Efficient and automatic deslagging method, system and device for top-blowing spray gun

Abstract

The invention relates to the technical field of top-blowing molten pool smelting, in particular to an efficient and automatic deslagging method, system and device for a top-blowing spray gun. The method comprises the steps that a spray gun crane is started to slowly lift a spray gun upwards, when the spray gun is lifted upwards, an air cooling program is started, a compressor is started, and air sprayed by a cooling device exchanges heat with melt on the surface of the spray gun to solidify the melt; after the air cooling program is started, the slag knocking program is started at the same time, the transposition motor is started to drive the annular support and the slag knocking hammer to rotate, and the slag knocking hammer is pushed to knock slag through compressed air conveyed by all the independent air inlet pipes; and when the spray gun crane lifts the spray gun to the spray gun limiting device, the air cooling program and the slag knocking program are stopped, the spray gun crane descends the spray gun, and the spray gun is reset. The system comprises a spray gun lifting module, a slag knocking module and a spray gun resetting module. According to the invention, air blowing cooling and slag knocking are carried out synchronously, and when the spray gun is completely lifted out, the slag removal work is completed; the whole process is highly coherent, and the purposes of energy conservation and emission reduction are achieved.

Description

Technical Field

[0001] The invention relates to the technical field of top-blown molten pool smelting, and in particular to a high-efficiency automatic slag removal method, system and device for a top-blowing spray gun. Background Art

[0002] Top-blown molten pool smelting is an important process that is widely used in the heavy metal smelting industry and the steel smelting industry. The top-blowing spray gun is one of the key components of the top-blowing process. During the smelting process, the splashing melt will adhere to the outer wall of the spray gun to form a layer of slag. In particular, in the submerged top-blowing process, since the spray gun needs to be immersed in the molten pool, the above-mentioned slag situation will be more serious. The thickness and texture of the slag are uneven, and there is a big difference with the spray gun material, which will cause the spray gun to be heated unevenly and cause it to deform, affecting the working performance of the spray gun and even causing the spray gun to fail. Therefore, in the current top-blowing production process, after a certain period of smelting, the spray gun needs to be lifted out of the furnace and the slag layer needs to be cooled and brittle before the staff uses a hammer to knock out the slag. This traditional spray gun deslagging method has some disadvantages: first, when the spray gun is used for deslagging, the smelting operation will be interrupted, which will seriously affect the continuity and production efficiency of the smelting process, resulting in a waste of time and manpower costs; second, the deslagging workers need to be in close contact with the high-temperature spray gun near the spray gun mouth, and the relatively harsh working environment will increase the physical burden of the workers and is not conducive to the safe production. Therefore, an efficient and automated spray gun deslagging method is urgently needed.

[0003] Prior art 1, Chinese patent, application number 202210672805.5 discloses a circumferential welding equipment for agricultural irrigation spray gun production, including: a seat plate, a telescopic clamping assembly, a motion assembly, a circumferential motion assembly, a slag removal assembly, a welding gun assembly and a workbench adjustment assembly, the ring gear is meshed with the motion assembly, the welding gun assembly includes a welding gun adjustment structure and a welding gun, the welding gun is fixed on the welding gun adjustment structure, the welding gun adjustment structure is provided with a number of and evenly fixed on the inner side of the ring gear, the slag removal assembly is provided with a number of and evenly fixed on the inner side of the ring gear, and the slag removal assembly and the welding gun assembly are arranged at intervals. Although the raw material pipe can be firmly clamped so that the butt joint fits and does not misalign, the annular butt joint can be stably welded at equal distances to make the weld layer thickness consistent, which prolongs its service life, has a high degree of automation, and saves labor costs; but it cannot fully adapt to the changes on the surface of complex workpieces, and there is still the problem of incomplete residue cleaning.

[0004] Prior art 2, Chinese patent, application number 202210700354.1 discloses a coal-fired boiler, including: a furnace body, a furnace having a furnace; a burner, including an air duct, the burner is arranged on the outer wall of the furnace body, and the outlet of the air duct is connected to the furnace; a decoking agent adding device, including a spray gun, the spray gun is located in the air duct, and the outlet of the spray gun can extend into the furnace to spray the decoking agent into the furnace. Although it has the advantages of saving decoking agent, good decoking slag effect and high decoking slag efficiency; but it is easy to accumulate ash and coke in high temperature areas, leading to high temperature corrosion and wear problems.

[0005] Prior art three, Chinese patent, application number 201110333240.X discloses a slag removal device, which includes a slag removal device, which is composed of a slag remover and a spray gun. The slag remover has a container-shaped body; one end of the body is provided with a slag inlet, the other end is provided with a slag outlet, and the top is provided with an air extraction port; the spray gun is composed of a shell and a nozzle, one end of the shell is provided with an inlet for connecting to a borehole, and the other end is provided with an outlet; one end of the nozzle extends into the shell and extends to the inlet end, and the other end passes through the side wall of the shell, and a gap is provided between the nozzle and the inlet, and the gap is connected to the outlet through the shell to form a slag discharge channel; the outlet is connected to the slag inlet through a pipeline. Although it realizes the safe, fast and convenient removal of coal powder in the borehole, and solves the technical problems of cumbersome and time-consuming secondary drilling construction in the prior art; however, it may be blocked due to the accumulation of coal powder or other impurities, affecting the slag removal efficiency.

[0006] At present, the prior art one, the prior art two and the prior art three cannot fully adapt to the changes in the surface of complex workpieces, and there are still problems such as incomplete residue cleaning, easy dust accumulation and coking in high-temperature areas, resulting in high-temperature corrosion and wear, and affecting the slag removal efficiency. Therefore, the present invention proposes a high-efficiency and automatic slag removal method, system and device for a top-blowing spray gun; proposes an integrated cooling + slag knocking system using compressed air as power; through this system and method, the slag cleaning work of the top-blowing spray gun can be carried out more efficiently, solving many disadvantages of traditional slag cleaning methods. Summary of the invention

[0007] The main purpose of the present invention is to provide a top-blowing spray gun efficient and automated slag removal method, system and device to solve the problems in the prior art that the slag cannot be fully adapted to the changes in the surface of complex workpieces, and there are still problems such as incomplete residue cleaning, easy accumulation of dust and coking in high-temperature areas, leading to high-temperature corrosion and wear, and affecting the slag removal efficiency.

[0008] To achieve the above object, the present invention provides the following technical solutions:

[0009] A high-efficiency automatic slag removal method using a top-blowing spray gun, the high-efficiency automatic slag removal method using a top-blowing spray gun comprising the following steps:

[0010] Start the spray gun hoist and slowly lift the spray gun upward. When the spray gun is lifted upward, start the air cooling program, the compressor starts, and the cooling device sprays air to exchange heat with the melt on the surface of the spray gun to solidify the melt;

[0011] After the air cooling program is started, the slag knocking program is started at the same time, the indexing motor is started, driving the annular support and the slag knocking hammer to rotate, and the compressed air supplied through each independent air inlet pipe drives the slag knocking hammer to knock the slag;

[0012] When the spray gun crane lifts the spray gun to the spray gun limit device, the air cooling program and the slag knocking program are stopped, and the spray gun crane lowers the spray gun to reset the spray gun.

[0013] As a further improvement of the present invention, the process of starting the air cooling program includes the following steps:

[0014] Real-time monitoring of the spray gun temperature data lifted by the spray gun crane and the air flow rate data of the cold air nozzle, and pre-processing of the collected data;

[0015] The pre-processed data is transmitted to the control system, the pre-processed data is analyzed, and a mapping relationship table is established according to the relationship between temperature and air flow rate;

[0016] Set the temperature threshold. If the real-time temperature of the spray gun is monitored to exceed the preset temperature threshold, adjust the air compressor according to the mapping relationship table between temperature and air flow and flow rate, and then adjust the air flow and flow rate, and continue real-time monitoring.

[0017] As a further improvement of the present invention, the process of rotating the slag hammer comprises the following steps:

[0018] During the shifting process of the slag knocking device, the current shifting status is monitored in real time, and the in-position signal is detected by the photoelectric tube. When the photoelectric tube is turned on, it outputs a low level, indicating that it is not in position; when the photoelectric tube is turned off, it outputs a high level, indicating that it is in position;

[0019] The detected indexing level signal is transmitted to the control system, and the control system analyzes the received level signal to obtain the real-time indexing data of the slag knocking device;

[0020] According to the analyzed indexing data, the indexing motor of the slag knocking hammer is adjusted through the control system to control the indexing of the slag knocking device.

[0021] As a further improvement of the present invention, the process of obtaining the real-time indexing data of the slag knocking device includes the following steps:

[0022] The transfer state of the slag knocking device is monitored in real time by a photoelectric tube. The photoelectric tube outputs different level signals according to the position change of the slag knocking hammer during the transfer process: when the slag knocking hammer has not reached the target position, the photoelectric tube is turned on and outputs a low level; when the slag knocking hammer reaches the target position, the photoelectric tube is turned off and outputs a high level; the change of the level signal directly reflects the transfer state of the slag knocking device;

[0023] The collected level signal is transmitted to the control system in real time through the signal transmission module. After receiving the level signal, the control system converts it into a recognized digital signal;

[0024] The control system analyzes the received digital signal and determines the real-time position of the slag knocking device in combination with the preset transfer logic. It determines whether the slag knocking hammer is in the target position by comparing the current level signal with the preset threshold. At the same time, it also records the time series data of the transfer process for dynamic adjustment.

[0025] As a further improvement of the present invention, the process of adjusting the slag hammer indexing motor by the control system includes the following steps:

[0026] During the transfer process of the slag knocking device, the transfer state of the device is monitored in real time. When the slag knocking device is in place, the electrical state of the sensor is changed. The state change will generate a corresponding electrical signal output. For example, a low-level signal indicates that the slag knocking device is not in place, while a high-level signal indicates that the slag knocking device is in place.

[0027] The detected electrical signal is transmitted to the control system, which is received and analyzed as the device's indexing status information; the indexing status information received by the control system is sent to the data processing unit for analysis, and is evaluated according to the preset logic rules and algorithms to determine the actual position and indexing status of the slag knocking device; the analysis results generate control instructions to instruct the specific actions that the slag knocking hammer indexing motor should perform;

[0028] Based on the results of data analysis, the control system will send instructions to the slag hammer indexing motor to dynamically adjust the motor's speed and direction; the motor control unit monitors the motor's operating status in real time and makes fine adjustments based on feedback information to compensate for any possible deviations.

[0029] As a further improvement of the present invention, the process of evaluating according to preset logical rules and algorithms includes the following steps:

[0030] Acquire diverse data from different sensors, including electrical signals, mechanical position encoders, and pressure sensor data; filter and denoise multi-source signals;

[0031] The received status information is processed hierarchically according to importance and urgency; the weights of different signals are dynamically allocated according to the current operating environment and historical data; a logical decision tree is constructed by combining expert systems and machine learning to achieve rapid identification and classification of the status of the slag knocking device;

[0032] The control strategy is adjusted dynamically according to the changes in the status of the slag knocking device. The historical data and current status are used to predict the future behavior of the device and make control decisions. The real-time feedback of the slag knocking device status is compared with the preset target state and fine-tuned through closed-loop control. When an abnormal state occurs, the system will automatically initiate an emergency plan, slow down, stop or switch to an alternative control strategy.

[0033] As a further improvement of the present invention, the process of resetting the spray gun comprises the following steps:

[0034] The control system controls the crane motor and monitors the displacement and tension of the crane traction rope in real time;

[0035] If it is detected that the pulling force on the crane increases and the crane traction rope stops moving, a limit signal is sent to the control system, indicating that the spray gun has been lifted to the spray gun limit device;

[0036] When the control system receives the limit signal, the air cooling program and the slag knocking program are stopped. After the program stops, the crane motor is controlled to run and the traction rope is slowly released to make the sprayer drop and reset.

[0037] As a further improvement of the present invention, the process of stopping the air cooling process and the slag knocking process includes the following steps:

[0038] During the spray gun lifting process, the encoder monitors the displacement information of the crane traction rope in real time; the torque sensor monitors the change of the pulling force on the crane in real time, and when the pulling force increases and the displacement stops, it is determined that the spray gun has reached the limit device;

[0039] During the reset process, the air cooling program is stopped by integrating an emergency stop device in the air cooling system. When receiving the limit signal, the power supply of the air cooling system is cut off to achieve a rapid stop of the air cooling program; the slag knocking program, when the limit signal is triggered, identifies and stops the slag knocking program;

[0040] After the air cooling and slag knocking procedures stop, the control system controls the crane motor to run at a steady speed, controlling the motor speed and the release speed of the traction rope.

[0041] To achieve the above object, the present invention provides the following technical solutions:

[0042] A top-blowing spray gun efficient automatic slag removal system, which is applied to the top-blowing spray gun efficient automatic slag removal method, the top-blowing spray gun efficient automatic slag removal system comprises:

[0043] The spray gun lifting module is used to start the spray gun hoist to lift the spray gun upward. When the spray gun is lifted upward, the air cooling program is started, the compressor is started, and the cooling device sprays air to exchange heat with the melt on the surface of the spray gun to solidify the melt;

[0044] The slag knocking module is used to start the slag knocking program at the same time after the air cooling program is started. The indexing motor is started to drive the annular bracket and the slag knocking hammer to rotate, and the compressed air supplied through each independent air inlet pipe drives the slag knocking hammer to knock the slag;

[0045] The spray gun reset module is used to stop the air cooling program and the slag knocking program when the spray gun crane lifts the spray gun to the spray gun limit device, and the spray gun crane lowers the spray gun to reset the spray gun.

[0046] To achieve the above object, the present invention provides the following technical solutions:

[0047] A top-blowing spray gun high-efficiency automatic slag removal device, which is applied to the top-blowing spray gun high-efficiency automatic slag removal device, the top-blowing spray gun high-efficiency automatic slag removal device comprises: a spray gun hoist, a top-blowing spray gun, a spray gun limit device, a slag knocking device, a cooling device, an air compressor, a compressed air delivery pipeline, an electric control flow regulating valve, a top-blowing furnace, a pneumatic slag knocking hammer, a slag knocking hammer bracket, an air nozzle and an air distribution pipe;

[0048] Among them, the spray gun hoist lifts the top-blowing spray gun through a steel cable, and the spray gun limit device is fixed through the upper part of the top-blowing spray gun; the lower part of the spray gun limit device is a slag knocking device, and a cooling device is installed below the slag knocking device; a pneumatic slag knocking hammer is fixed above the slag knocking hammer bracket in the slag knocking device, and an air nozzle facing the top-blowing spray gun is surrounded in the cooling device below, and each air nozzle is connected to an air distribution pipe; the air distribution pipe and the pneumatic slag knocking hammer are connected to the air compressor through a compressed air delivery pipeline, and an electric control flow regulating valve is provided in each air delivery pipeline; the top-blowing furnace is directly below the top-blowing spray gun;

[0049] The slag knocking device includes: a top-blowing lance, a pneumatic slag knocking hammer and a slag knocking hammer bracket;

[0050] The slag knocking operation is completed by a group of pneumatic slag knocking hammers arranged around the spray gun; all the pneumatic slag knocking hammers are fixed on a circular slag knocking hammer bracket, which can drive the pneumatic slag knocking hammers to rotate; each pneumatic slag knocking hammer uses a separate air inlet pipe as the air source;

[0051] The pneumatic slag hammer includes: a cylinder body, a distribution valve plate, a valve plate slide rod, an air inlet, a rear air chamber, a piston, a pressure relief port, a piston rod, a front air chamber, a hammer head and an axial channel;

[0052] Among them, the pneumatic slag hammer is mainly composed of three parts: cylinder body, piston and distribution valve; the cylinder body is provided with an air inlet, a pressure relief port and an axial channel, and the two ends of the channel are connected to the front air chamber and the left side space of the valve plate respectively. The piston is connected to the hammer head through the piston rod, and the reciprocating motion of the piston can drive the hammer head to complete the knocking action; the distribution valve is composed of a distribution valve plate and a valve plate slide rod. The distribution valve plate slides on the valve plate slide rod under the influence of the pressure difference on both sides to realize the distribution function.

[0053] In the present invention, air blowing cooling and slag knocking are carried out simultaneously, and the slag removal work is completed when the spray gun is fully raised. The whole process is highly coherent and the efficiency is much higher than the traditional slag removal method; all subsystems are coordinated by the control system, and the working parameters of the actuator (such as: the knocking force and frequency of the slag knocking hammer, the air flow of the cooling device, and the relative posture of the spray gun-actuator) can be set according to the actual production situation when debugging the equipment. After the equipment is debugged, each subsystem performs automated operations according to the preset, which greatly improves the working environment of the operator; the spray gun hoisting machine is the original equipment of the top-blown furnace. The air compressor that provides power for the cooling device and the slag knocking hammer is also an essential supporting equipment for the top-blown furnace. It only needs to slightly modify the gas pipeline to serve as the gas source of the slag removal system. In summary, the present invention has low transformation cost and can greatly save labor costs, which can promote cost savings and increase production capacity; only the throttle valve part of the actuator (cooling device and slag knocking device) needs to be electronically controlled, and the main power is all provided by compressed air, which can reduce carbon emissions in the whole process and achieve the purpose of energy saving, emission reduction and environmental friendliness. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] Figure 1 A schematic diagram of the steps of an embodiment of a method for efficient and automated slag removal using a top-blowing lance according to the present invention;

[0055] Figure 2 A schematic flow chart of the steps of starting the air cooling procedure of an embodiment of the method for efficient and automated slag removal of a top-blowing lance of the present invention;

[0056] Figure 3 It is a schematic flow chart of the steps of rotating the slag hammer in one embodiment of the method for efficient and automatic slag removal with a top-blowing lance of the present invention;

[0057] Figure 4 A schematic flow chart of the steps of resetting the top-blowing spray gun in one embodiment of the method for efficient and automated slag removal of the top-blowing spray gun of the present invention;

[0058] Figure 5 It is a functional module schematic diagram of an embodiment of a high-efficiency automatic slag removal system for a top-blowing lance of the present invention;

[0059] Figure 6 It is a structural schematic diagram of an embodiment of a top-blowing lance efficient slag removal device of the present invention;

[0060] Figure 7 It is a schematic diagram of an embodiment of a top-blowing lance efficient slag removal device of the present invention;

[0061] Figure 8 This is a schematic structural diagram of a cooling device of an embodiment of a top-blowing lance efficient slag removal device of the present invention;

[0062] Fig. 9 It is a structural schematic diagram of a slag knocking device of an embodiment of a high-efficiency slag removal device of a top-blowing lance of the present invention;

[0063] Fig.10 It is a schematic diagram of the structure of a slag hammer of an embodiment of a high-efficiency slag removal device for a top-blowing lance of the present invention;

[0064] Fig.11 This is a working principle diagram of a slag hammer of an embodiment of a high-efficiency slag removal device for a top-blowing lance of the present invention;

[0065] Fig.12 It is a structural schematic diagram of an embodiment of an electronic device of the present invention;

[0066] Fig.13 It is a schematic structural diagram of an embodiment of the storage medium of the present invention. DETAILED DESCRIPTION

[0067] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0068] The terms "first", "second" and "third" in the present invention are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of indicated technical features. Therefore, the features defined as "first", "second" and "third" can explicitly or implicitly include at least one of the features. In the description of the present invention, the meaning of "multiple" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined. All directional indications (such as up, down, left, right, front, back...) in the embodiments of the present invention are only used to explain the relative position relationship, movement, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication also changes accordingly. In addition, the terms "including" and "having" and any of their variations are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device that includes a series of steps or units is not limited to the listed steps or units, but optionally also includes steps or units that are not listed, or optionally also includes other steps or units inherent to these processes, methods, products or devices.

[0069] Reference to an "embodiment" herein means that a particular feature, structure, or characteristic described in conjunction with the embodiment may be included in at least one embodiment of the present invention. The appearance of the phrase in various places in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0070] like Figure 1 As shown, this embodiment also provides an embodiment of a high-efficiency automatic slag removal method using a top-blowing spray gun. In this embodiment, the high-efficiency automatic slag removal method using a top-blowing spray gun specifically includes the following steps:

[0071] Step S100: starting the spray gun hoist to slowly lift the spray gun upwards. When the spray gun is slowly lifted upwards, starting the air cooling program, starting the compressor, and the cooling device sprays air to exchange heat with the melt on the surface of the spray gun to solidify the melt;

[0072] Step S200: After the air cooling program is started, the slag knocking program is started at the same time, the indexing motor is started, driving the annular support and the slag knocking hammer to rotate, and the compressed air supplied through each independent air inlet pipe drives the slag knocking hammer to knock the slag;

[0073] Step S300: When the spray gun crane lifts the spray gun to the spray gun limit device, the air cooling program and the slag knocking program are stopped, and the spray gun crane slowly lowers the spray gun to reset the spray gun.

[0074] Preferably, in step S100 of this embodiment, the spray gun crane is started to lift the spray gun, and the air cooling program is started at the same time, the compressor starts working, and the cooling device sprays air to exchange heat with the melt on the surface of the spray gun; this ensures that the melt on the surface of the spray gun can quickly cool and solidify during the lifting process, and prevents the melt from dripping or causing other safety hazards during the lifting process; at step S200, when the air cooling program is started, the slag knocking program is also started, and the indexing motor drives the annular bracket and the slag knocking hammer to rotate, and the slag knocking hammer is pushed by compressed air to knock the slag; the slag cooled and solidified on the surface of the spray gun is effectively removed, ensuring the cleaning and smooth use of the spray gun; in step S300, when the spray gun is lifted to the limit device, the air cooling program and the slag knocking program are stopped, and the spray gun crane slowly lowers the spray gun to reset; this ensures that the spray gun can be safely and accurately reset after cooling and slag knocking.

[0075] To sum up, this embodiment improves the safety of the operation while ensuring the cleanliness of the spray gun surface; maintains the working efficiency of the spray gun, extends the service life of the spray gun, and also improves the operation efficiency; ensures the continuity and stability of the operation process, and also improves the safety and efficiency of the overall operation.

[0076] Furthermore, if Figure 2 As shown, the process of starting the air cooling program in step S100 specifically includes the following steps:

[0077] Step S101: real-time monitoring of the temperature data of the spray gun lifted by the spray gun crane and the air flow rate data of the cold air nozzle, and pre-processing the collected data;

[0078] Step S102: transmitting the preprocessed data to the control system, analyzing the preprocessed data, and establishing a mapping relationship table according to the relationship between temperature and air flow rate;

[0079] Step S103: Set a temperature threshold. If the real-time temperature of the spray gun is monitored to exceed the preset temperature threshold, adjust the air compressor according to the mapping relationship table between temperature, air flow and flow rate, and then adjust the air flow and flow rate, and continue real-time monitoring.

[0080] Among them, step S101 data collection and preprocessing, spray gun temperature data preprocessing formula:

[0081]

[0082] Where, T pre Represents the spray gun temperature data after pretreatment; T i represents the original data of the spray gun temperature at the i-th time point; t i represents the timestamp of the i-th time point; t0 represents the timestamp of the current time point; α represents the weighting coefficient of the temperature data, which is used to adjust the weight of the temperature data; β represents the time attenuation coefficient, which is used to control the influence of time on the temperature data; γ represents the standard deviation correction coefficient, which is used to adjust the fluctuation range of the temperature data; σ T Represents the standard deviation of temperature data, which is used to measure the dispersion of temperature data;

[0083] Air flow velocity data preprocessing formula:

[0084]

[0085] In the formula, Q pre Indicates the air flow rate data after preprocessing; Q j represents the original data of air flow rate at the jth time point; t j Indicates the timestamp of the jth time point; φ indicates the frequency coefficient, which is used to adjust the influence of periodic fluctuations; φ indicates the phase shift coefficient, which is used to adjust the influence of time shift; δ indicates the flow rate change correction coefficient, which is used to adjust the influence of flow changes; Indicates the rate of change of air flow velocity;

[0086] Step S102 indicates that a data mapping relationship is established, and the mapping relationship formula between temperature and air flow rate is:

[0087]

[0088] In the formula, Q map Indicates the air flow rate after mapping; T ref It represents the reference temperature value, which is used to adjust the influence of temperature on flow rate; κ represents the mapping coefficient between temperature and flow rate; η represents the temperature correction coefficient, which is used to adjust the influence of temperature on the mapping relationship; λ represents the flow logarithmic correction coefficient, which is used to adjust the influence of flow on the mapping relationship; μ represents the flow reference value, which is used to adjust the range of logarithmic calculation;

[0089] Step S103: Temperature threshold control and air compressor adjustment. The air compressor adjustment formula is:

[0090]

[0091] Where P comp Indicates the regulating power of the air compressor; T real Represents the real-time monitored spray gun temperature data; T th Indicates the preset temperature threshold; T max Indicates the maximum temperature value allowed by the system; ξ indicates the power adjustment coefficient, which is used to adjust the output power of the compressor; ρ indicates the temperature deviation index, which is used to adjust the impact of temperature deviation on power; ζ indicates the temperature change rate correction coefficient, which is used to adjust the impact of temperature change on power; Indicates the rate of change of temperature; the above formula design fully considers the complex relationship between temperature, air flow velocity and time factors, and can achieve high-precision air cooling control.

[0092] Preferably, step S101 of this embodiment monitors the temperature data of the spray gun lifted by the spray gun crane in real time, checks the air flow rate data of the cold air nozzle, and pre-processes the collected data; through real-time monitoring and pre-processing, the accuracy and reliability of the data can be guaranteed; step S102 transmits the pre-processed data to the control system, analyzes the pre-processed data, and establishes a mapping relationship table based on the relationship between temperature and air flow rate; through data analysis to establish a mapping relationship table, the relationship between temperature and air flow rate can be clarified; step S103 ensures that the spray gun temperature is within the preset range through real-time monitoring and dynamic adjustment to avoid overheating or overcooling.

[0093] In summary, this embodiment ensures the real-time and accuracy of the data, and provides the possibility for precise control; through data analysis, the best matching relationship between temperature and air flow rate can be found, thereby optimizing the control strategy; precise control of the spray gun temperature is achieved, ensuring the stability and efficiency of the production process, and also helping to extend the service life of the equipment.

[0094] Furthermore, if Figure 3 As shown, the specific steps of rotating the slag hammer in step S200 include:

[0095] Step S201: During the indexing process of the slag knocking device, the current indexing state is monitored in real time, and the in-position signal is detected by the photoelectric tube. When the photoelectric tube is turned on, a low level is output, indicating that it is not in position; when the photoelectric tube is turned off, a high level is output, indicating that it is in position;

[0096] Step S202: transmitting the detected indexing level signal to the control system, and the control system analyzes the received level signal to obtain real-time indexing data of the slag knocking device;

[0097] Step S203: According to the analyzed indexing data, the indexing motor of the slag knocking hammer is adjusted through the control system to control the indexing of the slag knocking device;

[0098] Preferably, step S201 of this embodiment ensures that during the rotation process of the slag knocking device, the system can continuously track its status to avoid operational errors or equipment damage caused by sudden changes in status; the physical properties of the photoelectric tube are used to accurately determine whether the slag knocking device has reached the predetermined position, with fast response speed and high accuracy; step S202 transmits the level signal detected by the photoelectric tube to the control system in real time, thereby realizing rapid transmission of information; the control system analyzes the received level signal to obtain real-time rotation data of the slag knocking device, thereby ensuring the accuracy and effectiveness of the information; step S203 adjusts the operating status of the slag knocking hammer rotation motor in real time according to the rotation data analyzed by the control system; it has the characteristics of flexibility and strong adaptability; by precisely controlling the operation of the slag knocking hammer rotation motor, precise control of the rotation of the slag knocking device is achieved; the accuracy and stability of the rotation of the slag knocking device are improved; the efficiency and safety of the slag knocking process are ensured, thereby improving production efficiency.

[0099] In summary, this embodiment improves the accuracy and reliability of the indexing control; provides accurate indexing status information to ensure the smooth progress of the entire control process; realizes the digital representation of the indexing status to facilitate control and processing; provides accurate indexing data support for the control system and provides a basis for adjusting the indexing motor of the slag knocking hammer; improves the accuracy and stability of the indexing of the slag knocking device; ensures the high efficiency and safety of the slag knocking process and improves production efficiency.

[0100] Furthermore, the process of obtaining the real-time indexing data of the slag knocking device in step S202 specifically includes the following steps:

[0101] Step S2021: The photoelectric tube monitors the position status of the slag knocking device in real time. The photoelectric tube outputs different level signals according to the position change of the slag knocking hammer during the position change: when the slag knocking hammer has not reached the target position, the photoelectric tube is turned on and outputs a low level; when the slag knocking hammer reaches the target position, the photoelectric tube is turned off and outputs a high level. The change of this level signal directly reflects the position status of the slag knocking device;

[0102] Step S2022: The collected level signal is transmitted to the control system in real time through the signal transmission module. After receiving the level signal, the control system converts it into a recognized digital signal;

[0103] Step S2023: the control system analyzes the received digital signal and determines the real-time position of the slag knocking device in combination with the preset transfer logic; for example, by comparing the current level signal with the preset threshold value, it is determined whether the slag knocking hammer is at the target position; at the same time, the time series data during the transfer process is recorded for dynamic adjustment;

[0104] Preferably, in step S2021 of this embodiment, the photoelectric tube monitors the shifting state in real time. The photoelectric tube outputs different level signals by monitoring the position change of the slag hammer; the change of this signal directly reflects the shifting state of the slag knocking device. Specifically: when the slag knocking hammer has not reached the target position, the photoelectric tube is turned on and outputs a low level; when the slag knocking hammer reaches the target position, the photoelectric tube is cut off and outputs a high level. Significance: real-time and accuracy. As a highly sensitive sensor, the photoelectric tube can quickly capture the position changes of the slag knocking hammer and convert these changes into recognizable level signals; real-time monitoring provides basic data for subsequent control and analysis to ensure that the shifting process of the slag knocking device is always in a controllable state. Step S2022 Transmission and processing of level signals, the collected level signals are transmitted to the control system in real time through the signal transmission module, and the control system converts the level signals into digital signals and analyzes them in combination with the preset shifting logic. Specifically including: comparing the current level signal with the preset threshold value to determine whether the slag knocking hammer is in the target position; recording the time series data during the shifting process for dynamic adjustment. Significance: signal transmission and processing efficiency. By converting analog signals into digital signals, the control system can more accurately analyze the position status of the slag hammer; at the same time, the recording of time series data provides data support for subsequent dynamic adjustment and optimization; it not only improves the response speed of the system, but also lays the foundation for fault diagnosis and performance optimization. Step S2023 Dynamic adjustment and data storage: According to the analyzed transposition data, the control system dynamically adjusts the operating parameters of the slag hammer transposition motor. Specifically, it includes: when it is detected that the slag hammer is not in place, the motor speed is increased; when the slag hammer approaches the target position, the speed is gradually reduced to achieve precise positioning; the data of each transposition is stored in the database for optimization analysis. Significance: intelligence and adaptability. By dynamically adjusting the operating parameters of the motor, the control system can achieve precise positioning of the slag hammer and avoid positioning deviations caused by too fast or too slow speed; at the same time, the storage and analysis of data make it possible for long-term optimization of the system; by identifying abnormal conditions during the transposition process, the system can automatically adjust the control strategy to further improve the stability and efficiency of operation.

[0105] In summary, this embodiment realizes real-time monitoring and precise control of the slag knocking device's transposition process through the coordinated work of the three steps of photoelectric tube monitoring, signal transmission and processing, and dynamic adjustment and data storage. This not only improves the working efficiency of the slag knocking device, but also reduces the need for manual intervention, providing strong support for industrial automation.

[0106] Furthermore, the process of adjusting the slag hammer indexing motor by the control system in step S203 specifically includes the following steps:

[0107] Step S2031: During the transfer process of the slag knocking device, the transfer state of the device is monitored in real time. When the slag knocking device is in place, the electrical state of the sensor is changed. The state change will generate a corresponding electrical signal output. For example, a low-level signal indicates that the slag knocking device is not in place, while a high-level signal indicates that the slag knocking device is in place.

[0108] Step S2032: The detected electrical signal is transmitted to the control system, and the electrical signal is received and analyzed as the indexing state information of the device; the indexing state information received by the control system is sent to the data processing unit for analysis, and is evaluated according to the preset logic rules and algorithms to determine the actual position and indexing state of the slag knocking device; the analysis result generates a control instruction to instruct the indexing motor of the slag knocking hammer to perform a specific action;

[0109] Step S2033: Based on the results of data analysis, the control system will send instructions to the slag hammer indexing motor to dynamically adjust the speed and direction of the motor; the motor control unit monitors the operating status of the motor in real time and makes fine adjustments based on the feedback information to compensate for any possible deviations.

[0110] Preferably, in step S2031 of this embodiment, the device's indexing status is monitored in real time. Real-time monitoring can ensure that the device is monitored at every stage of the indexing process, which helps to promptly detect any abnormalities, such as whether the device has reached the predetermined position or whether it has been stuck. Significance: Through real-time monitoring, the safe operation of the slag knocking device can be ensured, and equipment damage and production delays caused by the device not being in place or being stuck can be avoided. Step S2032 transmits and analyzes the indexing status information of the device through electrical signals, converts the physical state of the device into electrical signals, and then analyzes it through the control system to digitize the status information for subsequent processing and analysis. Significance: Digital status information allows the control system to process data at a faster speed and higher accuracy, thereby improving the response speed and accuracy of the entire system. Step S2033 issues instructions to the indexing motor of the slag knocking hammer, and the control system dynamically adjusts the speed and direction of the motor according to the analysis results, so that the motor can accurately move the slag knocking device to the correct position. Significance: This dynamic adjustment can greatly reduce energy consumption and improve work efficiency; at the same time, by fine-tuning the compensation deviation, the precise positioning of the device can be ensured, which is crucial to improving the efficiency and quality of slag knocking.

[0111] To sum up, the three steps of this embodiment jointly ensure the precise control of the slag knocking hammer indexing motor and improve the operating efficiency and reliability of the entire slag knocking device; a control system with a high degree of automation and fast response speed is of great significance to modern industrial production. It can not only reduce manual operation errors, but also reduce equipment failures and production accidents, thereby reducing costs and improving production efficiency.

[0112] Furthermore, the process of evaluating according to the preset logic rules and algorithms in step S2032 specifically includes the following steps:

[0113] Step S20321: Obtain diverse data from different sensors, such as position, velocity, acceleration, etc., including data from electrical signals, mechanical position encoders, and pressure sensors; filter and denoise multi-source signals;

[0114] Step S20322: hierarchically process the received status information according to importance and urgency; dynamically assign weights to different signals according to the current operating environment and historical data; and construct a logical decision tree by combining expert system and machine learning to achieve rapid identification and classification of the status of the slag knocking device;

[0115] Combine expert knowledge and machine learning models to build a logical decision tree; in the decision tree, each node represents a decision or classification problem, and each branch represents a decision path based on input features; ensure that the decision tree can cover all possible states and behaviors, as well as the corresponding control strategies;

[0116] Step S20323: Dynamically adjust the control strategy according to the changes in the state of the slag knocking device; use historical data and current status to predict the future behavior of the device and make control decisions; the real-time feedback of the slag knocking device status will be compared with the preset target state and fine-tuned through closed-loop control; when an abnormal state occurs, the system will automatically initiate an emergency plan, such as slowing down, stopping or switching to a backup control strategy.

[0117] Preferably, step S20321 of this embodiment obtains diversified data from different sensors, and filters and denoises multi-source signals; ensures that the system can obtain accurate data from multiple channels, including key parameters such as position, speed, acceleration, etc.; filtering and denoising help remove noise and inaccurate information in the data, and provide a clearer data basis for analysis. Significance: Accurate data is the basis for making correct decisions; improves the reliability and accuracy of the system, making subsequent analysis and control more reliable. Step S20322 hierarchically processes the received status information according to importance and urgency, and constructs a logical decision tree; through hierarchical processing, it can prioritize according to the importance and urgency of the signal to ensure that the most critical information is processed first. At the same time, the logical decision tree constructed using expert systems and machine learning technology can realize rapid identification and classification of device status; enables the system to quickly respond to various state changes, improve decision-making efficiency, and make appropriate control decisions based on state changes, enhancing the adaptability and response speed of the system. Step S20323 dynamically adjusts the control strategy according to the change of the state of the slag knocking device; the setting of closed-loop control and emergency plan ensures that the system can respond quickly when an abnormality occurs, ensuring the safe and stable operation of the device. Significance: Dynamically adjusting the control strategy can make the system more flexible and better adapt to changes in the external environment; through closed-loop control and emergency plan, the system can minimize the risks caused by abnormal situations and improve the safety and stability of the system.

[0118] In summary, the steps of this embodiment jointly construct an intelligent monitoring and control framework, which not only improves the operating efficiency of the slag knocking device, but also enhances the safety and reliability of the system, which is of great significance for improving production efficiency and reducing maintenance costs.

[0119] Furthermore, if Figure 4 As shown, the process of resetting the spray gun in step S300 specifically includes the following steps:

[0120] Step S301: The control system controls the crane motor and monitors the displacement and tension of the crane traction rope in real time;

[0121] Step S302: If it is detected that the pulling force on the crane increases and the traction rope of the crane stops moving, a limit signal is sent to the control system, indicating that the spray gun has been lifted to the spray gun limit device;

[0122] Step S303: When the control system receives the limit signal, the air cooling program and the slag knocking program are stopped immediately. After the program stops, the crane motor is controlled to run slowly, and the traction rope is slowly released to slowly lower the spray gun and reset it.

[0123] Preferably, in step S301 of this embodiment, the control system controls the crane motor and monitors the displacement and tension of the crane traction rope in real time; it ensures that the crane motor runs under precise control, and monitors the status of the traction rope in real time; if it is monitored in step S302 that the tension on the crane increases and the traction rope stops moving, a limit signal is sent; by judging the changes in tension and displacement, it is accurately identified that the spray gun has reached the position of the limit device; step S303 receives the limit signal, stops the air cooling and slag knocking procedures, and then slowly releases the traction rope to reset the spray gun; after confirming that the spray gun has reached the limit, stops the relevant procedures in time, and ensures the safe resetting of the spray gun by slowly releasing the traction rope.

[0124] In summary, the real-time monitoring of this embodiment helps to detect abnormal situations in time, ensure the safety and accuracy of operation; prevent damage or safety hazards caused by excessive lifting of the spray gun, ensure the accuracy and safety of operation; ensure the continuity of operation, reduce mechanical impact and wear by slow resetting, and extend the life of the equipment.

[0125] Furthermore, the process of immediately stopping the air cooling process and the slag knocking process in step S303 specifically includes the following steps:

[0126] Step S3031: During the spray gun lifting process, the displacement information of the crane traction rope is monitored in real time by the encoder; the change of the tension on the crane is monitored in real time by the torque sensor, and when the displacement stops due to the increase of the tension, it is determined that the spray gun has reached the limit device;

[0127] Step S3032: During the reset process, the air cooling program is stopped by integrating an emergency stop device in the air cooling system. When a limit signal is received, the power supply of the air cooling system is cut off to achieve a rapid stop of the air cooling program; the slag knocking program, when the limit signal is triggered, identifies and stops the slag knocking program;

[0128] Step S3033: After the air cooling and slag knocking procedures are stopped, the control system controls the crane motor to run at a steady speed, and controls the motor speed and the release speed of the traction rope.

[0129] Preferably, in step S3031 of this embodiment, the detection technology of the spray gun reaching the limit device monitors the displacement and force of the spray gun in real time through the encoder and torque sensor. Once the pulling force increases and the displacement stops, it is determined that the spray gun has reached the limit device, thereby realizing precise control of the spray gun position. Significance: effectively prevent the spray gun from exceeding the stroke, protect the limit device, and ensure the safe operation of the equipment. Step S3032 is the emergency stop technology of the air cooling and slag knocking program. The emergency stop device is integrated in the air cooling system, and the power supply is cut off when the limit signal is triggered to realize the rapid stop of the air cooling program; the slag knocking program can also be identified and stopped when the limit signal is triggered. Significance: Rapidly respond to the limit signal to avoid over-stroke of the spray gun and damage to the equipment, and improve the safety and reliability of the system. Step S3033 is the control technology for the stable operation of the crane motor. After the air cooling and slag knocking programs stop, the control system controls the crane motor to make it run at a stable speed, and controls the motor speed and the release speed of the traction rope. Significance: Ensure the smooth movement of the spray gun after stopping, avoid impact on the spray gun and equipment, reduce equipment wear, extend equipment service life, and improve operating efficiency.

[0130] In summary, this embodiment ensures that the spray gun can stop in time when it reaches the limit device through accurate position detection, emergency stop response and smooth operation control, effectively protecting the equipment, reducing equipment wear, and improving operating efficiency and equipment life. At the same time, fast response and smooth control also improve the safety and reliability of the system.

[0131] like Figure 5 As shown, this embodiment also provides an embodiment of a top-blowing spray gun efficient automatic slag removal system. In this embodiment, the top-blowing spray gun efficient automatic slag removal system is applied to the top-blowing spray gun efficient slag removal method in the above embodiment, specifically including:

[0132] The spray gun lifting module 25 is used to start the spray gun hoist to slowly lift the spray gun upwards. When the spray gun is slowly lifted upwards, the air cooling program is started, the compressor is started, and the cooling device sprays air to exchange heat with the melt on the surface of the spray gun to solidify the melt;

[0133] The slag knocking module 26 is used to start the slag knocking program at the same time after the air cooling program is started, the indexing motor is started, the annular support and the slag knocking hammer are driven to rotate, and the compressed air supplied through each independent air inlet pipe drives the slag knocking hammer to knock the slag;

[0134] The spray gun resetting module 27 is used to stop the air cooling program and the slag knocking program when the spray gun crane lifts the spray gun to the spray gun limit device, and the spray gun crane slowly lowers the spray gun to reset the spray gun.

[0135] Preferably, the spray gun lifting module 25 of this embodiment starts the spray gun crane to lift the spray gun, and at the same time starts the air cooling program, the compressor starts working, and the cooling device sprays air to exchange heat with the melt on the surface of the spray gun; this ensures that the melt on the surface of the spray gun can quickly cool and solidify during the lifting process, preventing the melt from dripping or causing other safety hazards during the lifting process; when the air cooling program of the slag knocking module 26 is started, the slag knocking program is also started, and the rotation motor drives the annular bracket and the slag knocking hammer to rotate, and the slag knocking hammer is pushed by compressed air to knock the slag; the slag cooled and solidified on the surface of the spray gun is effectively removed, ensuring the cleaning and smooth use of the spray gun; when the spray gun is lifted to the limit device, the spray gun reset module 27 stops the air cooling program and the slag knocking program, and the spray gun crane slowly lowers the spray gun to reset; this ensures that the spray gun can be safely and accurately reset after cooling and slag knocking.

[0136] To sum up, this embodiment improves the safety of the operation while ensuring the cleanliness of the spray gun surface; maintains the working efficiency of the spray gun, extends the service life of the spray gun, and also improves the operation efficiency; ensures the continuity and stability of the operation process, and also improves the safety and efficiency of the overall operation.

[0137] like Figure 6 As shown, this embodiment provides an embodiment of a top-blowing spray gun efficient slag removal device. In this embodiment, the top-blowing spray gun efficient slag removal device is applied to the top-blowing spray gun efficient slag removal system in the above embodiment, and specifically includes: a spray gun hoist 1, a top-blowing spray gun 2, a spray gun limit device 3, a slag knocking device 4, a cooling device 5, an air compressor 6, a compressed air delivery pipeline 7, an electric control flow regulating valve 8, a top-blowing furnace 9, a pneumatic slag knocking hammer 10, a slag knocking hammer bracket 11, an air nozzle 12 and an air distribution pipe 13;

[0138] Among them, the spray gun crane 1 lifts the top-blowing spray gun 2 through a steel cable, and the spray gun limiting device 3 is fixed through the upper part of the top-blowing spray gun 2; the lower part of the spray gun limiting device 3 is a slag knocking device 4, and a cooling device 5 is installed below the slag knocking device 4; a pneumatic slag knocking hammer 10 is fixed above the slag knocking hammer bracket 11 in the slag knocking device 4, and 8 air nozzles 12 facing the top-blowing spray gun 2 are surrounded in the cooling device 5 below, and each air nozzle 12 is connected to an air distribution pipe 13; the air distribution pipe 13 and the pneumatic slag knocking hammer 10 are connected to the air compressor 6 through a compressed air delivery pipeline 7, and an electrically controlled flow regulating valve 8 is respectively arranged in the air delivery pipeline 7; a top-blowing furnace 9 is directly below the top-blowing spray gun 2.

[0139] Preferably, when the device of this embodiment is in operation, the top-blowing lance 2 is first raised, and the air compressor 6 is started. When the top-blowing lance 2 is slowly raised, the air nozzle 12 sprays air to cool and solidify the slag layer. At the same time, the pneumatic slag hammer 10 knocks the slag, and the top-blowing lance 2 is rotated and then the slag is knocked. After the slag is knocked, the lance is reset (see the attached schematic diagram for the specific principle diagram). Figure 7 ).

[0140] In summary, in this embodiment, air blowing cooling and slag knocking are carried out simultaneously, and the slag removal work is completed when the spray gun is fully raised. The whole process is highly coherent and the efficiency is much higher than the traditional slag cleaning method; all subsystems are coordinated by the control system, and the working parameters of the actuator (such as: the knocking force and frequency of the pneumatic slag knocking hammer 10, the air flow of the cooling device 5, and the relative posture of the spray gun-actuator) can be set according to the actual production situation when debugging the equipment. After the equipment is debugged, each subsystem performs automated operations according to the preset settings, which greatly improves the working environment of the operator; the spray gun hoisting machine is the original equipment of the top-blown furnace. The air compressor 6 that provides power for the cooling device 5 and the pneumatic slag knocking hammer 10 is also an essential supporting equipment for the top-blown furnace. It can be used as the gas source for the slag removal system with only a slight modification of the gas pipeline. In summary, the present invention has low transformation cost and can greatly save labor cost, which can promote cost savings and increase production capacity; to execute the device (cooling device 5 and slag knocking device), only the throttle valve part needs to be electronically controlled, and the main power is all provided by compressed air, which can reduce the carbon emissions of the whole process and achieve the purpose of energy conservation, emission reduction and environmental friendliness.

[0141] Furthermore, if Figure 8 As shown, the cooling device 5 specifically includes:

[0142] The cold air nozzle cooling device 5 consists of two groups of air nozzles arranged up and down, each group of nozzles contains 8 nozzles arranged in a circumferential manner, wherein the ejected air exchanges heat with the melt on the surface of the spray gun to solidify the melt for subsequent slag removal work; the upper and lower groups of cooling nozzles are deflected by 22.5° to achieve uniform cooling of the melt over the entire circumference.

[0143] The relationship between melt solidification time and blowing parameters can be expressed by the following formula:

[0144]

[0145] Among them, M s 、c s and T s They represent the mass, specific heat and initial temperature of the melt in the area covered by the nozzle group; T f and L f represents the solidification temperature and latent heat of the melt; h represents the convective heat transfer coefficient, which is related to the flow rate and temperature of the sprayed air; A represents the effective coverage area of ​​the nozzle group; T a Represents the initial temperature of the sprayed air; the solidification process can be controlled by adjusting the flow rate of the sprayed air.

[0146] Preferably, the two groups of upper and lower air nozzles and the surrounding nozzles in this embodiment ensure that the surface of the melt can evenly receive cooling air, thereby improving the cooling efficiency; the air cooling principle is utilized to take away the heat of the melt, causing it to gradually solidify; the upper and lower groups of cooling nozzles have a 22.5° deflection to ensure that the melt can be evenly cooled over the entire circumference, thereby avoiding local overheating or insufficient cooling; the relationship between the melt solidification time and the blowing parameters provides a quantitative tool for evaluating and adjusting the influence of the blowing parameters on the melt solidification time.

[0147] In summary, this embodiment achieves a wider cooling coverage and accelerates the solidification speed of the melt by increasing the number of nozzles and arranging them reasonably; achieves rapid cooling of the melt through physical heat exchange to prepare for slag removal; achieves a more uniform cooling effect and improves product quality and consistency by adjusting the nozzle angle; and can accurately calculate and adjust the injection parameters, such as air flow and temperature, through the formula to achieve precise control of the solidification process and optimize the cooling effect.

[0148] Furthermore, if Fig. 9 As shown, the slag knocking device 4 includes: a top-blowing lance 2, a pneumatic slag knocking hammer 10 and a slag knocking hammer bracket 11;

[0149] The slag knocking operation is completed by a group of pneumatic slag knocking hammers 10 arranged around the spray gun; all the pneumatic slag knocking hammers 10 are fixed on an annular slag knocking hammer bracket 11, and the annular slag knocking hammer bracket 11 can drive the pneumatic slag knocking hammers 10 to rotate, so as to achieve the effect of slag removal without dead angles. In the present invention, in order to ensure that the knocking force and frequency of each pneumatic slag knocking hammer 10 are similar, each pneumatic slag knocking hammer 10 uses a separate air inlet pipe as an air source to ensure the uniformity and stability of air supply.

[0150] Preferably, this embodiment ensures that the knocking can cover all directions around the spray gun, which is conducive to comprehensive slag removal; the annular slag hammer bracket 11 provides a stable support for the slag hammer bracket 11, and is convenient for unified management and control; through rotation, the pneumatic slag hammer 10 can cover a wider area, ensuring slag removal without dead ends; separate air supply ensures the similarity of the knocking force and frequency of each pneumatic slag hammer 10, avoiding differences in knocking effects caused by uneven air supply.

[0151] In summary, this embodiment improves the efficiency and effect of slag removal, reduces dead corners, enhances the stability and controllability of the slag knocking system, further improves the comprehensiveness and efficiency of slag removal, ensures the uniformity and consistency of the slag knocking operation, and improves the quality of slag removal.

[0152] Furthermore, if Fig.10 and Fig.11As shown, the pneumatic slag hammer 10 includes: a cylinder body 14, a distribution valve plate 15, a valve plate slide rod 16, an air inlet 17, a rear air chamber 18, a piston 19, a pressure relief port 20, a piston rod 21, a front air chamber 22, a hammer head 23 and an axial channel 24;

[0153] The pneumatic slag hammer 10 is mainly composed of three parts: a cylinder body 14, a piston 19 and a distribution valve. The cylinder body 14 is provided with an air inlet 17, a pressure relief port 20 and an axial channel 24, and the two ends of the channel are connected to the front air chamber 22 and the left space of the valve plate. The piston 19 is connected to the hammer head 23 through the piston rod 21, and the reciprocating motion of the piston 19 can drive the hammer head 23 to complete the knocking action. The distribution valve is mainly composed of a distribution valve plate 15 and a valve plate slide rod 16. The distribution valve plate 15 slides on the valve plate slide rod 16 under the influence of the pressure difference on both sides to realize the distribution function.

[0154] Preferably, the distribution valve plate 15 of this embodiment is initially in the left extreme position, and the compressed air enters from the air inlet 17 and flows into the rear air chamber 18, pushing the piston 19 forward. At this time, the gas in the front air chamber 22 is discharged from the pressure relief port 20, and the piston 19 accelerates forward movement; the compressed air enters from the air inlet 17 and flows into the rear air chamber 18, pushing the piston 19 to start moving forward; at this time, the gas in the front air chamber 22 is discharged from the pressure relief port 20; the piston 19 continues to move forward, and when the rear end face of the piston 19 passes the pressure relief port 20, the compressed air in the rear air chamber 18 is discharged into the atmosphere, causing the pressure in the rear air chamber 18 to decrease. At this time, the pressure on the left side of the distribution valve plate 15 will be greater than the pressure on the right side, and the valve plate slides to the right to prevent the compressed air from continuing to enter the rear air chamber 18; the compressed air enters the axial channel 24 from the left side of the valve plate and flows into the front air chamber 22, pushing the piston 19 to start the backward return movement. At this time, the gas in the rear air chamber 18 is discharged from the pressure relief port 20; the piston 19 moves backward until the rear end face covers the pressure relief port 20 and then continues to move backward, the gas in the rear air chamber 18 is compressed, and the pressure on the right side of the valve plate gradually increases; the piston 19 continues to move backward and returns to the initial position. At this time, the front end face of the piston 19 passes over the pressure relief port 20, and the pressure in the front air chamber 22 decreases. The pressure on the right side of the valve plate is greater than the pressure on the left side, and the valve plate moves to the left and returns to the initial position. After the valve plate is reset, the compressed air re-enters the rear air chamber 18, pushing the piston 19 forward, and starting a new movement cycle.

[0155] To sum up, in this embodiment, the pneumatic slag hammer 10 is driven by compressed air to perform the knocking action quickly and continuously, effectively removing the slag generated during the top blowing spray gun operation; this efficient slag removal capability helps to maintain the continuity and stability of the production line and improve production efficiency; using compressed air as a power source has lower energy consumption and less carbon emissions than traditional mechanical or electric drive methods; at the same time, through the precise design of the distribution valve, the effective use of compressed air is achieved and energy waste is reduced; the reciprocating motion of the slag hammer is driven by compressed air and controlled by the distribution valve to achieve automated operation; the labor intensity is reduced and the accuracy and consistency of the operation are improved; by adjusting the pressure and flow of compressed air, the knocking force and frequency of the slag hammer can be flexibly controlled to meet different slag removal requirements; the main components of the slag hammer such as the cylinder body, piston and distribution valve are all standardized and easy to disassemble and replace; the maintenance cost is reduced and the reliability and service life of the equipment are improved.

[0156] like Fig.12 As shown, this embodiment provides an embodiment of an electronic device. In this embodiment, the electronic device 28 includes a processor 281 and a memory 282 coupled to the processor 281.

[0157] The memory 282 stores program instructions for implementing the efficient and automated slag removal method for the top-blowing lance of any of the above-mentioned embodiments.

[0158] The processor 281 is used to execute the program instructions stored in the memory 282 to perform a high-efficiency automated slag removal method for a top-blowing lance.

[0159] The processor 281 may also be referred to as a CPU (Central Processing Unit). The processor 281 may be an integrated circuit chip having signal processing capabilities. The processor 281 may also be a general-purpose processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components. The general-purpose processor may be a microprocessor or the processor may also be any conventional processor, etc.

[0160] Further, Fig.13This is a schematic diagram of the structure of a storage medium of an embodiment of the present application. The storage medium 29 of the embodiment of the present application stores program instructions 91 that can implement all the above methods, wherein the program instructions 291 can be stored in the above storage medium in the form of a software product, including several instructions for enabling a computer device (which can be a personal computer, server, or network device, etc.) or a processor to execute all or part of the steps of the methods described in each embodiment of the present application. The aforementioned storage medium includes: various media that can store program codes, such as a USB flash drive, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM), a disk or an optical disk, or terminal devices such as a computer, a server, a mobile phone, and a tablet.

[0161] In the several embodiments provided by the present invention, it should be understood that the disclosed systems, devices and methods can be implemented in other ways. For example, the device embodiments described above are only schematic, for example, the division of units is only a logical function division, and there may be other division methods in actual implementation, such as multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be an indirect coupling or communication connection through some interfaces, devices or units, which can be electrical, mechanical or other forms.

[0162] In addition, each functional unit in each embodiment of the present invention may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit. The above integrated unit may be implemented in the form of hardware or in the form of software functional units. The above is only an implementation mode of the present invention, and does not limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made by using the contents of the present invention specification and drawings, or directly or indirectly used in other related technical fields, is also included in the patent protection scope of the present invention.

[0163] The specific implementation methods of the invention are described in detail above, but they are only examples, and the invention is not limited to the specific implementation methods described above. For those skilled in the art, any equivalent modification or substitution of the invention is also within the scope of the invention, therefore, the equalization, modification, improvement, etc. made without departing from the spirit and principle of the invention should be included in the scope of the invention.

Claims

1. A high-efficiency automatic slag removal method using a top-blowing spray gun, characterized in that: The method for efficient and automated slag removal with a top-blowing lance comprises the following steps: Start the spray gun hoist and slowly lift the spray gun upward. When the spray gun is lifted upward, start the air cooling program, the compressor starts, and the cooling device sprays air to exchange heat with the melt on the surface of the spray gun to solidify the melt; After the air cooling program is started, the slag knocking program is started at the same time, the indexing motor is started, driving the annular bracket and the slag knocking hammer to rotate, and the compressed air supplied through each independent air inlet pipe drives the slag knocking hammer to knock the slag; When the spray gun crane lifts the spray gun to the spray gun limit device, the air cooling program and the slag knocking program are stopped, and the spray gun crane lowers the spray gun to reset the spray gun.

2. The method for efficient and automated slag removal using a top-blowing spray gun according to claim 1, characterized in that: The process of starting the air cooling program includes the following steps: Real-time monitoring of the spray gun temperature data lifted by the spray gun crane and the air flow rate data of the cold air nozzle, and pre-processing of the collected data; The pre-processed data is transmitted to the control system, the pre-processed data is analyzed, and a mapping relationship table is established according to the relationship between temperature and air flow rate; Set a temperature threshold. If the real-time temperature of the spray gun is detected to exceed the preset temperature threshold, adjust the air compressor according to the mapping relationship table between temperature, air flow and flow rate, and then adjust the air flow and flow rate, and continue real-time monitoring; Data collection and preprocessing, spray gun temperature data preprocessing formula: Where, T pre Represents the spray gun temperature data after pretreatment; T i represents the original data of the spray gun temperature at the i-th time point; t i represents the timestamp of the i-th time point; t0 represents the timestamp of the current time point; α represents the weighting coefficient of the temperature data, which is used to adjust the weight of the temperature data; β represents the time attenuation coefficient, which is used to control the influence of time on the temperature data; γ represents the standard deviation correction coefficient, which is used to adjust the fluctuation range of the temperature data; σ T Represents the standard deviation of temperature data, which is used to measure the dispersion of temperature data; Air flow velocity data preprocessing formula: In the formula, Q pre Indicates the air flow rate data after preprocessing; Q j represents the original data of air flow rate at the jth time point; t j Indicates the timestamp of the jth time point; φ indicates the frequency coefficient, which is used to adjust the influence of periodic fluctuations; φ indicates the phase shift coefficient, which is used to adjust the influence of time shift; δ indicates the flow rate change correction coefficient, which is used to adjust the influence of flow changes; Indicates the rate of change of air flow velocity; The data mapping relationship is established, and the mapping relationship formula between temperature and air flow rate is: In the formula, Q map Represents the air flow rate after mapping; T ref It represents the reference temperature value, which is used to adjust the influence of temperature on flow rate; κ represents the mapping coefficient between temperature and flow rate; η represents the temperature correction coefficient, which is used to adjust the influence of temperature on the mapping relationship; λ represents the flow logarithmic correction coefficient, which is used to adjust the influence of flow on the mapping relationship; μ represents the flow reference value, which is used to adjust the range of logarithmic calculation; Temperature threshold control and air compressor adjustment, air compressor adjustment formula: Where P comp Indicates the regulating power of the air compressor; T real Represents the real-time monitored spray gun temperature data; T th Indicates the preset temperature threshold; T max Indicates the maximum temperature value allowed by the system; ξ indicates the power adjustment coefficient, which is used to adjust the output power of the compressor; ρ indicates the temperature deviation index, which is used to adjust the impact of temperature deviation on power; ζ indicates the temperature change rate correction coefficient, which is used to adjust the impact of temperature change on power; Indicates the rate of change of temperature; the above formula design fully considers the complex relationship between temperature, air flow velocity and time factors, and can achieve high-precision air cooling control.

3. The high-efficiency automatic slag removal method using a top-blowing spray gun according to claim 1, characterized in that: The process of rotating the slag hammer includes the following steps: During the shifting process of the slag knocking device, the current shifting status is monitored in real time, and the in-position signal is detected by the photoelectric tube. When the photoelectric tube is turned on, it outputs a low level, indicating that it is not in position; when the photoelectric tube is turned off, it outputs a high level, indicating that it is in position; The detected indexing level signal is transmitted to the control system, and the control system analyzes the received level signal to obtain the real-time indexing data of the slag knocking device; According to the analyzed indexing data, the indexing motor of the slag knocking hammer is adjusted through the control system to control the indexing of the slag knocking device.

4. The method for efficient and automated slag removal using a top-blowing lance according to claim 3, characterized in that: The process of obtaining the real-time indexing data of the slag knocking device includes the following steps: The transfer state of the slag knocking device is monitored in real time by a photoelectric tube. The photoelectric tube outputs different level signals according to the position change of the slag knocking hammer during the transfer process: when the slag knocking hammer has not reached the target position, the photoelectric tube is turned on and outputs a low level; when the slag knocking hammer reaches the target position, the photoelectric tube is turned off and outputs a high level; the change of the level signal directly reflects the transfer state of the slag knocking device; The collected level signal is transmitted to the control system in real time through the signal transmission module; after receiving the level signal, the control system converts it into a recognized digital signal; The control system analyzes the received digital signal and determines the real-time position of the slag knocking device in combination with the preset transfer logic. It determines whether the slag knocking hammer is in the target position by comparing the current level signal with the preset threshold. At the same time, it also records the time series data of the transfer process for dynamic adjustment.

5. The high-efficiency automatic slag removal method using a top-blowing spray gun according to claim 3, characterized in that: The process of adjusting the slag hammer indexing motor through the control system includes the following steps: During the transfer process of the slag knocking device, the transfer state of the device is monitored in real time. When the slag knocking device is in place, the electrical state of the sensor is changed. The state change will generate a corresponding electrical signal output. A low-level signal indicates that the slag knocking device is not in place, while a high-level signal indicates that the slag knocking device is in place. The detected electrical signal is transmitted to the control system, which is received and analyzed as the device's indexing status information; the indexing status information received by the control system is sent to the data processing unit for analysis, and is evaluated according to the preset logic rules and algorithms to determine the actual position and indexing status of the slag knocking device; the analysis results generate control instructions to instruct the specific actions that the slag knocking hammer indexing motor should perform; Based on the results of data analysis, the control system will send instructions to the slag hammer indexing motor to dynamically adjust the motor's speed and direction; the motor control unit monitors the motor's operating status in real time and makes fine adjustments based on feedback information to compensate for any possible deviations.

6. The high-efficiency automatic slag removal method using a top-blowing spray gun according to claim 5, characterized in that: The evaluation process based on preset logical rules and algorithms includes the following steps: Acquire diverse data from different sensors, including electrical signals, mechanical position encoders, and pressure sensor data; filter and denoise multi-source signals; The received status information is processed hierarchically according to importance and urgency; the weights of different signals are dynamically allocated according to the current operating environment and historical data; a logical decision tree is constructed by combining expert systems and machine learning to achieve rapid identification and classification of the status of the slag knocking device; The control strategy is adjusted dynamically according to the changes in the status of the slag knocking device. The historical data and current status are used to predict the future behavior of the device and make control decisions. The real-time feedback of the slag knocking device status is compared with the preset target state and fine-tuned through closed-loop control. When an abnormal state occurs, the system will automatically initiate an emergency plan, slow down, stop or switch to an alternative control strategy.

7. The high-efficiency automatic slag removal method using a top-blowing spray gun according to claim 1, characterized in that: The process of resetting the spray gun includes the following steps: The control system controls the crane motor and monitors the displacement and tension of the crane traction rope in real time; If it is detected that the pulling force on the crane increases and the crane traction rope stops moving, a limit signal is sent to the control system, indicating that the spray gun has been lifted to the spray gun limit device; When the control system receives the limit signal, the air cooling program and the slag knocking program are stopped. After the program stops, the crane motor is controlled to run, and the traction rope is slowly released to lower and reset the spray gun.

8. The method for efficient and automated slag removal using a top-blowing lance according to claim 7, characterized in that: The process of stopping the air cooling process and the slag knocking process includes the following steps: During the spray gun lifting process, the encoder monitors the displacement information of the crane traction rope in real time; the torque sensor monitors the change of the pulling force on the crane in real time, and when the pulling force increases and the displacement stops, it is determined that the spray gun has reached the limit device; During the reset process, the air cooling program is stopped by integrating an emergency stop device in the air cooling system. When receiving the limit signal, the power supply of the air cooling system is cut off to achieve a rapid stop of the air cooling program; the slag knocking program, when the limit signal is triggered, identifies and stops the slag knocking program; After the air cooling and slag knocking procedures stop, the control system controls the crane motor to run at a steady speed, controlling the motor speed and the release speed of the traction rope.

9. A high-efficiency automatic slag removal system for a top-blowing spray gun, which is applied to the high-efficiency automatic slag removal method for a top-blowing spray gun as claimed in any one of claims 1 to 8, characterized in that: The top-blowing lance efficient and automated slag removal system comprises: The spray gun lifting module is used to start the spray gun hoist to lift the spray gun upward. When the spray gun is lifted upward, the air cooling program is started, the compressor is started, and the cooling device sprays air to exchange heat with the melt on the surface of the spray gun to solidify the melt; The slag knocking module is used to start the slag knocking program at the same time after the air cooling program is started. The indexing motor is started to drive the annular bracket and the slag knocking hammer to rotate, and the compressed air supplied through each independent air inlet pipe drives the slag knocking hammer to knock the slag; The spray gun reset module is used to stop the air cooling program and the slag knocking program when the spray gun crane lifts the spray gun to the spray gun limit device, and the spray gun crane lowers the spray gun to reset the spray gun.

10. A high-efficiency automatic slag removal device for a top-blowing spray gun, which is applied to the high-efficiency automatic slag removal device for a top-blowing spray gun as claimed in any one of claims 1 to 8, characterized in that: The top-blowing spray gun efficient and automatic slag removal device comprises: a spray gun hoist, a top-blowing spray gun, a spray gun limit device, a slag knocking device, a cooling device, an air compressor, a compressed air delivery pipeline, an electric control flow regulating valve, a top-blowing furnace, a pneumatic slag knocking hammer, a slag knocking hammer bracket, an air nozzle and an air distribution pipe; Among them, the spray gun hoist lifts the top-blowing spray gun through a steel cable, and the spray gun limit device is fixed through the upper part of the top-blowing spray gun; the lower part of the spray gun limit device is a slag knocking device, and a cooling device is installed below the slag knocking device; a pneumatic slag knocking hammer is fixed above the slag knocking hammer bracket in the slag knocking device, and several air nozzles facing the top-blowing spray gun are surrounded in the cooling device below, and each air nozzle is connected to an air distribution pipe; the air distribution pipe and the pneumatic slag knocking hammer are connected to the air compressor through a compressed air delivery pipeline, and an electric control flow regulating valve is provided in each air delivery pipeline; the top-blowing furnace is directly below the top-blowing spray gun; The slag knocking device includes: a top-blowing lance, a pneumatic slag knocking hammer and a slag knocking hammer bracket; The slag knocking operation is completed by a group of pneumatic slag knocking hammers arranged around the spray gun; all the pneumatic slag knocking hammers are fixed on a circular slag knocking hammer bracket, which can drive the pneumatic slag knocking hammers to rotate; each pneumatic slag knocking hammer uses a separate air inlet pipe as the air source; The pneumatic slag hammer includes: a cylinder body, a distribution valve plate, a valve plate slide rod, an air inlet, a rear air chamber, a piston, a pressure relief port, a piston rod, a front air chamber, a hammer head and an axial channel; Among them, the pneumatic slag hammer consists of three parts: a cylinder body, a piston and a distribution valve; the cylinder body is provided with an air inlet, a pressure relief port and an axial channel, and the two ends of the channel are respectively connected to the front air chamber and the space on the left side of the valve plate; the piston is connected to the hammer head through a piston rod, and the reciprocating motion of the piston can drive the hammer head to complete the knocking action; the distribution valve is composed of a distribution valve plate and a valve plate slide rod, and the distribution valve plate slides on the valve plate slide rod under the influence of the pressure difference on both sides to realize the distribution function.

Images