Leakage monitoring method for ladle argon blowing system
By using high-definition industrial cameras and computers to analyze images in the ladle argon blowing system, combined with Modbus data, monitoring argon leakage in the ladle, the problem of difficulty in monitoring argon leakage in the ladle is solved in the existing technology, and the precise control of argon flow is achieved and Improvement of the quality of molten steel.
Patent Information
- Application Number
- CN202411587980.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-08
- Publication Date
- 2025-02-18
AI Technical Summary
The existing ladle-blowing argon system is difficult to effectively monitor argon leakage, resulting in insufficient or excessive argon flow, affecting the purity and uniformity of the molten steel and increasing production costs.
Through the high-definition industrial camera installed on the dust collector of the argon blowing station, the ladle image is collected in real time, the computer analyzes the image to determine the motion trajectory of the ladle, and combines the Modbus data to analyze it, and determine the damage of the breathable brick when there is no molten steel in the ladle, and determines that there is a When the molten steel is exposed, the area of the molten steel is determined whether the argon is leaked.
Effective leakage monitoring of ladle argon blowing system is realized, guiding the adjustment of argon flow, ensuring the best argon blowing effect, reducing production costs, and improving the quality and operating efficiency of molten steel.
Smart Images
Figure CN119469593A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to a method for monitoring leakage of a ladle argon blowing system, belonging to the technical field of monitoring leakage of a ladle argon blowing system. Background Art
[0002] The ladle argon blowing system plays an important role in steel production. It stirs the molten steel by blowing argon into the bottom of the ladle, thereby improving the purity and uniformity of the molten steel. However, the argon blowing system in the prior art has some argon leakage problems, resulting in the bottom argon blowing failing to meet the needs of normal production, resulting in low argon blowing at the bottom of the ladle, or even no argon, which affects the refining and processing of the molten steel. Since there are two states: no molten steel in the ladle and no argon blowing, and molten steel in the ladle and argon blowing, it is difficult to monitor the leakage of the ladle argon blowing system with the prior art. Summary of the invention
[0003] The purpose of the present invention is to provide a method for monitoring leakage of a ladle argon blowing system, guide the adjustment of the argon flow rate to achieve the best argon blowing effect, reduce production costs, and accurately control the argon flow rate to avoid exposure and oxidation of molten steel due to excessive flow or affect the degassing and inclusion removal capabilities due to too small flow, thereby improving data accuracy, improving the quality of molten steel, improving operating efficiency, and reducing quality problems caused by improper manual pressure adjustment operations.
[0004] The technical solution of the present invention is: A method for monitoring leakage of a ladle argon blowing system, using a camera installed on a dust cover of an argon blowing station to collect images of the ladle in real time, a computer to read and analyze the collected images from the camera and determine the movement trajectory of the ladle, and monitoring is performed in two situations, one is that there is no molten steel in the ladle and argon is not blown, and the other is that there is molten steel in the ladle and argon is blown; a monitoring method when there is no molten steel in the ladle: using a camera to automatically capture a ladle state image, analyzing the air bricks (bottom blowing bricks) of the ladle when there is no molten steel in the ladle, using filtering and edge detection algorithms to enhance the edges in the image, highlighting surface damage of the air bricks, the surface damage is cracks or peeling, and judging whether the argon blowing system is leaking; a monitoring method when there is molten steel in the ladle: determining the position of the ladle according to the position of the ladle car, dividing a circle that just contains the entire ladle with the ladle position pixel point as the center and the ladle pixel length as the diameter, visually analyzing the area of the circle containing the entire ladle, using machine vision to analyze the exposed area of the molten steel, and judging whether the argon blowing system is leaking.
[0005] The specific steps of the monitoring method when there is no molten steel in the ladle are as follows: the identification computer first obtains the IP address, port number and register address of Modbus through the identification program, calls the camera after reading, captures the empty ladle image, checks the air bricks of the ladle according to the captured empty ladle image and evaluates the state of the air bricks at this time, uses filtering and edge detection algorithms to enhance the edges in the image, and highlights the surface damage of the air bricks; the surface damage is usually cracks or peeling, thereby judging whether there is a leak.
[0006] The monitoring method in the state of molten steel in the ladle has the following specific steps: first, in real time, an argon blowing image, a ladle car position, an argon blowing signal, and an argon flow rate and pressure of branches corresponding to two bottom blowing holes are collected; the position of the ladle is determined according to the position of the ladle car; a circle that just contains the entire ladle is divided with the ladle position pixel point as the center and the ladle pixel length as the diameter; a visual analysis is performed on the area of the circle containing the entire ladle, and the image in the circle is rotated counterclockwise by a certain angle, so that the two bottom blowing holes of the ladle are located in the lower semicircle of the analysis area; the lower semicircle is evenly divided into a lower left area A and a lower right area B, which are the locations of the two bottom blowing holes of the ladle; the exposed area of molten steel is identified in area A and area B; the formed slag eye area is identified using contour recognition; and whether there is leakage is analyzed based on the formed slag eye area combined with the argon flow rate and pressure of the two bottom blowing eyes of the ladle.
[0007] The analysis of leakage based on the formed slag eye area and the argon flow rate and pressure of the two bottom blowing holes of the ladle includes two methods: one is to compare the slag eye areas of region A and region B. Under the same argon gas and flow rate, if the area difference between the two is large, it is considered that the bottom blowing eye corresponding to the area with a smaller area has argon leakage; the other is to compare the identified slag eye areas of region A and region B with the standard area: under a certain argon gas flow rate and pressure, the standard area that should be formed by argon blowing is m. If the slag eye areas of region A and region B are smaller than m, it is considered that the bottom blowing eye corresponding to the area has argon leakage.
[0008] Argon gas is blown into the molten steel through these "slag eyes", which helps to even out the composition and temperature of the molten steel, remove inclusions, and improve the quality of the molten steel.
[0009] The camera is a high-definition industrial camera that is resistant to high temperatures.
[0010] The automatic capture of empty ladle pictures is captured according to the position of the ladle car and whether argon is blown.
[0011] The air brick analysis is to detect surface damage of the air brick, determine the position of the air brick in the captured empty package image, which is usually a fixed position; analyze the position of the air brick, use filtering and edge detection algorithms to enhance the edges in the image, and highlight the surface damage of the air brick; the surface damage is usually cracks or peeling.
[0012] The ladle position is the pixel position of the ladle center in the image, and the pixel position is fitted by the actual position of the ladle car; the molten steel exposed area analyzes the circle with the ladle position as the center and including the entire ladle, including filtering and contour recognition, and calculates the slag eye area formed by blowing argon at two bottom blowing holes; combined with the argon flow and pressure of the two bottom blowing holes, analyzes whether the argon is leaking.
[0013] The position of the ladle car, the pressure and flow of the two bottom blowing holes and the argon blowing signal are all from the Modbus server.
[0014] After the data is collected, the present invention reads the camera signal for analysis, which can improve the utilization rate of the recognition computer, and at the same time, it can capture the empty ladle and identify and analyze the slag eye area.
[0015] The beneficial effects of the present invention are as follows: guiding the adjustment of argon gas flow rate to achieve the best argon blowing effect, reducing production costs, and accurately controlling the argon gas flow rate to avoid the exposed oxidation of molten steel due to excessive flow rate or the ability to degas and remove inclusions due to too small flow rate, thereby improving data accuracy, improving the quality of molten steel, improving operating efficiency, and reducing quality problems caused by improper manual gas pressure adjustment. The present invention has significant positive effects on improving the automation level of the steel metallurgical process, ensuring product quality, reducing production costs, and improving operating efficiency, ensuring that the produced steel can meet customer needs and industry standards. BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Figure 1 It is a system diagram of an embodiment of the present invention; Figure 2 This is a distribution diagram of camera groups according to an embodiment of the present invention; Figure 3 This is a flow chart of an embodiment of the present invention; Figure 4 This is a rendering of an embodiment of the present invention; In the figure: 1 is the identification computer, 2 is the PLC, 3 is the switch, 4 is the camera, 5 is the ladle, 6 is the argon blowing baffle, and 7 is the dust hood. DETAILED DESCRIPTION
[0017] The present invention will be further described below by way of embodiments in conjunction with the accompanying drawings.
[0018] In conjunction with the accompanying drawings, this embodiment provides a method for monitoring leakage of a ladle argon blowing system, including a camera and a recognition computer, calling the camera to obtain the required image, collecting data through Modbus, and finally analyzing the data and image.
[0019] A method for monitoring the leakage of a ladle argon blowing system, using a camera installed on a dust cover of an argon blowing station to collect images of the ladle, and a computer reads and analyzes the collected images from the camera. The present invention relates to two methods for judging whether argon gas has leaked. The first method is to automatically capture an image of an empty ladle, analyze the air-permeable bricks in the empty ladle, and judge whether there is a leak by judging the state of the bottom blowing rotation; the second method is to collect images of the ladle during argon blowing, and use machine vision to analyze the exposed area of molten steel to judge whether the argon blowing system has leaked.
[0020] The camera is a high-definition industrial camera that is resistant to high temperatures.
[0021] The automatic capture of empty ladle pictures is captured according to the position of the ladle car and whether argon is blown.
[0022] The air brick analysis is to detect surface damage of the air brick, determine the position of the air brick in the captured empty package image, which is usually a fixed position; analyze the position of the air brick, use algorithms such as filtering and edge detection to enhance the edges in the image, and highlight the surface damage of the air brick; the surface damage is usually cracks or peeling.
[0023] The ladle position is the pixel position of the ladle center in the image, and the pixel position is fitted by the actual position of the ladle car; the molten steel exposed area analyzes the circle with the ladle position as the center and including the entire ladle, including filtering and contour recognition, and calculates the slag eye area formed by blowing argon at two bottom blowing holes; combined with the argon flow and pressure of the two bottom blowing holes, analyzes whether the argon is leaking.
[0024] The position of the ladle car, the pressure and flow of the two bottom blowing holes and the argon blowing signal are all from the Modbus server.
[0025] The specific steps of the first method are: real-time acquisition of ladle images, argon blowing signals and ladle car position data; when argon blowing is not performed and the ladle car is parked at the argon blowing position, capture the image of the ladle at this time and space, determine the position of the air bricks, analyze the position of the air bricks, and analyze whether their surfaces are damaged. If damaged, it is considered that the argon blowing system is leaking; the damage is usually cracks or peeling.
[0026] The second method is to judge whether there is leakage based on the exposed area of molten steel. The specific steps are as follows: Firstly, the argon blowing image, the position of the ladle car, the argon blowing signal and the argon flow rate and pressure of the two bottom blowing holes corresponding to the branch pipes are collected in real time. The position of the ladle is determined according to the position of the ladle car. A circle that just contains the entire ladle is divided with the pixel point of the ladle position as the center and the pixel length of the ladle as the diameter. The area of the circle containing the entire ladle is visually analyzed, and the image in the circle is rotated counterclockwise by a certain angle, so that the two bottom blowing holes of the ladle are located in the lower half of the analysis area. The lower half of the circle is evenly divided into the lower left area A and the lower right area B, which are the locations of the two bottom blowing holes of the ladle. The exposed area of molten steel is identified in area A and area B. The area of the slag eye formed is identified using contour recognition. According to the area of the slag eye formed, combined with the argon flow rate and pressure of the two bottom blowing holes of the ladle, it is analyzed whether there is leakage.
[0027] The analysis of leakage based on the formed slag eye area and the argon flow rate and pressure of the two bottom blowing holes of the ladle includes two methods: one is to compare the slag eye areas of region A and region B. Under the same argon gas and flow rate, if the area difference between the two is large, it is considered that the bottom blowing eye corresponding to the area with a smaller area has argon leakage; the other is to compare the identified slag eye areas of region A and region B with the standard area: under a certain argon gas flow rate and pressure, the standard area that should be formed by argon blowing is m. If the slag eye areas of region A and region B are smaller than m, it is considered that the bottom blowing eye corresponding to the area has argon leakage.
[0028] When argon gas leakage is detected, an alarm will be sounded and the alarm information will be printed on the camera screen.
Claims
1. A method for monitoring leakage of a ladle argon blowing system, characterized in that: The camera installed on the dust cover of the argon blowing station is used to collect the image of the ladle in real time. The computer reads and analyzes the collected image from the camera and determines the movement trajectory of the ladle. The monitoring is divided into two situations, one is that there is no molten steel in the ladle and argon is not blown, and the other is that there is molten steel in the ladle and argon is blown; the monitoring method when there is no molten steel in the ladle: the camera is used to automatically intercept the ladle state image, the air bricks of the ladle are analyzed when there is no molten steel in the ladle, and the edges in the image are enhanced by filtering and edge detection algorithms to highlight the surface damage of the air bricks. The surface damage is cracks or peeling, and it is judged whether the argon blowing system is leaking; the monitoring method when there is molten steel in the ladle: the position of the ladle is determined according to the position of the ladle car, and a circle that just contains the entire ladle is divided with the ladle position pixel point as the center and the ladle pixel length as the diameter. The area of the circle containing the entire ladle is visually analyzed, and the exposed area of the molten steel is analyzed using machine vision to judge whether the argon blowing system is leaking.
2. A method for monitoring leakage of a ladle argon blowing system according to claim 1, characterized in that: The specific steps of the monitoring method when there is no molten steel in the ladle are as follows: the identification computer first obtains the IP address, port number and register address of Modbus through the identification program, calls the camera after reading, captures the empty ladle image, checks the air bricks of the ladle according to the captured empty ladle image and evaluates the state of the air bricks at this time, uses filtering and edge detection algorithms to enhance the edges in the image, and highlights the surface damage of the air bricks; the surface damage is usually cracks or peeling, thereby judging whether there is a leak.
3. The method for monitoring leakage of ladle argon blowing system according to claim 1, characterized in that: The monitoring method in the state of molten steel in the ladle has the following specific steps: first, in real time, an argon blowing image, a ladle car position, an argon blowing signal, and an argon flow rate and pressure of two bottom blowing holes corresponding to the branch pipes are collected; the position of the ladle is determined according to the position of the ladle car; a circle that just includes the entire ladle is divided with the ladle position pixel point as the center and the ladle pixel length as the diameter; a visual analysis is performed on the area of the circle including the entire ladle, and the image in the circle is rotated counterclockwise by a certain angle, so that the two bottom blowing holes of the ladle are located in the lower semicircle of the analysis area; the lower semicircle is evenly divided into a lower left area A and a lower right area B, which are the positions of the two bottom blowing holes of the ladle; The exposed area of molten steel in area A and area B is identified; the area of the slag eye formed is identified using contour recognition; based on the area of the slag eye formed, combined with the argon flow and pressure of the two bottom blowing holes of the ladle, analysis is performed to determine whether there is leakage.
4. A method for monitoring leakage of a ladle argon blowing system according to claim 3, characterized in that: The analysis of leakage based on the formed slag eye area and the argon flow rate and pressure of the two bottom blowing holes of the ladle includes two methods: one is to compare the slag eye areas of region A and region B. Under the same argon gas and flow rate, if the area difference between the two is large, it is considered that the bottom blowing eye corresponding to the area with a smaller area has argon leakage; the other is to compare the identified slag eye areas of region A and region B with the standard area: under a certain argon gas flow rate and pressure, the standard area that should be formed by argon blowing is m. If the slag eye areas of region A and region B are smaller than m, it is considered that the bottom blowing eye corresponding to the area has argon leakage.
5. A method for monitoring leakage of a ladle argon blowing system according to claim 1 or 2, characterized in that: The camera is a high-definition industrial camera that is resistant to high temperatures.
6. The method for monitoring leakage of ladle argon blowing system according to claim 2, characterized in that: The automatic capture of empty ladle pictures is captured according to the position of the ladle car and whether argon is blown.
7. A method for monitoring leakage of a ladle argon blowing system according to claim 1 or 2, characterized in that: The air brick analysis is to perform surface damage detection on the air brick and determine the position of the air brick in the captured empty bag image, which is a fixed position.
8. The method for monitoring leakage of ladle argon blowing system according to claim 3, characterized in that: The ladle position is the pixel position of the ladle center in the image, and the pixel position is fitted by the actual position of the ladle car; the molten steel exposed area analyzes the circle with the ladle position as the center and including the entire ladle, including filtering and contour recognition, and calculates the slag eye area formed by blowing argon at two bottom blowing holes; combined with the argon flow and pressure of the two bottom blowing holes, analyzes whether the argon is leaking.
9. The method for monitoring leakage of ladle argon blowing system according to claim 3, characterized in that: The position of the ladle car, the pressure and flow of the two bottom blowing holes and the argon blowing signal are all from the Modbus server.