Risk monitoring method for aluminum processing deep well casting
Through the use of visual detection cameras and AI visual recognition systems during the aluminum processing deep well casting process, and combined with the deep well casting lock control system, it solves the problem of high -risk explosion in existing technologies, and achieves rapid emergency measures and risk prediction judgment. Essence
Patent Information
- Application Number
- CN202411530846.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-30
- Publication Date
- 2025-01-24
AI Technical Summary
The high risk of prone to explosion during the casting of deep wells in aluminum processing is that the existing technology relies too much on visual monitoring and network transmission, resulting in long data upload time and it is difficult to implement emergency measures quickly.
The visual inspection camera, AI visual recognition system and deep well casting interlocking control system are used to capture the vortex image at the grinding plate mold hole through the camera, and the AI system is used to identify aluminum leakage and generate an alarm signal to achieve rapid emergency measures.
It reduced the explosion hazard brought by aluminum leakage during the deep well casting process of aluminum processing. The analysis results were accelerated through localized deployment, the risks predicted in advance, and reducing the visual monitoring dependence and network transmission time.
Smart Images
Figure CN119363793A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of deep well casting for aluminum processing, and in particular to a risk monitoring method for deep well casting for aluminum processing. Background Art
[0002] Deep well casting of aluminum processing is a high-risk production process that is prone to explosion. If the operator operates improperly or the grinding disc is not crystallized well, the high-temperature molten aluminum liquid will easily leak into the deep well. If the aluminum liquid is not cut off in a short period of time and the casting continues and the crystallization disc is blocked with a plug, the high-temperature aluminum liquid flowing into the deep well will cause the water to boil instantly and produce a large amount of water vapor. Because the deep well is a limited space, the water vapor will expand and explode if it cannot be released. Because aluminum reacts with water to produce hydrogen, the power of the explosion is aggravated, causing the workshop and even the enterprise to be blown up, and even endangering the lives and property of the surrounding residents. Therefore, in view of these current situations, it is urgent to develop a risk monitoring method for deep well casting of aluminum processing to meet the needs of actual use. Summary of the invention
[0003] The purpose of the present invention is to provide a risk monitoring method for deep well casting of aluminum processing, which is used to reduce the excessive reliance on network transmission in visual monitoring of deep well casting of aluminum processing, reduce the time for data uploading, and enable the deep well casting interlocking control system to implement rapid emergency measures and reduce the explosion risk caused by aluminum leakage.
[0004] In order to solve the above technical problems, the present invention adopts the following technical solutions: A risk monitoring method for deep well casting of aluminum processing comprises a visual inspection camera, a local server, an AI visual recognition system and a deep well casting interlocking control system, wherein the visual inspection camera is arranged above a grinding disc crystallizer hole, the visual inspection camera is used to shoot a vortex image at the grinding disc crystallizer hole, the vortex image shot by the visual inspection camera is uploaded to a large-capacity storage hard disk of a local server, the AI visual recognition system is arranged in the local server, an aluminum leakage recognition database is established inside the AI visual recognition system, the vortex image is identified by the AI visual recognition system to determine whether aluminum liquid has penetrated, and an aluminum liquid judgment signal is generated, and a deep well casting interlocking control system is provided, wherein the deep well casting interlocking control system is arranged inside the local server, and the AI visual recognition system communicates with the deep well casting interlocking control system through a controller.
[0005] In the above description, as a further solution, the aluminum leakage identification database is manually marked with more static images through the vortex images taken in the local server, and the AI visual recognition system improves the judgment criteria of the aluminum leakage identification database through the recognition algorithm.
[0006] In the above description, as a further solution, the deep well casting interlocking control system includes: The first sensor is installed at the casting furnace outlet and is used to detect the liquid level of the casting furnace outlet chute; The second sensor is installed at the casting plate entrance and is used to detect the liquid level of the casting plate entrance chute; The third sensor is installed on the water inlet pipe of the casting plate and is used to detect the water inlet temperature of the casting plate; The fourth sensor is installed in the foundation pit and is used to detect the water outlet temperature of the casting plate; The monitoring module is installed in the hydraulic cylinder to detect the casting length of the aluminum rod; A liquid level warning module, wherein the liquid level warning module is signal-connected to the first sensor, the second sensor, the third sensor, and the fourth sensor; A first automatic baffle, the first automatic baffle is arranged at the casting plate entrance; a second automatic baffle, the second automatic baffle is arranged at the aluminum discharge chute; A safety interlocking device, wherein the safety interlocking device is signal-connected to the monitoring module, the first automatic baffle, and the second automatic baffle; The controller is signal-connected with the liquid level warning module, the safety interlock device, the first automatic baffle, and the second automatic baffle.
[0007] In the above description, as a further solution, the liquid level warning module includes a first alarm module, the first alarm module is signal-connected to the first sensor, and a plurality of casting furnace outlet chute liquid level thresholds are arranged in the first alarm module.
[0008] In the above description, as a further solution, the liquid level warning module also includes a second alarm module, the second alarm module is signal-connected to the second sensor, and a plurality of casting plate inlet chute liquid level thresholds are arranged in the second alarm module.
[0009] In the above description, as a further solution, the liquid level warning module also includes a third alarm module, the third alarm module is signal-connected to the third sensor, and a plurality of casting plate water inlet temperature thresholds are arranged in the third alarm module.
[0010] In the above description, as a further solution, the liquid level warning module also includes a fourth alarm module, the fourth alarm module is signal-connected to the fourth sensor, and a plurality of casting plate water outlet temperature thresholds are provided in the fourth alarm module.
[0011] In the above description, as a further solution, the liquid level warning module also includes a fifth alarm module, and the fifth alarm module is signal-connected to the monitoring module, and a plurality of aluminum rod casting length thresholds are provided in the fifth alarm module.
[0012] In the above description, as a further solution, the first sensor and the second sensor are both laser liquid level sensors or radar liquid level sensors.
[0013] The beneficial effects produced by the present invention are as follows: The risk monitoring method of deep well casting of aluminum processing in the present application, on the one hand, installs sensors to monitor production parameters during the entire casting process, sets early warning and alarm multi-level reminders, adds the function of gate interlocking to automatically cut off the casting, and introduces a risk early warning alarm system, a visual large-screen real-time data monitoring plus video AI monitoring, so as to achieve comprehensive monitoring from all directions and reduce the occurrence of risk accidents; On the other hand, through more precise visual technology to shoot, through research, it was found that when the grinding disc leaks aluminum, a large or small vortex will appear above the crystallizer hole. When a vortex appears, it means that aluminum leakage is occurring. We collect video data through the camera to the main server, and use the built-in aluminum leakage recognition model of the AI visual recognition system to determine whether aluminum leakage occurs. After identifying aluminum leakage, an alarm record and an on-site alarm sound are generated to remind the operating personnel. This aluminum leakage solution mainly uses visual recognition, supplemented by AI video analysis, and combines software and hardware. The advantage of its localized deployment is that it does not need to rely too much on network transmission, which speeds up the analysis results and predicts risks in advance. BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Figure 1 This is a system logic diagram of a risk monitoring method for deep well casting of aluminum processing described in the present invention. DETAILED DESCRIPTION
[0015] In order to facilitate the understanding of those skilled in the art, the present invention is further described below in conjunction with the embodiments and drawings, and the contents mentioned in the embodiments are not intended to limit the present invention. The present invention is described in detail below in conjunction with the drawings.
[0016] See also Figure 1 , a risk monitoring method for deep well casting of aluminum processing is specifically implemented, including a visual inspection camera, a local server, an AI visual recognition system and a deep well casting interlocking control system, wherein the visual inspection camera is arranged above the grinding disc crystallizer hole, and the visual inspection camera is used to shoot a vortex picture at the grinding disc crystallizer hole, and the vortex picture shot by the visual inspection camera is uploaded to a large-capacity storage hard disk of the local server, the AI visual recognition system is arranged in the local server, and an aluminum leakage recognition database is established inside the AI visual recognition system. The vortex picture is identified by the AI visual recognition system to determine whether aluminum liquid has penetrated, and an aluminum liquid judgment signal is generated, and a deep well casting interlocking control system is provided. The deep well casting interlocking control system is arranged inside the local server, and the AI visual recognition system communicates with the deep well casting interlocking control system through a controller.
[0017] Through more precise visual technology to shoot, through research, it is found that when the grinding disc leaks aluminum, a vortex of varying sizes will appear above the crystallizer hole. When a vortex appears, it means that aluminum leakage is occurring. We collect video data through the camera to the main server, and use the built-in aluminum leakage recognition model of the AI visual recognition system to determine whether aluminum leakage occurs. After identifying aluminum leakage, an alarm record and an on-site alarm sound are generated to remind the operating personnel. This aluminum leakage solution mainly uses visual recognition, supplemented by AI video analysis, and combines software and hardware. The advantage of its localized deployment is that it does not need to rely too much on network transmission, which speeds up the analysis results and predicts risks in advance.
[0018] In a further solution, the aluminum leakage identification database is manually marked with multiple static images through the vortex images taken in the local server, and the AI visual recognition system improves the judgment criteria of the aluminum leakage identification database through the recognition algorithm. The aluminum leakage identification database can be continuously learned through the AI visual recognition system, and the data based on which the AI visual recognition system is identified is more perfect, and its judgment speed and accuracy are also faster and more accurate.
[0019] Among them, the deep well casting interlocking control system includes: The first sensor is installed at the casting furnace outlet and is used to detect the liquid level of the casting furnace outlet chute; The second sensor is installed at the casting plate entrance and is used to detect the liquid level of the casting plate entrance chute; The third sensor is installed on the water inlet pipe of the casting plate and is used to detect the water inlet temperature of the casting plate; The fourth sensor is installed in the foundation pit and is used to detect the water outlet temperature of the casting plate; The monitoring module is installed in the hydraulic cylinder to detect the casting length of the aluminum rod; A liquid level warning module, wherein the liquid level warning module is signal-connected to the first sensor, the second sensor, the third sensor, and the fourth sensor; A first automatic baffle, the first automatic baffle is arranged at the casting plate entrance; a second automatic baffle, the second automatic baffle is arranged at the aluminum discharge chute; A safety interlocking device, wherein the safety interlocking device is signal-connected to the monitoring module, the first automatic baffle, and the second automatic baffle; The controller is signal-connected with the liquid level warning module, the safety interlock device, the first automatic baffle, and the second automatic baffle.
[0020] Furthermore, the liquid level warning module includes a first alarm module, the first alarm module is connected to the first sensor by signal, and the first alarm module is provided with a plurality of liquid level thresholds of the casting furnace outlet chute, and the liquid level warning module also includes a second alarm module, the second alarm module is connected to the second sensor by signal, and the second alarm module is provided with a plurality of liquid level thresholds of the casting plate inlet chute. Both the first sensor and the second sensor are laser liquid level sensors or radar liquid level sensors.
[0021] In the above description, as a further solution, the liquid level warning module also includes a third alarm module, the third alarm module is signal-connected to the third sensor, and the third alarm module is provided with a number of casting plate water inlet temperature thresholds. The liquid level warning module also includes a fourth alarm module, the fourth alarm module is signal-connected to the fourth sensor, and the fourth alarm module is provided with a number of casting plate water outlet temperature thresholds.
[0022] In a further solution, the liquid level warning module also includes a fifth alarm module, and the fifth alarm module is signal-connected to the monitoring module, and a plurality of aluminum rod casting length thresholds are provided in the fifth alarm module.
[0023] Among them, the first sensor and the second sensor can be laser liquid level sensors or radar liquid level sensors, and the third sensor and the fourth sensor can be temperature sensors, which can monitor the liquid level and temperature by connecting with the early warning module signal; the monitoring module can calculate the casting length of the aluminum rod according to the value monitored by the flow meter by installing a flow meter in the hydraulic cylinder; the early warning module can specifically send an alarm signal to the staff through, for example, an alarm light, a buzzer or a display screen; the controller is preferably an existing PLC controller, which can be used to control the operation and coordination of the entire deep well casting interlocking control system. The PLC controller can receive the signal from the sensor, and process and judge it according to the preset existing logic and algorithm, so as to control the opening and closing status of the above-mentioned first automatic baffle and the second automatic baffle, and send out an early warning signal and start the safety interlocking device.
[0024] Specifically, the first automatic baffle and the second automatic baffle can control their opening and closing states through a motor or a pneumatic device, and the controller can be used to control the casting plate entrance and the aluminum discharge chute. Specifically: the first automatic baffle is installed 300-500mm away from the casting plate entrance, and the second automatic baffle is installed at the aluminum discharge chute. The control method of the two automatic baffles can be manual and automatic; the manual state is mainly used for cleaning the chute during the non-casting process, and the operating states of the two automatic baffles are rising and falling; the automatic state is mainly used to detect the high and low liquid levels at the casting furnace outlet and the distribution chute (or casting plate) inlet chute, and the liquid level reaches the limit value, and the water inlet pressure and flow rate of the crystallizer (or casting plate) are lower than the limit When the inlet and return water temperatures reach the limit values, the two automatic baffles will operate (one rising and one falling). The two automatic baffles can be connected to the PLC controller through the switch signal of the solenoid valve. A switch processing program and a baffle alarm processing program are added to the PLC control program of the casting machine. When the position signal of the first automatic baffle is a descending signal or the signal of the second automatic baffle is an ascending signal, it means that the liquid level at the outlet of the casting furnace and the inlet chute of the distribution chute (or casting plate) reaches the limit value, the inlet water pressure and flow rate of the crystallizer (or casting plate) are lower than the limit value, and the inlet and return water temperatures have one or more of the preset conditions reaching the limit value, resulting in the operation of the two baffles. At this time, the operator should immediately block the furnace eye to terminate the casting.
[0025] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Although the present invention is disclosed as a preferred embodiment as above, it is not used to limit the present invention. Any technician familiar with the profession can make some changes or modifications to equivalent embodiments of equivalent changes by using the technical contents disclosed above without departing from the scope of the technical solution of the present invention. However, any simple modification, equivalent changes and modifications made to the above embodiments according to the technology of the present invention are all within the scope of the technical solution of the present invention without departing from the content of the technical solution of the present invention.
Claims
1. A risk monitoring method for deep well casting of aluminum processing, characterized in that: include: A visual inspection camera, wherein the visual inspection camera is arranged above the grinding disc crystallizer hole, and the visual inspection camera is used to photograph the vortex image at the grinding disc crystallizer hole; A local server, wherein the vortex image captured by the visual detection camera is uploaded to a large-capacity storage hard disk of the local server; An AI visual recognition system is provided in a local server. An aluminum leakage recognition database is established inside the AI visual recognition system. The vortex image is recognized by the AI visual recognition system to determine whether aluminum liquid has penetrated, and an aluminum liquid judgment signal is generated; A deep well casting interlocking control system, wherein the deep well casting interlocking control system is arranged inside a local server, and the AI visual recognition system communicates with the deep well casting interlocking control system through a controller.
2. The risk monitoring method for deep well casting of aluminum processing according to claim 1 is characterized in that: The aluminum leakage identification database is manually marked with multiple static images through the vortex images taken in the local server, and the AI visual recognition system improves the judgment standard of the aluminum leakage identification database through the recognition algorithm.
3. The risk monitoring method for deep well casting of aluminum processing according to claim 1 is characterized in that: The deep well casting interlocking control system comprises: The first sensor is installed at the casting furnace outlet and is used to detect the liquid level of the casting furnace outlet chute; The second sensor is installed at the casting plate entrance and is used to detect the liquid level of the casting plate entrance chute; The third sensor is installed on the water inlet pipe of the casting plate and is used to detect the water inlet temperature of the casting plate; The fourth sensor is installed in the foundation pit and is used to detect the water outlet temperature of the casting plate; The monitoring module is installed in the hydraulic cylinder to detect the casting length of the aluminum rod; A liquid level warning module, wherein the liquid level warning module is signal-connected to the first sensor, the second sensor, the third sensor, and the fourth sensor; A first automatic baffle, the first automatic baffle is arranged at the casting plate entrance; a second automatic baffle, the second automatic baffle is arranged at the aluminum discharge chute; A safety interlocking device, wherein the safety interlocking device is signal-connected to the monitoring module, the first automatic baffle, and the second automatic baffle; A controller is signal-connected with the liquid level warning module, the safety interlock device, the first automatic baffle, and the second automatic baffle.
4. The risk monitoring method for deep well casting of aluminum processing according to claim 3 is characterized in that: The liquid level early warning module comprises a first alarm module, the first alarm module is connected to the first sensor by signal, and a plurality of liquid level thresholds of the casting furnace outlet chute are arranged in the first alarm module.
5. The risk monitoring method for deep well casting of aluminum processing according to claim 3 is characterized in that: The liquid level warning module also includes a second alarm module, the second alarm module is signal-connected to the second sensor, and a plurality of casting plate inlet chute liquid level thresholds are arranged in the second alarm module.
6. The risk monitoring method for deep well casting of aluminum processing according to claim 3 is characterized in that: The liquid level warning module also includes a third alarm module, and the third alarm module is signal-connected to the third sensor. The third alarm module is provided with a plurality of casting plate water inlet temperature thresholds.
7. The risk monitoring method for deep well casting of aluminum processing according to claim 3 is characterized in that: The liquid level warning module also includes a fourth alarm module, and the fourth alarm module is signal-connected to a fourth sensor. The fourth alarm module is provided with a plurality of casting plate outlet water temperature thresholds.
8. The risk monitoring method for deep well casting of aluminum processing according to claim 3 is characterized by: The liquid level warning module also includes a fifth alarm module, and the fifth alarm module is signal-connected to the monitoring module. A plurality of aluminum rod casting length thresholds are arranged in the fifth alarm module.
9. The risk monitoring method for deep well casting of aluminum processing according to claim 3 is characterized by: The first sensor and the second sensor are both laser liquid level sensors or radar liquid level sensors.