An online system and method for judging and diagnosing the deburring quality of a continuous casting machine

Abstract

This invention relates to an online quality assessment and diagnostic system and method for deburring a continuous casting machine, belonging to the technical field of electrical control equipment and methods in the metallurgical industry. The technical solution of this invention is as follows: a camera (5) is installed below the roller conveyor (2) behind the deburring machine (1), a sound acquisition device is installed on the outlet side of the deburring machine (1), the camera (5) and the sound acquisition device are connected to the assessment and diagnostic model (10), and the deburring machine PLC control system (11) is set between the assessment and diagnostic model (10) and the continuous casting PLC control system. The beneficial effects of this invention are: by adopting the assessment and diagnostic model, and comprehensively analyzing images and sounds, the online quality assessment and diagnostic function of the deburring machine is realized, greatly improving the deburring quality effect, creating favorable conditions for subsequent billet rolling, reducing adverse effects on subsequent hot rolling quality and roll life, reducing the safety risks of manual on-site inspection, and alleviating labor intensity.

Description

Technical Field

[0001] This invention relates to an online judgment and diagnosis system and method for deburring quality of continuous casting machines, belonging to the technical field of electrical control equipment and methods in the metallurgical industry. Background Technology

[0002] Modern large-scale slab continuous casting equipment generally uses flame cutting machines to cut the slab into lengths to meet rolling process requirements. During the cutting process, oxide slag generated often spreads along the lower edge of the cut seam as the molten steel flows, adhering to the lower surface of the slab and forming burrs. These burrs contain a large amount of oxide slag, are hard and loose, have a rough and uneven surface, and may even contain extremely hard particles. In subsequent output and into the next process, these burrs can cause damage to equipment such as rollers and rolls, including impacts, roll surface scratches, and roll body cracks. Furthermore, because oxide slag can be trapped at the beginning and end of the hot-rolled steel sheet, it affects the quality of the rolled product and reduces the yield. Therefore, the effectiveness of deburring directly affects the surface quality of the slab.

[0003] The deburring process is carried out on the lower surface of the billet. The height of the billet conveyor roller is 0.7 meters. In the past, it relied on human observation, which required inspectors to bend over and look up from the bottom of the billet at a relatively close distance. When the billet was moving, the human eye had to follow the head and tail. Occasionally, burrs would fly off on site, posing a safety risk of foreign objects getting into the eyes. The quality inspection was labor-intensive and could not achieve 100% quality inspection. Summary of the Invention

[0004] The purpose of this invention is to provide an online quality assessment and diagnosis system and method for deburring machines. By employing a assessment and diagnosis model and comprehensively analyzing images and sounds, the system achieves online quality assessment and diagnosis of the deburring machine, greatly improving the deburring quality effect, creating favorable conditions for subsequent billet rolling, reducing adverse effects on the rolling quality and roll life of subsequent hot rolling, reducing the safety risks of manual on-site inspection, reducing labor intensity, and effectively solving the aforementioned problems existing in the background technology.

[0005] The technical solution of this invention is: an online judgment and diagnosis system for deburring quality of a continuous casting machine, comprising a camera, a sound acquisition device, a network device, a judgment and diagnosis model, a deburring machine PLC control system, and a continuous casting PLC control system. The camera is installed below the roller conveyor at the rear of the deburring machine. The sound acquisition device includes a sound probe and an audio-visual domain time-domain exchange. The sound probe is installed on the outlet side of the deburring machine, and the sound probe and the audio-visual domain time-domain exchange are connected. The camera and the sound acquisition device are connected to the judgment and diagnosis model through the network device. The deburring machine PLC control system is located 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 mounted on the camera; the camera is fixedly mounted on the side below the roller conveyor behind the deburring machine by a bracket.

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

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

[0009] The diagnostic model 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.

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

[0011] A method for online assessment and diagnosis of deburring quality in continuous casting machines includes the following steps:

[0012] (1) The camera is fixedly installed on the lower side of the roller conveyor 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 on the outlet side of the deburring machine using a bracket and connected to the audio-visual domain time domain exchange and connected to the judgment and diagnosis model through a network device; (3) In the judgment and diagnosis model, the image analysis module and the sound analysis module convert and process the identified head and tail images and audio information, transmit the processed data to the slab burr quality judgment module, perform comparison analysis to obtain the quality judgment and diagnosis result, output the quality judgment and diagnosis result to the deburring equipment parameter strategy adjustment module, and transmit the parameter adjustment strategy to the deburring machine PLC control system; (4) The judgment and diagnosis model outputs information and alarm information and sends them to the deburring machine PLC control system and the continuous casting PLC control system to display the alarm. The deburring machine PLC control system and the continuous casting PLC control system send the deburring machine operation status and slab steel grade information to the judgment and diagnosis model.

[0013] In step (1), a camera protective cover and a compressed air filter pressure reducing valve are installed on the camera.

[0014] In step (2), the sound probe is installed 0.5 meters from the outlet side of the deburring machine.

[0015] In step (2), the audio-visual domain time-domain switch is a microcomputer, and the sound probe is connected to the audio-visual domain time-domain switch via Ethernet.

[0016] In step (3), the quality judgment diagnosis results and parameter adjustment strategies are used to judge the deburring quality of the slab, statistically analyze the deburring removal rate, analyze the defect causes and countermeasures based on the deburring defects of the slab, analyze the striking force and striking length when deburring the slab, control the lifting height of the hydraulic cylinder of the flying hammer of the deburring machine according to the billet steel grade information, and adjust the action sequence and action time of the flying hammer of the deburring machine to finally meet the requirements of striking force and striking length of 100-150mm.

[0017] The beneficial effects of this invention are: by adopting a judgment and diagnosis model to comprehensively analyze images and sounds, the online quality judgment and diagnosis function of the online deburring machine is realized, which greatly improves the deburring quality effect, creates favorable conditions for subsequent billet rolling, reduces adverse effects on subsequent hot rolling quality and roll life, reduces the safety risks of manual on-site inspection, and reduces labor intensity. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of the present invention;

[0019] Figure 2 This is a flowchart of the process of this invention;

[0020] In the diagram: 1. Deburring machine; 2. Roller conveyor; 3. Continuous casting slab; 4. Camera protective cover; 5. Camera; 6. Compressed air filter pressure reducing valve; 7. Sound probe; 8. Audio-frequency domain and time-domain switch; 9. Network equipment; 10. Judgment and diagnosis model; 11. Deburring machine PLC control system; 12. Continuous casting PLC control system. Detailed Implementation

[0021] To make the purpose, technical solutions, and advantages of the invention's embodiments clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described are only a small part of the embodiments of the present invention, not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the protection scope of the present invention.

[0022] An online quality assessment and diagnostic system for deburring in a continuous casting machine includes a camera 5, a sound acquisition device, a network device 9, a diagnostic model 10, a PLC control system 11 for the deburring machine, and a PLC control system 12 for continuous casting. The camera 5 is installed below the roller conveyor 2 behind the deburring machine 1. The sound acquisition device includes a sound probe 7 and an audio-visual domain-time domain exchange 8. The sound probe 7 is installed on the outlet side of the deburring machine 1, and the sound probe 7 and the audio-visual domain-time domain exchange 8 are connected. The camera 5 and the sound acquisition device are connected to the diagnostic model 10 through the network device 9. The PLC control system 11 for the deburring machine is located between the diagnostic model 10 and the PLC control system 12 for continuous casting.

[0023] It also includes a camera protective cover 4 and a compressed air filter pressure reducing valve 6, which are mounted on the camera 5; the camera 5 is fixedly mounted on the side below the roller conveyor 2 behind the deburring machine 1 by a bracket.

[0024] The sound probe 7 is fixedly installed 0.5 meters from the outlet side of the deburring machine 1 by a bracket.

[0025] The sound probe 7 and the audio-visual domain time-domain switch 8 are connected via Ethernet.

[0026] 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.

[0027] The network device 9 is a high-speed switch.

[0028] A method for online assessment and diagnosis of deburring quality in continuous casting machines includes the following steps:

[0029] (1) The camera is fixedly installed on the lower side of the roller conveyor 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 on the outlet side of the deburring machine using a bracket and connected to the audio-visual domain time domain exchange and connected to the judgment and diagnosis model through a network device; (3) In the judgment and diagnosis model, the image analysis module and the sound analysis module convert and process the identified head and tail images and audio information, transmit the processed data to the slab burr quality judgment module, perform comparison analysis to obtain the quality judgment and diagnosis result, output the quality judgment and diagnosis result to the deburring equipment parameter strategy adjustment module, and transmit the parameter adjustment strategy to the deburring machine PLC control system; (4) The judgment and diagnosis model outputs information and alarm information and sends them to the deburring machine PLC control system and the continuous casting PLC control system to display the alarm. The deburring machine PLC control system and the continuous casting PLC control system send the deburring machine operation status and slab steel grade information to the judgment and diagnosis model.

[0030] In step (1), a camera protective cover and a compressed air filter pressure reducing valve are installed on the camera.

[0031] In step (2), the sound probe is installed 0.5 meters from the outlet side of the deburring machine.

[0032] In step (2), the audio-visual domain time-domain switch is a microcomputer, and the sound probe is connected to the audio-visual domain time-domain switch via Ethernet.

[0033] In step (3), the quality judgment diagnosis results and parameter adjustment strategies are used to judge the deburring quality of the slab, statistically analyze the deburring removal rate, analyze the defect causes and countermeasures based on the deburring defects of the slab, analyze the striking force and striking length when deburring the slab, control the lifting height of the hydraulic cylinder of the flying hammer of the deburring machine according to the billet steel grade information, and adjust the action sequence and action time of the flying hammer of the deburring machine to finally meet the requirements of striking force and striking length of 100-150mm. Example

[0034] After the continuous casting process, the continuously cast slab 3 is cut into specific dimensions by a flame cutting machine. Cutting burrs are generated at the junction of the outer arc surface of the continuously cast slab 3 and the flame-cut surface. These burrs can cause considerable problems in subsequent production processes. To eliminate these problems, a deburring machine 1 is installed between two rollers of the roller conveyor 2 to perform deburring operations on the continuously cast slab 3 during its normal travel. When the head or tail of the continuously cast slab 3 reaches the deburring machine, the roller conveyor speed drops to 20 m / min. At this time, the rotating cutter shaft located at the bottom of the slab rotates first, and then, according to the action command of the deburring machine PLC system 11, the hydraulic cylinder of the flying hammer executes a lifting action, removing the burrs. During the deburring process, the camera 5 and the sound probe 7 measure the images and audio of the deburring at the head and tail of the continuously cast slab 3, respectively, and simultaneously acquire the data at high speed via Ethernet. The camera 5 is equipped with a compressed air filter pressure reducing valve 6 and a camera protective cover 4, making it suitable for harsh industrial environments with high temperatures and dust. The audio-frequency domain-time domain exchange 8 uses a microcomputer to perform frequency domain and time domain transformation on the audio signal. It collects image and audio information and transmits it to the judgment and diagnosis model 10 to judge the deburring quality of the slab. Simultaneously, it analyzes the causes and countermeasures for defects in the deburring process. Finally, through the deburring machine PLC control system 11, it facilitates the exchange of casting information, alarm results, and parameter adjustment data between the judgment and diagnosis model 10 and the continuous casting PLC control system 12.

[0035] The deburring machine's PLC control system 11 is a SIEMENS S7-300 model. The entire working process is set to automatic operation. The deburring machine is linked with the billet discharge roller conveyor to complete the automatic cycle of deburring. After the operator starts the deburring machine and sets the "remote" status, the machine automatically completes the deburring work at the head and tail of the billet.

[0036] Camera 5 is equipped with a 2MP 25x zoom network all-in-one camera (IDS-2ZCN2507N). The camera is connected to a hard disk recorder system, and the images are displayed on the monitor in the cutting control room. An RK3399 Linux microcomputer is installed to capture images of the deburring effect at the head or tail of the continuously cast slab. Image analysis and recognition are performed, including image classification, image localization, image detection, and image segmentation. This ultimately achieves high-precision measurement, ensures rapid batch data transmission, easy maintenance, and remote diagnostics. It also boasts a compact installation size.

[0037] The sound probe 7 collects the sound of the deburring impact, amplifies the audio signal by about 200 times, and the amplitude of the output audio signal is adjustable. A noise reduction resistor is added to suppress the generation of background noise. The sound signal is transformed in the frequency domain and time domain by using an audio-visual domain time-domain switch 8, which is a Linux microcomputer RK3399.

[0038] The continuous casting PLC control system 12 adopts Siemens S7-400 PLC hardware configuration and is connected to network device 9 (network device 9 is a high-speed data switch) via industrial Ethernet transmission. The PLC system is programmed and uses communication function blocks to successfully read the billet deburring effect diagnostic information and transmit the billet specification information to the judgment and diagnosis model 10 in real time, which is used as the basic parameters of the deburring model to participate in the system calculation.

[0039] The diagnostic model 10 operates in the following mode: it collects image and sound information, identifies and processes and analyzes the data, judges the quality of the deburring machine, statistically analyzes the deburring removal rate, analyzes the causes of defects and countermeasures based on the defects of the deburring machine, automatically analyzes the striking force and striking length of the deburring machine, and controls the lifting height of the hydraulic action of the deburring machine according to the steel grade.

Claims

1. A method for online judgment and diagnosis of deburring quality in continuous casting machines, characterized in that... Includes the following steps: (1) The camera is fixedly installed on the lower side of the roller conveyor of the deburring machine using a bracket, and is connected to the judgment and diagnosis model through network equipment. The camera is equipped with a camera protective cover and a compressed air filter pressure reducing valve. (2) The sound probe is fixedly installed on the outlet side of the deburring machine using a bracket. The sound probe is connected to the audio-frequency domain time domain exchange and connected to the judgment and diagnosis model through a network device. (3) In the judgment and diagnosis model, the image analysis module and the sound analysis module convert and process the identified head and tail images and audio information, and transmit the processed data to the slab burr quality judgment module for comparison and analysis to obtain the quality judgment and diagnosis result. When the quality does not meet the requirements, the judgment and diagnosis model outputs information and alarm information to the deburring machine PLC control system and the continuous casting PLC control system to display the alarm. The deburring machine PLC control system and the continuous casting PLC control system send the deburring machine operation status and slab steel grade information to the judgment and diagnosis model and output the quality judgment and diagnosis result to the deburring equipment parameter strategy adjustment module, and transmit the parameter adjustment strategy to the deburring machine PLC control system. The quality assessment and diagnostic results, along with parameter adjustment strategies, are used to determine the deburring quality of slabs. The deburring removal rate is statistically analyzed, and the causes and countermeasures for defects in slab deburring are analyzed. The impact force and impact length during slab deburring are determined. Based on the billet steel grade information, the lifting height of the hydraulic cylinder of the flying hammer of the deburring machine is controlled, and the action sequence and action time of the flying hammer of the deburring machine are adjusted to ultimately meet the requirements of impact force and impact length of 100-150mm.

2. The online quality assessment and diagnosis method for deburring in a continuous casting machine according to claim 1, characterized in that: In step (2), the audio-visual domain time-domain switch is a microcomputer, and the sound probe is connected to the audio-visual domain time-domain switch via Ethernet.

3. An online quality assessment and diagnostic system for deburring in a continuous casting machine, used in the online assessment and diagnostic method of claim 1 or 2, characterized in that: The system includes a camera (5), a sound acquisition 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). The camera (5) is installed below the roller conveyor (2) behind the deburring machine (1). The sound acquisition device includes a sound probe (7) and an audio-visual domain time-domain exchanger (8). The sound probe (7) is installed on the outlet side of the deburring machine (1), and the sound probe (7) and the audio-visual domain time-domain exchanger (8) are connected. The camera (5) and the sound acquisition device are connected to the judgment and diagnosis model (10) through the network device (9). The deburring machine PLC control system (11) is located between the judgment and diagnosis model (10) and the continuous casting PLC control system (12).

4. The online quality assessment and diagnosis system for deburring of a continuous casting machine according to claim 3, characterized in that: It also includes a camera protective cover (4) and a compressed air filter pressure reducing valve (6), which are mounted on the camera (5); the camera (5) is fixedly mounted on the side below the roller conveyor (2) behind the deburring machine (1) by a bracket.

5. The online quality assessment and diagnosis system for deburring of a continuous casting machine according to claim 3, characterized in that: The sound probe (7) is fixedly installed 0.5 meters from the outlet side of the deburring machine (1) by a bracket.

6. The online quality assessment and diagnosis system for deburring of a continuous casting machine according to claim 3, characterized in that: The sound probe (7) and the audio-visual domain time-domain switch (8) are connected via Ethernet.

7. The online quality assessment and diagnosis system for deburring of a continuous casting machine according to claim 3, characterized in that: 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.

8. The online quality assessment and diagnosis system for deburring of a continuous casting machine according to claim 3, characterized in that: The network device (9) is a high-speed switch.

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