Crystallizer monitoring system and method for aluminum processing

Abstract

The invention relates to the technical field of aluminum processing, and particularly provides a crystallizer monitoring system and method for aluminum processing, and the system comprises an image obtaining module which obtains an image of molten aluminum in a crystallizer in real time, and transmits the image information to a molten aluminum state monitoring module; the molten aluminum state monitoring module is used for analyzing the image information in real time, filtering interference through feature extraction and judging whether the state of the internal molten aluminum is abnormal or not through an abnormality judgment model; the temperature monitoring module is used for monitoring the temperature distribution conditions of the molten aluminum crystals and the cooling system in real time and judging whether the temperatures of the molten aluminum crystals and the cooling system are abnormal or not; and the automatic control module is used for remotely receiving molten aluminum state monitoring and temperature monitoring results, analyzing the probability and risk level of accidents caused by the monitoring results by using an event tree model, and remotely controlling equipment start and stop and operation parameter adjustment according to preset program logic. The technical problem that in the prior art, monitoring of a crystallizer and cooling water in the deep well casting process cannot be achieved is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of aluminum processing, and in particular to a crystallizer monitoring system and method for aluminum processing. Background Art

[0002] The deep well casting process for aluminum processing is a semi-continuous casting method in which the molten aluminum and aluminum alloy molten liquid is injected into the mold plate under certain process conditions, cooled and solidified, and then continuously stretched downward in the vertical direction through the ingot traction device to form an ingot. After reaching a certain length, the casting is stopped and the ingot is lifted out of the casting well. Deep well casting can obtain castings of specific length and shape. The ingot is cooled rapidly during the production process, has a fine crystalline structure, high mechanical properties, good tensile and extrusion properties, and the quality of the profile is stable and controllable. This process is widely used in aluminum processing production, but the production process itself is dangerous because high-temperature aluminum water is very likely to explode when it comes into contact with water.

[0003] In the prior art, the crystallizer cooling water system monitoring and alarm device for the deep well casting process of aluminum processing is interlocked with the quick shut-off valve, the emergency discharge valve, and the flow channel disconnection device. The casting furnace aluminum liquid outlet flow channel and the connection between the flow channel and the mold plate (distribution flow channel) inlet are provided with a liquid level monitoring and alarm device, and the aluminum liquid outlet of the fixed casting furnace is provided with a mechanical locking device. The aluminum liquid flow channel of the fixed casting furnace is provided with an emergency discharge valve, or a quick shut-off valve (disconnection device) is provided at the connection between the flow channel and the mold plate (distribution flow channel) inlet, or the liquid level monitoring and alarm device at the connection between the flow channel and the mold plate (distribution flow channel) inlet is interlocked with the quick shut-off valve (disconnection device) and the emergency discharge valve. The tilting casting furnace flow channel is provided with a quick shut-off valve (disconnection device) at the connection between the mold plate (distribution flow channel) inlet, or the liquid level monitoring and alarm device at the connection between the flow channel and the mold plate (distribution flow channel) inlet is interlocked with the casting furnace tilting control system and the quick shut-off valve (disconnection device). The steel wire winch system of the casting machine uses non-steel core steel wire rope, or implements a regular inspection and replacement system for the steel wire rope. The implementation of these measures has greatly promoted the improvement of the intrinsic safety of deep well casting, but the above content focuses on the control of the front end of casting, but cannot realize the monitoring of the crystallizer and cooling water during the deep well casting process. Summary of the invention

[0004] The object of the present invention is to provide a crystallizer monitoring system and method for aluminum processing, so as to solve the technical problem that the prior art cannot realize the monitoring of the crystallizer and cooling water in the deep well casting process.

[0005] The embodiments of the present invention are implemented by the following technical solutions:

[0006] A crystallizer monitoring system for aluminum processing, comprising:

[0007] Image acquisition module: acquires the image of aluminum liquid inside the crystallizer in real time and transmits the image information to the aluminum liquid status monitoring module;

[0008] Aluminum liquid state monitoring module: Real-time analysis of image information, filtering interference through feature extraction, and judging whether there is abnormality in the internal aluminum liquid state through the abnormality judgment model;

[0009] Temperature monitoring module: real-time monitoring of the temperature distribution of aluminum liquid crystals and cooling system, to determine whether there are abnormalities in the temperature of aluminum liquid crystals and cooling system;

[0010] Automation control module: remotely receives the aluminum liquid status monitoring and temperature monitoring results through the GPRS wireless network, uses the event tree model to analyze the probability and risk level of accidents caused by the monitoring results, and remotely controls the start and stop of equipment and the adjustment of operating parameters according to the preset program logic.

[0011] Preferably, it also includes:

[0012] Alarm system: When the aluminum liquid status monitoring module and temperature monitoring module detect an abnormality, the alarm system is activated to notify the operator.

[0013] Preferably, the alarm system adopts an audible and visual alarm system.

[0014] Preferably, the image acquisition module comprises a high-definition camera, which is arranged above the aluminum liquid surface and placed toward the liquid surface, and is used for real-time monitoring of the flow state and liquid level changes of the aluminum liquid surface.

[0015] Preferably, the abnormality judgment model in the aluminum liquid state monitoring module is obtained by the following method:

[0016] S001. Collecting, by means of an image acquisition module, images of the aluminum liquid surface containing sudden drops, vortices, swirls, bubbles or abnormally increased water vapor;

[0017] S002, pre-processing the images collected in S001 to establish a liquid level abnormality data set;

[0018] S003. Use the liquid level abnormality data set to train an abnormality judgment model.

[0019] Preferably, the abnormal state of the aluminum liquid includes abnormal flow of the aluminum liquid and abnormal solidification of the aluminum liquid.

[0020] Preferably, the temperature monitoring module monitors the temperature distribution of the aluminum liquid crystal and the cooling system by infrared thermal imaging technology or temperature sensors. When the temperature of the aluminum liquid crystal and the cooling system is unstable or abnormally increased, it is determined as temperature abnormality. When the temperature of the crystallization disk is not between 10-20°C, it is considered as temperature instability.

[0021] Preferably, it also includes a DCS distributed control module for centrally monitoring and managing safety accessories.

[0022] Preferably, the safety accessories include: an emergency shut-off valve, an emergency discharge valve and a tilting furnace tilting control device.

[0023] A method for monitoring a crystallizer for aluminum processing comprises the following steps:

[0024] S1. An image acquisition device is arranged above the aluminum liquid surface to acquire an image of the aluminum liquid inside the crystallizer in real time;

[0025] S2. Analyze the image information in real time, filter out interference through feature extraction, and determine whether there is an abnormality in the internal aluminum liquid state through an abnormality judgment model;

[0026] S3, real-time monitoring of the temperature distribution of the aluminum liquid crystal and the cooling system, and judging whether there are any abnormalities in the temperature of the aluminum liquid crystal and the cooling system;

[0027] S4. Based on the judgment results of the aluminum liquid state, aluminum liquid crystal and cooling system temperature, the equipment is started and stopped and the operating parameters are adjusted according to the preset program logic.

[0028] The technical solution of the embodiment of the present invention has at least the following advantages and beneficial effects:

[0029] (1) By real-time monitoring of the flow state and liquid level changes of the aluminum liquid in the crystallizer, capturing high-definition images, and transmitting them in real time, the system can intuitively observe the detailed state of the aluminum liquid during the casting process, and can promptly detect abnormal situations such as aluminum liquid leakage, effectively preventing accidents.

[0030] (2) Using artificial intelligence algorithms, the collected image data is analyzed in real time to determine whether the state of the aluminum liquid in the crystallizer is normal and to intervene in abnormal situations in a timely manner, thereby reducing human factors and reaction time in actual production and ensuring the safety of the casting process.

[0031] (3) Using infrared thermal imaging technology to monitor the temperature of the crystal and cooling system in real time can detect abnormalities in time and avoid accidents.

[0032] (4) The start and stop of safety accessories are controlled according to the preset logic program to accurately judge parameters such as the aluminum liquid crystal temperature and the cooling system temperature during the casting process, thereby improving the safety of the casting process.

[0033] (5) The modules work together to improve the safety and intelligence level of the deep well casting process, significantly improve production stability and safety, reduce the risk of production accidents, and achieve an efficient and safe production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments of the present invention are briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0035] Figure 1 This is a schematic diagram of the structure of the crystallizer monitoring system provided in Example 1 of the present invention. DETAILED DESCRIPTION

[0036] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0037] In order to solve the technical problem that the prior art cannot monitor the crystallizer and cooling water during deep well casting, an embodiment of the present invention provides a crystallizer monitoring system, which is specifically as follows.

[0038] Embodiment 1

[0039] like Figure 1 As shown, an embodiment of the present invention provides a crystallizer monitoring system for aluminum processing, comprising:

[0040] Image acquisition module: acquires the image of aluminum liquid inside the crystallizer in real time and transmits the image information to the aluminum liquid status monitoring module;

[0041] In this embodiment, a high-definition camera is used to monitor the flow of molten aluminum and the changes in the liquid level inside the crystallizer in real time. Specifically, the high-definition camera is suspended above the liquid aluminum level with the lens facing the liquid aluminum level. The high-definition camera can capture high-definition video images and transmit them in real time, so as to help the system intuitively observe the detailed state of the molten aluminum during the casting process. The captured high-definition video images are then transmitted to the molten aluminum state monitoring module in real time, and the video data collected by the camera are analyzed in real time using advanced artificial intelligence algorithms.

[0042] Aluminum liquid state monitoring module: Real-time analysis of image information, filtering interference through feature extraction, and judging whether there is abnormality in the internal aluminum liquid state through the abnormality judgment model;

[0043] In this embodiment, the abnormality judgment model in the aluminum liquid state monitoring module is obtained by the following method:

[0044] S001. Collecting, by means of an image acquisition module, images of the aluminum liquid surface containing sudden drops, vortices, swirls, bubbles, or abnormally increased water vapor;

[0045] S002, pre-processing the images collected in S001 to establish a liquid level abnormality data set;

[0046] S003. Use the liquid level abnormality data set to train an abnormality judgment model.

[0047] Specifically, the abnormal state of the aluminum liquid includes abnormal flow of the aluminum liquid and abnormal solidification of the aluminum liquid.

[0048] Specifically, in this embodiment, the abnormality judgment model constructed by the advanced artificial intelligence algorithm is first used to analyze the video data collected by the camera in real time. The process algorithm is: collect NG pictures → AI model training → result output, and the abnormality judgment model is obtained through the process training. Then the collected video image is input into the abnormality judgment model, and the image is identified and judged by the model, and then it is identified whether the aluminum liquid and liquid level inside the crystallizer are normal.

[0049] Specifically, the following standards are used to determine whether the fluidity and solidification of the aluminum liquid inside the crystallizer are normal. Under normal circumstances, the liquid level is stable, without fluctuations or turbulence. If there is a sudden drop in the liquid level, vortices, swirls, bubbles, or an abnormal increase in water vapor, it is considered abnormal.

[0050] In this embodiment, interference filtering is achieved through feature extraction to avoid interference with judgment due to other abnormal interventions such as personnel and equipment in production, so as to timely judge and analyze whether there is a leakage and ensure casting safety.

[0051] Temperature monitoring module: real-time monitoring of the temperature distribution of aluminum liquid crystals and cooling system, to determine whether there are abnormalities in the temperature of aluminum liquid crystals and cooling system;

[0052] In this embodiment, infrared thermal imaging technology is used to monitor the temperature distribution of aluminum liquid crystals and cooling water. This technology can detect abnormalities in aluminum liquid crystals and cooling systems. If the temperature of aluminum liquid crystals and cooling water is unstable or abnormally increased, it is determined to be a temperature abnormality and an instruction is issued to the automation control module. Specifically, the inlet water temperature is controlled within 35°C and the outlet water temperature is controlled within 55°C. If the outlet water temperature abnormally increases by more than 50°C, it is determined to be aluminum leakage; when the crystallization disk temperature is not between 10-20°C, it is considered to be temperature unstable. It should be noted that this data can be adjusted according to different casting products.

[0053] Automation control module: remotely receives the aluminum liquid status monitoring and temperature monitoring results through the GPRS wireless network, uses the event tree model to analyze the probability and risk level of accidents caused by the monitoring results, and remotely controls the start and stop of equipment and the adjustment of operating parameters according to the preset program logic.

[0054] In this embodiment, in combination with the aluminum liquid state monitoring and temperature monitoring results, the key parameters in the casting process are accurately monitored by the automatic control system, the probability and risk level of the accident caused by the current situation are analyzed by the event tree model, and the safety accessories are started to ensure that the casting process is operated under safe and controllable conditions. Specifically, when at least one of the aluminum liquid state monitoring and temperature monitoring results is abnormal, the probability and risk level of the accident caused by the abnormality are evaluated. The risk level is divided into five levels of 1-5, 1-2 levels are low risk, 3-5 are medium and high risk, and the larger the abnormal value, the higher the risk level and the probability of occurrence. When the probability of occurrence is greater than 50% and the risk level reaches level 3, the emergency shut-off valve, emergency discharge valve, tilting furnace tilting control device and other corresponding safety accessories are started, and the temperature and other parameters are adjusted at the same time until the aluminum liquid level state, cooling water and aluminum liquid temperature return to the normal range, the casting equipment is restarted, and the product is cast. Through this centralized management and real-time monitoring method, the safety of the casting process can be guaranteed to the maximum extent and the risk of accidents can be reduced.

[0055] In this embodiment, an audible and visual alarm system is also provided. When abnormalities are detected in the aluminum liquid level state and the system temperature, the audible and visual alarm system is immediately activated to promptly notify the operator through whistle and light alarm, thereby helping on-site staff to deal with the abnormalities as soon as possible and avoid accidents.

[0056] Embodiment 2

[0057] In this embodiment, a new type of intelligent sensor, such as a temperature sensor, is used to monitor the temperature distribution of the aluminum liquid crystals and the cooling water.

[0058] The basic concepts have been described above. Obviously, for those skilled in the art, the above detailed disclosure is only for example and does not constitute a limitation of this specification. Although not explicitly stated here, those skilled in the art may make various modifications, improvements and corrections to this specification. Such modifications, improvements and corrections are suggested in this specification, so such modifications, improvements and corrections still belong to the spirit and scope of the exemplary embodiments of this specification.

[0059] Finally, it should be understood that the embodiments described in this specification are only used to illustrate the principles of the embodiments of this specification. Other variations may also fall within the scope of this specification. Therefore, as an example and not a limitation, alternative configurations of the embodiments of this specification may be considered consistent with the teachings of this specification. Accordingly, the embodiments of this specification are not limited to the embodiments explicitly introduced and described in this specification.

Claims

1. A crystallizer monitoring system for aluminum processing, characterized in that: include: Image acquisition module: acquires the image of aluminum liquid inside the crystallizer in real time and transmits the image information to the aluminum liquid status monitoring module; Aluminum liquid state monitoring module: Real-time analysis of image information, filtering interference through feature extraction, and judging whether there is abnormality in the internal aluminum liquid state through the abnormality judgment model; Temperature monitoring module: real-time monitoring of the temperature distribution of aluminum liquid crystals and cooling system, to determine whether there are abnormalities in the temperature of aluminum liquid crystals and cooling system; Automation control module: remotely receives the aluminum liquid status monitoring and temperature monitoring results through the GPRS wireless network, uses the event tree model to analyze the probability and risk level of accidents caused by the monitoring results, and remotely controls the start and stop of equipment and the adjustment of operating parameters according to the preset program logic.

2. A crystallizer monitoring system for aluminum processing according to claim 1, characterized in that: Also includes: Alarm system: When the aluminum liquid status monitoring module and temperature monitoring module detect an abnormality, the alarm system is activated to notify the operator.

3. A crystallizer monitoring system for aluminum processing as claimed in claim 2, characterized in that: The alarm system adopts an audible and visual alarm system.

4. A crystallizer monitoring system for aluminum processing as claimed in claim 1, characterized in that: The image acquisition module includes a high-definition camera, which is arranged above the aluminum liquid surface and placed toward the liquid surface, and is used to monitor the flow state and liquid level changes of the aluminum liquid surface in real time.

5. The crystallizer monitoring system for aluminum processing according to claim 1, characterized in that: The abnormality judgment model in the aluminum liquid state monitoring module is obtained by the following method: S001. Collecting, by means of an image acquisition module, images of the aluminum liquid surface containing sudden drops, vortices, swirls, bubbles or abnormally increased water vapor; S002, pre-processing the images collected in S001 to establish a liquid level abnormality data set; S003. Use the liquid level abnormality data set to train an abnormality judgment model.

6. A crystallizer monitoring system for aluminum processing as claimed in claim 1, characterized in that: The abnormal state of the aluminum liquid includes abnormal flow of the aluminum liquid and abnormal solidification of the aluminum liquid.

7. A crystallizer monitoring system for aluminum processing as claimed in claim 1, characterized in that: The temperature monitoring module monitors the temperature distribution of the aluminum liquid crystal and the cooling system through infrared thermal imaging technology or temperature sensors. When the temperature of the aluminum liquid crystal and the cooling system is unstable or abnormally increased, it is judged as temperature abnormality. When the temperature of the crystallization plate is not between 10-20°C, it is considered as temperature instability.

8. The crystallizer monitoring system for aluminum processing according to claim 1, characterized in that: It also includes a DCS distributed control module for centralized monitoring and management of safety accessories.

9. A crystallizer monitoring system for aluminum processing as claimed in claim 8, characterized in that: The safety accessories include: an emergency shut-off valve, an emergency discharge valve and a tilting furnace tilting control device.

10. A method for monitoring a crystallizer for aluminum processing, characterized in that: The following steps are involved: S1. An image acquisition device is arranged above the aluminum liquid surface to acquire an image of the aluminum liquid inside the crystallizer in real time; S2. Analyze the image information in real time, filter out interference through feature extraction, and determine whether there is an abnormality in the internal aluminum liquid state through an abnormality judgment model; S3, real-time monitoring of the temperature distribution of the aluminum liquid crystal and the cooling system, and judging whether there are any abnormalities in the temperature of the aluminum liquid crystal and the cooling system; S4. Based on the judgment results of the aluminum liquid state, aluminum liquid crystal and cooling system temperature, the equipment is started and stopped and the operating parameters are adjusted according to the preset program logic.

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