three-dimensional image scanning unit and a temperature detection unit; The three-dimensional image scanning unit is used to obtain three-dimensional image data of the furnace eye contour of the ore furnace; and send the three-dimensional image data to the control device; The temperature detection unit is used to obtain the temperature data of the furnace eye and the graphite electrode, and send the temperature data to the control device.

8. The system according to claim 1, characterized in that The data acquisition device is also used to measure the sound data of the graphite electrode and the current data of the discharge current of the burn-through unit; The control device comprises: a fuzzy control unit, a fuzzy processing unit, and an execution unit; The fuzzy control unit is used to receive the temperature data, the sound data and the current data sent by the data acquisition device; perform fuzzy processing on the temperature data, the sound data and the current data to obtain a fuzzy signal; and send the fuzzy signal to the fuzzy processing unit; The fuzzy processing unit is used to generate a PID parameter corresponding to the fuzzy signal according to a preset fuzzy rule; and send the PID parameter to the execution unit; The execution unit is used to generate a control instruction including an expected position of the motion trajectory of the burn-through device based on the PID parameters.

9. The system according to claim 1, characterized in that The data acquisition device also includes a video acquisition unit; The video acquisition unit is used to shoot and acquire video data of the robot unit.

Images