Online judgment and diagnosis system and method for deburring quality of continuous casting machine

Abstract

The invention relates to an online judgment and diagnosis system and method for the deburring quality of a continuous casting machine, and belongs to the technical field of electrical control equipment and methods in the metallurgical industry. According to the technical scheme, a camera (5) is installed on the lower side of a roller way (2) behind a deburring machine (1), a sound collecting device is installed on the outlet side of the deburring machine (1), the camera (5) and the sound collecting device are connected with a judgment and diagnosis model (10), and a deburring machine PLC control system (11) is arranged between the judgment and diagnosis model (10) and a continuous casting PLC control system. The method has the beneficial effects that the online quality judgment and diagnosis function of the online deburring machine is achieved by adopting the judgment and diagnosis model and comprehensively analyzing pictures and sounds, the deburring quality effect is greatly improved, good conditions are created for subsequent steel billet rolling, adverse effects on the rolling quality of subsequent hot rolling, the service life of rollers and the like are reduced, and the service life of the rollers is prolonged. The safety risk of manual on-site inspection is reduced, and the labor intensity is reduced.

Description

Technical Field

[0001] The invention relates to an online determination and diagnosis system and method for the deburring quality of a continuous casting machine, belonging to the technical field of electrical control equipment and methods in the metallurgical industry. Background Art

[0002] Modern large-scale slab continuous casting equipment generally uses flame cutting machines to cut the ingot into fixed lengths to meet the rolling process requirements. The slag generated during the cutting process tends to spread to both sides of the lower edge of the cutting seam as it flows with the molten steel, and adheres to the lower surface of the ingot to form burrs. This burr contains a lot of slag components, which are hard and loose, with a rough and uneven surface, and may also contain particles with extremely high hardness. During the subsequent output and entering the next process, this burr may not only cause damage to equipment such as rollers, rollers, such as impact, roller surface scratches, and roller body cracks, but also affect the quality of the rolled material and reduce the yield rate because the slag will be mixed in the head and tail of the hot-rolled steel plate. Therefore, the deburring effect directly affects the surface quality of the ingot.

[0003] The burrs are removed on the lower surface of the ingot. The height of the ingot conveyor roller is 0.7 meters. In the past, it relied on human visual observation. The inspectors needed to bend down and look up from the bottom of the ingot for observation at a close distance. When the ingot moves, the human eyes need to track the head and tail. Occasionally, burrs will fly on site, posing a safety risk of foreign objects entering the eyes. The quality inspection is labor-intensive and 100% quality inspection cannot be achieved. Summary of the invention

[0004] The purpose of the present invention is to provide a continuous casting machine deburring quality online judgment and diagnosis system and method, by adopting a judgment and diagnosis model, comprehensive analysis of pictures and sounds, to achieve online deburring machine quality online judgment and diagnosis function, greatly improve the deburring quality effect, create good conditions for subsequent billet rolling, reduce the subsequent hot rolling quality, roller life and other adverse effects, reduce the safety risks of manual on-site inspections, reduce labor intensity, and effectively solve the above-mentioned problems existing in the background technology.

[0005] The technical solution of the present invention is: an online judgment and diagnosis system for the deburring quality of a continuous casting machine, comprising a camera, a sound collection device, a network device, a judgment and diagnosis model, a deburring machine PLC control system and a continuous casting PLC control system, wherein the camera is installed below the roller side behind the deburring machine, the sound collection device comprises a sound probe and a sound frequency domain time domain converter, the sound probe is installed on the outlet side of the deburring machine, and the sound probe and the sound frequency domain time domain converter are connected; the camera and the sound collection device are connected to the judgment and diagnosis model through the network device, and the deburring machine PLC control system is arranged between the judgment and diagnosis model and the continuous casting PLC control system.

[0006] It also includes a camera protective cover and a compressed air filter pressure reducing valve, which are installed on the camera; the camera is fixedly installed below the roller table side behind the deburring machine through a bracket.

[0007] The sound probe is fixedly installed at 0.5 meters on the outlet side of the deburring machine through a bracket.

[0008] The sound probe and the sound frequency domain and time domain switch are connected via Ethernet.

[0009] The judgment and diagnosis model comprises an image analysis module, a sound analysis module, a slab burr quality judgment module and a deburring equipment parameter strategy adjustment module. The image analysis module and the sound analysis module are respectively connected to the input end of the slab burr quality judgment module, and the output end of the slab burr quality judgment module is connected to the deburring equipment parameter strategy adjustment module.

[0010] The network device is a high-speed switch.

[0011] A method for online determination and diagnosis of deburring quality of a continuous casting machine comprises the following steps: (1) The camera is fixedly installed at the lower side of the rear roller of the deburring machine using a bracket and connected to the judgment and diagnosis model through a network device; (2) The sound probe is fixedly installed at the outlet side of the deburring machine using a bracket, and the sound probe is connected to the sound domain and time domain switcher, and connected to the judgment and diagnosis model through a network device; (3) In the judgment and diagnosis model, the identified head and tail images and audio information are converted and processed by the image analysis module and the sound analysis module, and the processed data is transmitted to the slab burr quality judgment module for comparison and analysis to obtain the quality judgment and diagnosis result, and the quality judgment and diagnosis result is output to the deburring equipment parameter strategy adjustment module, and the parameter adjustment strategy is transmitted to the deburring machine PLC control system; (4) The judgment and diagnosis model outputs information and alarm information and sends it to the deburring machine PLC control system and the continuous casting PLC control system to display the alarm, and the deburring machine PLC control system and the continuous casting PLC control system send the deburring machine action status and the ingot steel grade information to the judgment and diagnosis model.

[0012] In the step (1), the camera is installed with a camera protective cover and a compressed air filter pressure reducing valve.

[0013] In the step (2), the sound probe is installed at 0.5 meters from the outlet side of the deburring machine.

[0014] In the step (2), the sound frequency domain and time domain switch is a microcomputer, and the sound probe and the sound frequency domain and time domain switch are connected via Ethernet.

[0015] In the step (3), the quality judgment diagnosis result and parameter adjustment strategy are used to judge the quality of slab deburring, the deburring removal rate is statistically analyzed, the cause of the defect and the countermeasure are analyzed based on the slab deburring defects, the impact force and impact length during slab deburring are analyzed, the lifting height of the fly hammer hydraulic cylinder of the continuous casting deburring machine is controlled according to the information of the cast steel grade, the action sequence and action time of the fly hammer of the deburring machine are adjusted, and finally the requirements of the impact force and impact length of 100-150mm are met.

[0016] The beneficial effects of the present invention are as follows: by adopting a judgment and diagnosis model, a comprehensive analysis of images and sounds is performed to realize the online judgment and diagnosis function of the online deburring machine quality, thereby greatly improving the deburring quality effect, creating good conditions for subsequent billet rolling, reducing the adverse effects on the subsequent hot rolling quality, the life of the rolling rollers, etc., reducing the safety risks of manual on-site inspections, and alleviating labor intensity. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic diagram of the structure of the present invention; Figure 2 It is a work flow chart of the present invention; In the figure: deburring machine 1, roller table 2, continuous casting slab 3, camera protective cover 4, camera 5, compressed air filter pressure reducing valve 6, sound probe 7, sound domain and time domain converter 8, network equipment 9, judgment and diagnosis model 10, deburring machine PLC control system 11, continuous casting PLC control system 12. DETAILED DESCRIPTION

[0018] In order to make the purpose, technical solutions and advantages of the invention implementation cases clearer, the technical solutions in the implementation cases of the present invention will be clearly and completely described below in conjunction with the drawings in the implementation cases. Obviously, the implementation cases described are only a small part of the implementation cases of the present invention, rather than all the implementation cases. Based on the implementation cases in the present invention, all other implementation cases obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0019] A continuous casting machine deburring quality online judgment and diagnosis system comprises a camera 5, a sound collection device, a network device 9, a judgment and diagnosis model 10, a deburring machine PLC control system 11 and a continuous casting PLC control system 12, wherein the camera 5 is installed below the roller table 2 at the rear of the deburring machine 1, the sound collection device comprises a sound probe 7 and a sound frequency domain time domain converter 8, the sound probe 7 is installed at the outlet side of the deburring machine 1, and the sound probe 7 is connected to the sound frequency domain time domain converter 8; the camera 5 and the sound collection device are connected to the judgment and diagnosis model 10 via the network device 9, and the deburring machine PLC control system 11 is arranged between the judgment and diagnosis model 10 and the continuous casting PLC control system 12.

[0020] It also includes a camera protection cover 4 and a compressed air filter pressure reducing valve 6, which are installed on the camera 5; the camera 5 is fixedly installed on the lower side of the roller 2 behind the deburring machine 1 through a bracket.

[0021] The sound probe 7 is fixedly installed at 0.5 meters on the outlet side of the deburring machine 1 through a bracket.

[0022] The sound probe 7 and the sound frequency domain and time domain switch 8 are connected via Ethernet.

[0023] The judgment and diagnosis model 10 includes an image analysis module, a sound analysis module, a slab burr quality judgment module and a deburring equipment parameter strategy adjustment module. The image analysis module and the sound analysis module are respectively connected to the input end of the slab burr quality judgment module, and the output end of the slab burr quality judgment module is connected to the deburring equipment parameter strategy adjustment module.

[0024] The network device 9 is a high-speed switch.

[0025] A method for online determination and diagnosis of deburring quality of a continuous casting machine comprises the following steps: (1) The camera is fixedly installed at the lower side of the rear roller of the deburring machine using a bracket and connected to the judgment and diagnosis model through a network device; (2) The sound probe is fixedly installed at the outlet side of the deburring machine using a bracket, and the sound probe is connected to the sound domain and time domain switcher, and connected to the judgment and diagnosis model through a network device; (3) In the judgment and diagnosis model, the identified head and tail images and audio information are converted and processed by the image analysis module and the sound analysis module, and the processed data is transmitted to the slab burr quality judgment module for comparison and analysis to obtain the quality judgment and diagnosis result, and the quality judgment and diagnosis result is output to the deburring equipment parameter strategy adjustment module, and the parameter adjustment strategy is transmitted to the deburring machine PLC control system; (4) The judgment and diagnosis model outputs information and alarm information and sends it to the deburring machine PLC control system and the continuous casting PLC control system to display the alarm, and the deburring machine PLC control system and the continuous casting PLC control system send the deburring machine action status and the ingot steel grade information to the judgment and diagnosis model.

[0026] In the step (1), the camera is installed with a camera protective cover and a compressed air filter pressure reducing valve.

[0027] In the step (2), the sound probe is installed at 0.5 meters from the outlet side of the deburring machine.

[0028] In the step (2), the sound frequency domain and time domain switch is a microcomputer, and the sound probe and the sound frequency domain and time domain switch are connected via Ethernet.

[0029] In the step (3), the quality judgment diagnosis result and parameter adjustment strategy are used to judge the quality of slab deburring, the deburring removal rate is statistically analyzed, the cause of the defect and the countermeasure are analyzed based on the slab deburring defects, the impact force and impact length during slab deburring are analyzed, the lifting height of the fly hammer hydraulic cylinder of the continuous casting deburring machine is controlled according to the information of the cast steel grade, the action sequence and action time of the fly hammer of the deburring machine are adjusted, and finally the requirements of the impact force and impact length of 100-150mm are met. Example

[0030] After the continuous casting process, the continuous casting slab 3 is cut into certain specifications, and the cutting process is completed by a flame cutting machine. Cutting burrs will be generated at the intersection of the outer arc surface of the continuous casting slab 3 and the flame cutting surface. In the production of the next process, these burrs will cause quite a lot of problems. In order to eliminate these problems, the deburring machine 1 is installed between the two rollers of the roller 2, so as to complete the deburring operation of the continuous casting slab 3 during normal walking. When the head or tail of the continuous casting slab 3 reaches the deburring machine, the roller speed drops to 20m / min. At this time, the rotating knife shaft located at the bottom of the casting first rotates, and then the flying hammer hydraulic cylinder performs a lifting action according to the action instruction of the deburring machine PLC system 11, and the hammer knife knocks off the burrs. During the deburring process, the camera 5 and the sound probe 7 respectively measure the image and audio of the deburring of the head and tail of the continuous casting slab 3, and collect them at high speed through Ethernet. The camera 5 is equipped with a compressed air filter pressure reducing valve 6 and a camera protective cover 4, which is suitable for harsh industrial environments with high temperature and dust. The sound frequency domain and time domain converter 8 uses a microcomputer to transform the sound signal in the frequency domain and time domain. The collected image and sound information are transmitted to the judgment and diagnosis model 10 to judge the quality of the slab deburring. At the same time, the cause of the defect and the countermeasure are analyzed according to the slab deburring defect. Finally, through the deburring machine PLC control system 11, the exchange of the casting information, alarm result information and parameter adjustment data is realized between the judgment and diagnosis model 10 and the continuous casting PLC control system 12.

[0031] The deburring machine PLC control system 11 is SIEMENS S7-300 model. The entire working process is set to automatic working mode. The deburring machine is linked with the billet discharge roller to complete the automatic cycle of deburring. After the operator starts the deburring machine and sets the "remote" state, the machine automatically completes the deburring work at the head and tail of the billet.

[0032] Camera 5 is equipped with 2 million 25 times zoom network all-in-one machine IDS-2ZCN2507N. The camera is connected to the hard disk recorder system and displayed on the monitoring TV in the cutting operation room. Linux microcomputer RK3399 is installed to collect the deburring effect image of the head or tail of the continuous casting slab and perform image analysis and recognition. Image recognition mainly includes image classification, image positioning, image detection, and image segmentation, which ultimately achieves high-precision measurement, ensures fast batch data transmission, simple and easy maintenance and remote diagnosis. It also has a compact installation size.

[0033] The sound probe 7 collects the de-burred striking sound, amplifies the audio signal by about 200 times, and the output audio signal has an adjustable amplitude. A noise elimination resistor is added to suppress the generation of background noise, and the sound signal is transformed in frequency domain and time domain by using an audio-frequency domain time domain converter 8. The audio-frequency domain time domain converter 8 is a Linux microcomputer RK3399.

[0034] The continuous casting PLC control system 12 adopts Siemens S7-400PLC hardware configuration, is connected to the network device 9 (network device 9 is a data high-speed switch) through the transmission mode of industrial Ethernet, is programmed in the PLC system, and uses the communication function block to successfully read the diagnostic information of the deburring effect of the ingot, and transmits the ingot specification information to the judgment diagnosis model 10 in real time, as the basic parameters of the deburring model to participate in the system calculation.

[0035] The normal operation mode of the judgment diagnosis model 10 is: collecting image and sound information, identifying model processing and analysis, judging the quality of the deburring machine, statistically analyzing the deburring removal rate, analyzing the causes and countermeasures of the defects of the deburring machine, automatically analyzing the impact force and impact length of the deburring machine, and the model controls the lifting height of the hydraulic action of the deburring machine according to the type of steel.

Claims

1. An online determination and diagnosis system for the deburring quality of a continuous casting machine, characterized in that: The system comprises a camera (5), a sound collection device, a network device (9), a judgment and diagnosis model (10), a deburring machine PLC control system (11) and a continuous casting PLC control system (12), wherein the camera (5) is installed below the roller table (2) behind the deburring machine (1), the sound collection device comprises a sound probe (7) and a sound frequency domain time domain switch (8), the sound probe (7) is installed at the outlet side of the deburring machine (1), and the sound probe (7) and the sound frequency domain time domain switch (8) are connected; the camera (5) and the sound collection device are connected to the judgment and diagnosis model (10) via the network device (9), and the deburring machine PLC control system (11) is arranged between the judgment and diagnosis model (10) and the continuous casting PLC control system (12).

2. The online determination and diagnosis system for deburring quality of a continuous casting machine according to claim 1, characterized in that: It also comprises a camera protection cover (4) and a compressed air filter pressure reducing valve (6), wherein the camera protection cover (4) and the compressed air filter pressure reducing valve (6) are mounted on the camera (5); the camera (5) is fixedly mounted on the lower side of the roller table (2) behind the deburring machine (1) via a bracket.

3. The online judgment and diagnosis system for deburring quality of a continuous casting machine according to claim 1, characterized in that: The sound probe (7) is fixedly mounted via a bracket at a position 0.5 m from the outlet side of the deburring machine (1).

4. The online determination and diagnosis system for deburring quality of a continuous casting machine according to claim 1, characterized in that: The sound probe (7) and the sound frequency domain and time domain switch (8) are connected via Ethernet.

5. The online determination and diagnosis system for deburring quality of a continuous casting machine according to claim 1, characterized in that: The determination and diagnosis model (10) comprises an image analysis module, a sound analysis module, a slab burr quality determination module and a deburring equipment parameter strategy adjustment module, wherein the image analysis module and the sound analysis module are respectively connected to the input end of the slab burr quality determination module, and the output end of the slab burr quality determination module is connected to the deburring equipment parameter strategy adjustment module.

6. The online determination and diagnosis system for deburring quality of a continuous casting machine according to claim 1, characterized in that: The network device (9) is a high-speed switch.

7. A method for online determination and diagnosis of deburring quality of a continuous casting machine, characterized in that The following steps are involved: (1) The camera is fixedly installed at the lower side of the rear roller of the deburring machine using a bracket and connected to the judgment and diagnosis model through a network device; (2) The sound probe is fixedly installed at the outlet side of the deburring machine using a bracket, and the sound probe is connected to the sound domain and time domain switcher, and connected to the judgment and diagnosis model through a network device; (3) In the judgment and diagnosis model, the identified head and tail images and audio information are converted and processed by the image analysis module and the sound analysis module, and the processed data is transmitted to the slab burr quality judgment module for comparison and analysis to obtain the quality judgment and diagnosis result, and the quality judgment and diagnosis result is output to the deburring equipment parameter strategy adjustment module, and the parameter adjustment strategy is transmitted to the deburring machine PLC control system; (4) The judgment and diagnosis model outputs information and alarm information and sends it to the deburring machine PLC control system and the continuous casting PLC control system to display the alarm, and the deburring machine PLC control system and the continuous casting PLC control system send the deburring machine action status and the ingot steel grade information to the judgment and diagnosis model.

8. The method for online determination and diagnosis of deburring quality of a continuous casting machine according to claim 7, characterized in that: In the step (1), the camera is installed with a camera protective cover and a compressed air filter pressure reducing valve.

9. The method for online determination and diagnosis of deburring quality of a continuous casting machine according to claim 7, characterized in that: In the step (2), the sound frequency domain and time domain switch is a microcomputer, and the sound probe and the sound frequency domain and time domain switch are connected via Ethernet.

10. The method for online determination and diagnosis of deburring quality of a continuous casting machine according to claim 7, characterized in that: In the step (3), the quality judgment diagnosis result and parameter adjustment strategy are used to judge the quality of slab deburring, the deburring removal rate is statistically analyzed, the cause of the defect and the countermeasure are analyzed based on the slab deburring defects, the impact force and impact length during slab deburring are analyzed, the lifting height of the fly hammer hydraulic cylinder of the continuous casting deburring machine is controlled according to the information of the cast steel grade, the action sequence and action time of the fly hammer of the deburring machine are adjusted, and finally the requirements of the impact force and impact length of 100-150mm are met.

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