Method and system for detecting bottom blowing air permeability of steel ladle

Abstract

The invention relates to the technical field of steel ladle detection, and discloses a steel ladle bottom blowing air permeability detection method which comprises the following steps: step 1, gas pretreatment: filtering and pre-regulating pressure of input gas by using a gas pretreatment system; 2, pressure monitoring, wherein the original pressure of the system and the pressure of an outlet of a mass flow meter are collected through a pressure monitoring system; and 3, monitoring the gas flow of the air brick by using an online mass flow meter, and accessing a signal to a PLC system through an RS485 or hard wiring mode. According to the steel ladle bottom blowing air permeability detection method and system, after the pressure buffer device is introduced, pressure fluctuation can be effectively absorbed, damage to detection equipment caused by sudden pressure change is reduced, the service life of the equipment is prolonged, meanwhile, the pressure buffer device can protect a sensor against high-pressure impact, and the detection accuracy is improved. And the stability of the system is improved.

Description

Technical Field

[0001] The invention relates to the technical field of ladle detection, and in particular to a ladle bottom blowing permeability detection method and system. Background Art

[0002] Ladle bottom blowing is a metallurgical process that involves blowing inert gas into the ladle through the air-permeable element at the bottom of the ladle to stir the molten steel, promote the floating of inclusions, and even out the composition and temperature of the molten steel. This process is of great significance for improving the quality of various steels, smooth production, and reducing production costs. However, the key to the successful implementation of the bottom blowing process lies in the air permeability of the ladle bottom blowing air bricks. In actual production, due to the insufficient air permeability of the air bricks, such as lack of air flow or low flow, production accidents such as ladle inversion may occur, seriously affecting production efficiency and product quality. When testing the air permeability of existing ladle air bricks, only a simple pointer pressure gauge is used for pressure testing, and there is a lack of a pressure buffer device, resulting in inaccurate test data.

[0003] In order to solve the above problems, the present application proposes a ladle bottom blowing permeability detection method and system. Summary of the invention

[0004] Based on the technical problems existing in the background technology, the present invention proposes a ladle bottom blowing permeability detection method and system.

[0005] The present invention provides a ladle bottom blowing permeability detection method, comprising the following steps: Step 1: Gas pretreatment, using a gas pretreatment system to filter and pre-regulate the input gas; Step 2: Pressure monitoring, collecting the system original pressure and mass flow meter outlet pressure through the pressure monitoring system; Step 3: Use an online mass flow meter to monitor the gas flow of the air brick, and connect the signal to the PLC system via RS485 or hard wiring; Step 4: Data collection and processing: a mathematical calculation model is built into the PLC program to collect pressure and flow simulation signals and perform error processing; Step 5: Comprehensive judgment of pressure difference: judge the collected pressure difference to determine whether it is within the normal range and the specific stage of detection; Step 6: Comprehensive flow judgment: judge whether the collected flow is within the normal range and determine the abnormal state of the sensor; Step 7: Testing the performance of air bricks. Based on the above data, the input brick type and historical effective value data are used to determine whether the performance of the air bricks is good, average, needs maintenance or offline; Step 8: Output the results, and display the results with sound and light or on a large screen.

[0006] Preferably, the gas pretreatment system comprises a multimedia system, and argon, nitrogen or compressed air can be used as required.

[0007] Preferably, the pressure monitoring system includes a system bypass, which can be used temporarily in the event of a power outage or system failure to ensure the safety and continuity of the system.

[0008] Preferably, the flow monitoring system comprises a signal processing unit, which is capable of amplifying, filtering and converting the signal of the mass flow meter to adapt to the input requirements of the PLC system.

[0009] Preferably, the digital calculation model includes a historical data storage module, which can store historical effective value data for long-term trend analysis of the performance of the air brick.

[0010] Preferably, the mathematical calculation model built into the PLC program also includes an adaptive adjustment module, which can automatically adjust parameters according to actual detection results to optimize the detection process.

[0011] Preferably, the mathematical calculation model includes a remote monitoring module and a diagnosis module, which can realize remote monitoring and fault diagnosis through a network connection.

[0012] Preferably, the result output includes a multi-layer lighthouse-type alarm device, which intuitively reflects the performance of the air-permeable brick according to indicator lights of different colors, thereby improving the intuitiveness and convenience of operation.

[0013] A ladle bottom blowing permeability detection system, comprising: Gas pre-treatment module, used to filter and pre-regulate the input gas; Pressure monitoring module, used to collect the original system pressure and mass flow meter outlet pressure; A flow monitoring module is used to monitor the gas flow of the air brick using an online mass flow meter; The digital calculation model module is built into the PLC program and is used to collect pressure and flow analog signals and perform error processing, as well as to perform air brick performance testing based on the above data; The result output module is used to provide sound and light indication or large-screen display of the judgment results.

[0014] The digital computing model module includes: A. Analog quantity acquisition module, which comprehensively collects pressure and flow analog signals and performs error processing; B. The pressure difference comprehensive judgment module determines whether the collected pressure difference is within the normal range and the specific stage of the detection; C. Flow comprehensive judgment module, which judges whether the collected flow is within the normal range and determines the abnormal state of the sensor; D. The performance test model of air bricks combines the data collected in A, B, and C above. If all values ​​are normal effective values, the model determines whether the performance is good, average, needs maintenance, or offline based on the input brick type and historical effective value data; E. Digital quantity processing module, which provides sound and light indication or large-screen display of the judgment results.

[0015] The above technical solution of the present invention has the following beneficial technical effects: 1. By replacing the simple pointer pressure gauge with an electronic pressure sensor and mass flow meter, more accurate pressure and flow readings can be provided, thereby significantly improving the accuracy of air permeability testing. This high-precision measurement method reduces human reading errors and ensures the reliability of test data; 2. After the pressure buffer device is introduced, it can effectively absorb pressure fluctuations, reduce the damage to the detection equipment caused by sudden pressure changes, and extend the service life of the equipment. At the same time, the pressure buffer device can protect the sensor from high-pressure shocks and improve the stability of the system; 3. Combined with the PLC control system and the built-in mathematical calculation model, this system can automatically collect and process data and conduct a comprehensive evaluation of the performance of the air brick, reducing manual intervention and improving the automation and intelligence level of the detection process; 4. This system is designed with a multi-layer lighthouse-type alarm device and a large LED screen display, which can intuitively display the performance data of the breathable bricks even in low light or complex environments, improving the adaptability of the system and the flexibility of operation. In addition, the system design allows adjustments based on different detection requirements and environmental conditions, enhancing the flexibility of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 The present invention provides a flow chart of a ladle bottom blowing permeability detection method.

[0017] Figure 2 This is a system diagram of a ladle bottom blowing permeability detection system proposed by the present invention.

[0018] Figure 3 This is a structural block diagram of a digital calculation model module in a ladle bottom blowing permeability detection system proposed by the present invention.

[0019] Figure 4 The present invention provides a flow chart of a digital calculation model module in a ladle bottom blowing permeability detection system. DETAILED DESCRIPTION

[0020] In order to make the purpose, technical scheme and advantages of the present invention clearer, the present invention is further described in detail below in conjunction with specific embodiments and with reference to the accompanying drawings. It should be understood that these descriptions are only exemplary and are not intended to limit the scope of the present invention. In addition, in the following description, the description of well-known structures and technologies is omitted to avoid unnecessary confusion of the concept of the present invention.

[0021] like Figure 1-4 As shown, a ladle bottom blowing permeability detection method proposed by the present invention comprises the following steps: Step 1: Gas pretreatment, using a gas pretreatment system to filter and pre-regulate the input gas; Step 2: Pressure monitoring, collecting the system original pressure and mass flow meter outlet pressure through the pressure monitoring system; Step 3: Use an online mass flow meter to monitor the gas flow of the air brick, and connect the signal to the PLC system via RS485 or hard wiring; Step 4: Data collection and processing: a mathematical calculation model is built into the PLC program to collect pressure and flow simulation signals and perform error processing; Step 5: Comprehensive judgment of pressure difference: judge the collected pressure difference to determine whether it is within the normal range and the specific stage of detection; Step 6: Comprehensive flow judgment: judge whether the collected flow is within the normal range and determine the abnormal state of the sensor; Step 7: Testing the performance of air bricks. Based on the above data, the input brick type and historical effective value data are used to determine whether the performance of the air bricks is good, average, needs maintenance or offline; Step 8: Output the results, and display the results with sound and light or on a large screen.

[0022] In a specific embodiment, the gas pretreatment system includes a multi-media system, and argon, nitrogen or compressed air can be used as required.

[0023] In a specific embodiment, the pressure monitoring system includes a system bypass, which can be temporarily used in the event of a power outage or system failure to ensure system safety and continuity.

[0024] In a specific embodiment, the flow monitoring system includes a signal processing unit, which can amplify, filter and convert the signal of the mass flow meter to adapt to the input requirements of the PLC system.

[0025] In a specific embodiment, the digital computing model includes a historical data storage module, which can store historical effective value data for long-term trend analysis of the performance of the air brick.

[0026] In a specific embodiment, the mathematical calculation model built into the PLC program also includes an adaptive adjustment module, which can automatically adjust parameters according to actual detection results to optimize the detection process.

[0027] In a specific embodiment, the mathematical calculation model includes a remote monitoring module and a diagnosis module, which can realize remote monitoring and fault diagnosis through a network connection.

[0028] In a specific embodiment, the result output includes a multi-layer lighthouse-type alarm device, which intuitively reflects the performance of the air-permeable brick according to indicator lights of different colors, thereby improving the intuitiveness and convenience of operation.

[0029] A ladle bottom blowing permeability detection system, comprising: Gas pre-treatment module, used to filter and pre-regulate the input gas; Pressure monitoring module, used to collect the original system pressure and mass flow meter outlet pressure; A flow monitoring module is used to monitor the gas flow of the air brick using an online mass flow meter; The digital calculation model module is built into the PLC program and is used to collect pressure and flow analog signals and perform error processing, as well as to perform air brick performance testing based on the above data; The result output module is used to provide sound and light indication or large-screen display of the judgment results.

[0030] A. Connection between gas pretreatment module and pressure monitoring module: The gas pretreatment module is responsible for filtering and pre-regulating the input gas to ensure that the gas reaches the required purity and pressure level; The pre-treated gas is directly transported to the pressure monitoring module through a pipeline. The module collects the original system pressure and the outlet pressure of the mass flow meter to provide basic data for subsequent gas permeability performance evaluation; Connection method: Through pipeline connection, ensure that the gas is transported from the pretreatment module to the pressure monitoring module without leakage.

[0031] B. Connection between pressure monitoring module and flow monitoring module: The pressure data collected by the pressure monitoring module is an important reference for the flow monitoring module to perform flow monitoring; The flow monitoring module uses an online mass flow meter to monitor the gas flow of the air brick, and the pressure data provided by the pressure monitoring module is needed to calibrate the flow reading; Connection method: connected through pipelines and signal lines. The pipeline is used to transport gas, and the signal line is used to transmit pressure data to the flow monitoring module.

[0032] C. Connection between flow monitoring module and digital calculation model module: The gas flow data monitored by the flow monitoring module needs to be transmitted to the digital calculation model module for further analysis and processing; The digital calculation model module is built into the PLC program, receiving the flow data from the flow monitoring module and the pressure data from the pressure monitoring module, and performs comprehensive analysis to determine the performance of the air brick; Connection method: The data of the flow monitoring module is transmitted to the PLC through industrial communication protocols (such as RS485 or hard wiring).

[0033] D. Connection between digital calculation model module and result output module: After the digital calculation model module completes the test of the performance of the air brick, it needs to output the test results to the operator; The result output module is responsible for presenting the detection results of the digital calculation model module to the operator in the form of sound and light indication or large-screen display; Connection method: Connect to the sound and light alarm device and large-screen display through the output interface of PLC to realize intuitive display of results; E. Overall connection of the system: The entire system is coordinated by a central control unit (usually a PLC), which is responsible for receiving data from all modules and processing it according to the built-in digital calculation model module; The connections between modules include not only physical connections (such as pipes and wires), but also logical connections (such as data flow and control signals), ensuring that the system works together as a whole.

[0034] The digital computing model modules include: A. Analog quantity acquisition module, which comprehensively collects pressure and flow analog signals and performs error processing; B. The pressure difference comprehensive judgment module determines whether the collected pressure difference is within the normal range and the specific stage of the detection; C. Flow comprehensive judgment module, which judges whether the collected flow is within the normal range and determines the abnormal state of the sensor; D. The performance test model of air bricks combines the data collected in A, B, and C above. If all values ​​are normal effective values, the model determines whether the performance is good, average, needs maintenance, or offline based on the input brick type and historical effective value data; E. Digital quantity processing module, which provides sound and light indication or large-screen display of the judgment results.

[0035] It should be understood that the above specific embodiments of the present invention are only used to illustrate or explain the principles of the present invention, and do not constitute a limitation of the present invention. Therefore, any modifications, equivalent substitutions, improvements, etc. made without departing from the spirit and scope of the present invention should be included in the protection scope of the present invention. In addition, the appended claims of the present invention are intended to cover all changes and modifications that fall within the scope and boundaries of the appended claims, or the equivalent forms of such scope and boundaries.

Claims

1. A ladle bottom blowing permeability detection method, characterized in that: The following steps are involved: Step 1: Gas pretreatment, using a gas pretreatment system to filter and pre-regulate the input gas; Step 2: Pressure monitoring, collecting the system original pressure and mass flow meter outlet pressure through the pressure monitoring system; Step 3: Use an online mass flow meter to monitor the gas flow of the air brick, and connect the signal to the PLC system via RS485 or hard wiring; Step 4: Data collection and processing: a mathematical calculation model is built into the PLC program to collect pressure and flow simulation signals and perform error processing; Step 5: Comprehensive judgment of pressure difference: judge the collected pressure difference to determine whether it is within the normal range and the specific stage of detection; Step 6: Comprehensive flow judgment: judge whether the collected flow is within the normal range and determine the abnormal state of the sensor; Step 7: Testing the performance of air bricks. Based on the above data, the input brick type and historical effective value data are used to determine whether the performance of the air bricks is good, average, needs maintenance or offline; Step 8: Output the results, and display the results with sound and light or on a large screen.

2. A ladle bottom blowing permeability detection method according to claim 1, characterized in that: The gas pretreatment system includes a multi-media system and can use argon, nitrogen or compressed air as required.

3. A ladle bottom blowing permeability detection method according to claim 2, characterized in that: The pressure monitoring system includes a system bypass, which can be used temporarily in the event of a power outage or system failure to ensure system safety and continuity.

4. A ladle bottom blowing permeability detection method according to claim 3, characterized in that: The flow monitoring system includes a signal processing unit, which can amplify, filter and convert the signal of the mass flow meter to meet the input requirements of the PLC system.

5. A ladle bottom blowing permeability detection method according to claim 4, characterized in that: The digital calculation model includes a historical data storage module, which can store historical effective value data for long-term trend analysis of the performance of the air-permeable brick.

6. A ladle bottom blowing permeability detection method according to claim 5, characterized in that: The mathematical calculation model built into the PLC program also includes an adaptive adjustment module, which can automatically adjust parameters according to actual detection results to optimize the detection process.

7. A ladle bottom blowing permeability detection method according to claim 6, characterized in that: The mathematical calculation model includes a remote monitoring module and a diagnosis module, and the module can realize remote monitoring and fault diagnosis through a network connection.

8. A ladle bottom blowing permeability detection method according to claim 7, characterized in that: The result output includes a multi-layer lighthouse-type alarm device, which intuitively reflects the performance of the air-permeable brick according to indicator lights of different colors, thereby improving the intuitiveness and convenience of operation.

9. A ladle bottom blowing permeability detection system, characterized in that: include: Gas pre-treatment module, used to filter and pre-regulate the input gas; Pressure monitoring module, used to collect the original system pressure and mass flow meter outlet pressure; A flow monitoring module is used to monitor the gas flow of the air brick using an online mass flow meter; The digital calculation model module is built into the PLC program and is used to collect pressure and flow analog signals and perform error processing, as well as to perform air brick performance testing based on the above data; The result output module is used to provide sound and light indication or large-screen display of the judgment results.

10. A ladle bottom blowing permeability detection system according to claim 9, characterized in that: The digital computing model module includes: A. Analog quantity acquisition module, which comprehensively collects pressure and flow analog signals and performs error processing; B. The pressure difference comprehensive judgment module determines whether the collected pressure difference is within the normal range and the specific stage of the detection; C. Flow comprehensive judgment module, which judges whether the collected flow is within the normal range and determines the abnormal state of the sensor; D. The performance test model of air bricks combines the data collected in A, B, and C above. If all values ​​are normal effective values, the model determines whether the performance is good, average, needs maintenance, or offline based on the input brick type and historical effective value data; E. Digital quantity processing module, which provides sound and light indication or large-screen display of the judgment results.

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