Method and system for measuring thickness of casting powder layer of section round billet crystallizer

Abstract

The invention provides a section round billet crystallizer casting powder layer thickness measuring method and system, relates to the technical field of casting, and is applied to a casting powder layer thickness measuring system.The measuring system comprises a crystallizer, a casting powder layer, a laser scanning measuring module, a liquid level detecting module and a data processing module; the measuring method comprises the following steps: acquiring height distribution data of the surface of the casting powder layer through a laser scanning measuring module, wherein the surface height distribution data comprises height data corresponding to different positions; correcting each height data through a data processing module according to a preset correction algorithm to obtain corresponding height correction data; liquid level height data are obtained through a liquid level detection module, and the liquid level height data and the height data are in one-to-one correspondence; and the thickness data of the casting powder layer of the crystallizer are determined through the data processing module according to the height correction data and the corresponding liquid level height data. According to the invention, the measurement precision of the thickness of the casting powder layer is obviously improved through the laser scanning technology.

Description

Technical Field

[0001] The present invention relates to the field of casting technology, and more particularly, to a method and system for measuring the thickness of the mold powder layer of a round billet with a cross-section. Background Art

[0002] In the vertical semi-continuous casting process of ultra-large cross-section round billets, the function of the mold powder is crucial. The mold powder not only provides lubrication to reduce the friction between the billet and the mold, but also has a heat insulation effect to prevent the molten steel from cooling too quickly. At the same time, the mold powder has the ability to absorb inclusions, which helps to improve the quality of the billet. Reasonably controlling the thickness of the mold powder layer is of great significance for stabilizing the surface quality of the billet, preventing mold leakage, and optimizing the heat transfer conditions.

[0003] However, in the actual continuous casting production process, due to the large width of the mold and the complex liquid level conditions, the fluidity and melting rate of the mold powder show non-uniformity, which leads to the non-uniform distribution of the slag layer thickness and thus affects the overall quality of the billet. At present, in industrial practice, the thickness of the mold powder layer is mainly measured by manually inserting a metal wire and randomly measuring at a single point. This method has several significant problems.

[0004] First of all, the limitations of the manual measurement method are obvious. Although traditional measurement methods such as manual probes or sampling analysis are still widely used, these methods not only have discontinuous measurements and high labor intensity, but also are prone to errors in measurement results due to the influence of human operation. Secondly, the method of calculating the slag layer thickness based on a single-point temperature or liquid level sensor is restricted by the complexity of the mold liquid level and often cannot accurately reflect the thickness distribution of the entire slag layer, making it difficult to meet the requirements of fine control in ultra-large cross-section continuous casting. In addition, the current measurement methods also lack the ability to interact with the production control system and cannot provide real-time feedback of the slag layer thickness data. This defect makes the feeding control of the mold powder lack real-time performance and may lead to an over-thick or under-thin slag layer, thereby having a negative impact on the quality of the billet. Summary of the Invention

[0005] The problem solved by the present invention is one or more of the above-related technical problems.

[0006] To solve the above problems, the present invention provides a method and system for measuring the thickness of the mold powder layer of a round billet with a cross-section.

[0007] In a first aspect, the present invention provides a method for measuring the thickness of the mold powder layer of a round billet with a cross-section, which is applied to a system for measuring the thickness of the mold powder layer. The system for measuring the thickness of the mold powder layer includes a mold, a laser scanning measurement module, a liquid level detection module, and a data processing module. The measurement method includes:

[0008] Obtain the height distribution data of the surface of the powder layer in the mold through the laser scanning measurement module, where the surface height distribution data includes the height data corresponding to different positions;

[0009] Through the data processing module, correct each of the height data according to a preset correction algorithm to obtain the corresponding height correction data;

[0010] Obtain the liquid level height data through the liquid level detection module, and the liquid level height data corresponds one-to-one with the height data;

[0011] Through the data processing module, determine the thickness data of the powder layer in the mold according to each of the height correction data and the corresponding liquid level height data.

[0012] Optionally, the powder layer thickness measurement system further includes a temperature acquisition module, the temperature acquisition module is connected to the data processing module, and the correction of the corresponding height data according to a preset correction algorithm to obtain height correction data includes:

[0013] Obtain the ambient temperature data through the temperature acquisition module,

[0014] Obtain the refractive index of air according to the ambient temperature data, and determine the deviation amount of the corresponding laser path according to the refractive index of air;

[0015] Correct each of the height data through the deviation amounts of the respective laser paths to obtain first height correction data, and use the first height correction data as the height correction data.

[0016] Optionally, the correction of each of the height data through the deviation amounts of the respective laser paths to obtain the height correction data includes:

[0017] Through Equation 1, correct each of the height data according to the deviation amounts of the respective laser paths to obtain the height correction data;

[0018] Equation l is:

[0019] Z′ suface (x,y)=Z surface (x,y)-Δd;

[0020] Wherein, Z′ suface (x,y) is the height correction data, Z surface (x,y) is the height data, and Δd is the deviation amount of the laser path; wherein, n(T) is the refractive index of air, L is the laser propagation path length, and T is the ambient temperature data.

[0021] Optionally, the process of determining the thickness data of the mold powder layer of the mold by the data processing module based on each of the height correction data and the corresponding liquid level height data includes:

[0022] Obtain the offset angles of the lasers in the laser scanning measurement module;

[0023] For each of the first height correction data, correct it through the corresponding offset angle to obtain second height correction data, and filter the second height correction data based on a preset Kalman filter to obtain target correction height data;

[0024] Determine the thickness data of the mold powder layer of the mold according to each of the target correction height data and the corresponding liquid level height data.

[0025] Optionally, the process of determining the thickness data of the mold powder layer of the mold according to each of the target correction height data and the corresponding liquid level height data includes:

[0026] Based on a preset liquid level fluctuation correction algorithm, correct each of the liquid level height data to obtain corresponding liquid level correction data;

[0027] Determine the thickness data of the mold powder layer of the mold according to each of the target correction height data and the corresponding liquid level correction data.

[0028] Optionally, the process of determining the thickness data of the mold powder layer of the mold according to each of the target correction height data and the corresponding liquid level height data includes:

[0029] Use the preset quadratic surface least squares method to smooth each of the target correction height data to obtain corresponding target correction data;

[0030] Determine the thickness data of the mold powder layer of the mold according to each of the target correction data and the corresponding liquid level height data.

[0031] Optionally, the process of correcting each of the liquid level height data based on a preset liquid level fluctuation correction algorithm to obtain corresponding liquid level correction data includes:

[0032] Obtain a preset moving window size, and correct each of the liquid level height data through Equation 2 to obtain corresponding liquid level correction data;

[0033] Equation 2 is as follows:

[0034]

[0035] where Z′ steel，tis the liquid level correction data, t is the current time point, ω is the preset moving window size, and Z steel，i is the liquid level height data, and i is the serial number of the liquid level height data.

[0036] Optionally, the measuring system for the thickness of the mold powder layer further includes a synchronization module, which is respectively connected to the laser scanning measurement module, the liquid level detection module and the data processing module. The measuring method further includes:

[0037] Receiving the data from the laser scanning measurement module and the liquid level detection module respectively through the synchronization module, and performing synchronization processing on the received data to obtain the data after synchronization processing;

[0038] Transmitting the data after synchronization processing to the data processing module.

[0039] In a second aspect, the present invention provides a measuring system for the thickness of the mold powder layer of a cross-section round billet continuous casting mold, including a memory and a processor; the memory is used to store a computer program; the processor is used to implement the method for measuring the thickness of the mold powder layer of a cross-section round billet continuous casting mold as described in the first aspect when executing the computer program

[0040] In a third aspect, the present invention provides a computer-readable storage medium, characterized in that a computer program is stored on the storage medium, and when the computer program is executed by a processor, the method for measuring the thickness of the mold powder layer of a cross-section round billet continuous casting mold as described in the first aspect is implemented.

[0041] The beneficial effects of the method for measuring the thickness of the mold powder layer of the cross-section round billet continuous casting mold of the present invention are:

[0042] The method for measuring the thickness of the mold powder layer of the cross-section round billet continuous casting mold aims to accurately measure the thickness of the mold powder layer in the cross-section round billet continuous casting mold through a set of systematic measurement processes.

[0043] First, through the laser scanning measurement module applied to the measuring system for the thickness of the mold powder layer, the surface of the mold powder layer inside the mold is scanned comprehensively. This module uses a laser beam to obtain the height distribution data of the slag layer surface. During the scanning process, the laser beam will be reflected at different positions, and the laser scanning measurement module records the time delay of these reflected lights, thereby calculating the height data of each position. The finally obtained surface height distribution data includes multiple groups of height values corresponding to different positions, forming a height map.

[0044] Since the acquired height data may be affected by various factors (such as temperature, environmental interference, etc.), it is necessary to correct each height data through a data processing module. Specifically, the data processing module corrects each height data one by one according to a preset correction algorithm (such as temperature compensation, refractive index correction, etc.) to obtain height-corrected data. The correction algorithm aims to eliminate the influence of the external environment on laser measurement, thereby improving the measurement accuracy.

[0045] Meanwhile, the liquid level detection module is responsible for acquiring liquid level height data, which reflects the actual liquid level of the molten metal in the mold. This liquid level height data corresponds to each previously acquired height data to ensure effective comparison and processing during subsequent calculations.

[0046] Finally, through the data processing module, each height-corrected data is combined with the corresponding liquid level height data, and the thickness measurement data of the mold powder layer is obtained through simple mathematical operations.

[0047] In summary, the present invention significantly improves the measurement accuracy of the mold powder layer thickness through laser scanning technology. Compared with the traditional manual measurement method, this high-resolution measurement method can capture the changes on the surface of the slag layer more comprehensively. At the same time, the automated measurement process realizes real-time data acquisition, which helps to continuously monitor and adjust the mold powder layer thickness during the production process, thereby avoiding slab quality problems caused by excessive thickness changes. In addition, since the machine automatically performs measurement and correction, it can significantly reduce the errors caused by manual operation, ensure the reliability of the acquired data, and further improve the measurement accuracy of the mold powder layer thickness.

[0048] Through the acquired height distribution data, further data analysis (such as fluidity research, heat conduction simulation, etc.) can provide a rich data basis for optimizing the casting process. The ability to monitor the slag layer thickness in real time enables the automated control of the mold powder, reduces the adjustment time required due to too thick or too thin slag layer, and improves the overall production efficiency. Brief Description of the Drawings

[0049] Figure 1 It is a schematic flow chart of a method for measuring the thickness of the mold powder layer of a round billet mold in an embodiment of the present invention;

[0050] Figure 2 It is a schematic structural diagram of a mold powder layer thickness measurement system in an embodiment of the present invention;

[0051] Figure 3 It is a schematic structural diagram of a mold powder layer thickness measurement system for a round billet mold in an embodiment of the present invention.

[0052] Explanation of the Reference Numerals:

[0053] 1 - Mold, 2 - Mold powder layer, 3 - Laser dot matrix, 4 - Laser scanning measurement module, 5 - Liquid level detection module, 6 - Synchronization module, 7 - Data processing module, 8 - Temperature acquisition module, 9 - Display and feedback control module. Specific embodiments

[0054] To make the above - mentioned objects, features, and advantages of the present invention more obvious and understandable, the following detailed description of specific embodiments of the present invention will be given with reference to the accompanying drawings. Although some embodiments of the present invention are shown in the drawings, it should be understood that the present invention can be implemented in various forms and should not be construed as limited to the embodiments described herein. On the contrary, these embodiments are provided to more thoroughly and completely understand the present invention. It should be understood that the drawings and embodiments of the present invention are only for exemplary purposes and are not used to limit the protection scope of the present invention.

[0055] It should be understood that the various steps recorded in the method embodiments of the present invention can be executed in different orders and / or in parallel. In addition, the method embodiments may include additional steps and / or omit the steps shown. The scope of the present invention is not limited in this regard.

[0056] As used herein, the term "including" and its variants are open - ended, that is, "including but not limited to"; the term "based on" means "at least partially based on"; the term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one additional embodiment"; the term "some embodiments" means "at least some embodiments"; the term "optionally" means "optional embodiments". The relevant definitions of other terms will be given in the following description. It should be noted that the concepts such as "first" and "second" mentioned in the present invention are only used to distinguish different devices, modules, or units, and are not used to limit the order of functions executed by these devices, modules, or units or their interdependent relationships.

[0057] It should be noted that the modification of "one" and "multiple" mentioned in the present invention is illustrative rather than restrictive. Those skilled in the art should understand that, unless otherwise clearly stated in the context, it should be understood as "one or more".

[0058] The names of the messages or information exchanged between multiple devices in the embodiments of the present invention are only for illustrative purposes and are not used to limit the scope of these messages or information.

[0059] In view of the problems existing in the above - mentioned related technologies, this embodiment provides a method and device for measuring the thickness of the mold powder layer of a round - section bloom mold.

[0060] As Figure 1As shown in the figure, a method for measuring the thickness of the mold powder layer provided by an embodiment of the present invention is applied to a mold powder layer thickness measurement system. The mold powder layer thickness measurement system includes a mold 1, a laser scanning measurement module 4, a liquid level detection module 5, and a data processing module 7. The measurement method includes:

[0061] Step S100, obtain the height distribution data of the surface of the mold powder layer 2 in the mold 1 through the laser scanning measurement module 4. The surface height distribution data includes height data corresponding to different positions.

[0062] Specifically, as Figure 2 shown, the mold powder layer thickness measurement system is composed of multiple components, including a mold 1.

[0063] The mold 1 is a container for cooling molten metal to form solid metal during the casting process. In this system, the mold 1 contains molten metal inside, and the mold powder layer 2 is located above it, which can prevent oxidation and the intrusion of impurities.

[0064] The mold powder layer 2 is located above the molten metal, which plays a role in reducing the contact between the metal and air, reducing oxidation and heat dissipation. At the same time, it can also adsorb metal impurities to ensure the quality of the casting.

[0065] The laser dot matrix 3 is used to form multiple laser points, that is, to cover the surface of the mold powder layer 2 in the mold 1. During the scanning process, the laser dot matrix 3 irradiates the laser beam onto the surface of the slag layer, so that the measurement system can obtain the height distribution data of the slag layer surface.

[0066] The laser scanning measurement module 4 is responsible for emitting the laser beam and receiving the reflected optical signal. By measuring the laser time delay, the module can accurately calculate the height of the surface of the mold powder layer 2 and generate height distribution data.

[0067] The liquid level detection module 5 is used to detect the liquid level height of the molten metal in the mold 1. It monitors the liquid level change in real time through a specific sensor and provides the liquid level data to the subsequent data processing module 7 for effective comparison and analysis of the height data.

[0068] The synchronization module 6 is used to coordinate the work of the laser scanning measurement module 4 and the liquid level detection module 5. Ensure that the measurement data of the two systems are consistent in time for effective correlation during subsequent processing.

[0069] The data processing module 7 receives the data from the laser scanning measurement module 4 and the liquid level detection module 5, and corrects and analyzes the height data through a preset algorithm. Finally, it outputs the thickness measurement data of the mold powder layer 2 to ensure the accuracy and reliability of the result.

[0070] The temperature acquisition module 8 is responsible for acquiring ambient temperature data for necessary temperature compensation. Temperature changes may affect the accuracy of laser measurement. Therefore, the deviation of the laser path can be corrected specifically based on the temperature data.

[0071] The display and feedback control module 9 is used to display the processed measurement results and provide a user interface to achieve real-time viewing and feedback control of the data. Users can make necessary adjustments and operations according to the information feedback by the system to ensure the high efficiency and safety of the casting process. For example, the display interface can display the slag layer thickness distribution map in 2D / 3D form in real time, with an update frequency ≥ 10Hz. Operators can visually monitor the state of the protective slag layer 2. At the same time, the system dynamically generates a feedback control signal based on the thickness data to adjust the slag addition operation.

[0072] Specifically, the laser scanning measurement module 4 includes multiple lasers. For example, high-power semiconductor lasers (wavelength 1550nm, strong steam penetration ability) can be selected. In terms of the laser layout, a preset number of laser emission points (lasers) can be arranged in a ring above the mold 1 to cover the entire cross-section of the round billet. And the timing synchronization of laser pulses can be achieved through the FPGA controller. Thus, the height data corresponding to different positions on the upper surface of the protective slag on the mold 1 can be obtained, that is, the three-dimensional coordinate data of each laser point.

[0073] Through laser scanning technology, a high-precision surface height distribution can be obtained, accurately capturing the minute changes in the slag layer, providing a reliable data basis for subsequent processing. At the same time, the laser scanning system has a fast response ability, enabling this process to complete large-area surface measurements in a short time and achieve real-time data acquisition. This system can cover all parts inside the mold 1 to ensure there are no dead angles, thereby obtaining complete height distribution data and more comprehensively reflecting the actual situation of the slag layer.

[0074] The obtained height distribution data provides key inputs for subsequent height correction, liquid level detection, and thickness calculation, helping to improve the accuracy and reliability of the overall measurement. Through this process, the laser scanning measurement module 4 can effectively and comprehensively obtain the detailed surface data of the protective slag layer 2, laying a solid foundation for subsequent analysis and control.

[0075] Step S200, the data processing module 7 corrects each of the height data according to a preset correction algorithm to obtain corresponding height correction data;

[0076] Specifically, when the data processing module 7 receives the original height data obtained from the laser scanning measurement module 4, these height data may be affected by various factors such as temperature changes and environmental interference. Therefore, correction is required.

[0077] According to different influencing factors, the data processing module 7 adopts preset correction algorithms. These algorithms may include: Temperature compensation algorithm: Considering the influence of temperature change on the laser propagation speed, corresponding height correction is performed. Refractive index correction algorithm: Since the refractive index of air or other media may affect the laser measurement, corresponding adjustments are required. Environmental interference correction: Compensate for measurement errors caused by environmental factors such as wind speed and humidity.

[0078] Input all the original height data item by item into the selected correction algorithm. This process will generate a new height correction data set, and each value is corrected accordingly to eliminate errors.

[0079] After correction, the module will generate a new height correction data set, which accurately reflects the true height of the slag layer surface and eliminates the deviation caused by environmental impacts.

[0080] Through targeted correction, the influence of different influencing factors on the height data can be eliminated, significantly improving the accuracy of the measurement results. The corrected data is more reliable, reducing the risk brought by errors, and ensuring that the measurement results can be used for production decisions. The preset correction algorithms can be flexibly adjusted according to the actual situation, adapting to different environmental requirements, and improving the versatility and applicability of the system.

[0081] Meanwhile, the generated height correction data provides accurate input for subsequent liquid level detection and slag layer thickness calculation, laying a foundation for the performance improvement and economic benefits of the entire measurement system. The automated data correction process reduces the manual intervention time, improves the overall work efficiency, and enables the system to quickly respond to real-time changes.

[0082] Through this process, this data processing method provides a data basis with high precision and high reliability for the thickness measurement of the protective slag layer 2, thereby optimizing the casting process and improving the production quality

[0083] Step S300, obtain the liquid level height data through the liquid level detection module 5, and the liquid level height data corresponds one-to-one with the height data.

[0084] Specifically, the liquid level detection module 5 is activated and ready to start measuring. This module usually consists of a sensor assembly and can monitor the liquid level height of the molten metal in real time. The liquid level detection module 5 can select different measurement methods according to the actual application, such as ultrasonic, laser, float or capacitance technologies. For example, an electromagnetic induction liquid level gauge can be selected, and the liquid level fluctuation is required to be controlled within ±5 mm. The selection of these methods depends on the specific measurement requirements and environmental conditions. The liquid level sensor measures the liquid level height of the molten metal in the mold 1 in real time. The sensor will continuously send signals and receive return information to capture the dynamic changes in the liquid surface position. Once the liquid level height is measured, the liquid level detection module 5 will preliminarily process this data to remove noise or irrelevant interference information. Subsequently, the liquid level data will be stored and output in the corresponding format. The key is to ensure that each liquid level measurement corresponds one by one with the height data obtained by the laser scanning measurement module 4. To this end, the liquid level detection module 5 maintains time consistency through the synchronization module 6 with the laser measurement system to ensure the accuracy and relevance of the liquid level data.

[0085] Finally, the liquid level detection module 5 transfers the processed liquid level height data to the data processing module 7 for subsequent thickness calculation and height data correction.

[0086] Through the real-time monitoring of the liquid level detection module 5, the accuracy of the liquid level height data is ensured, thus improving the measurement accuracy of the entire system. At the same time, each liquid level height data corresponds one by one with the height data obtained by laser scanning, ensuring that effective comparison and analysis can be carried out during subsequent processing and reducing possible errors. In addition, the immediacy of the liquid level monitoring enables the system to quickly respond to changes in the molten metal state and provides support for the accurate control of the production process.

[0087] Real-time monitoring of the liquid level height helps to avoid safety hazards caused by too low or too high liquid levels and ensures the smooth progress of the production process. Through precise liquid level detection, more reasonable control of the molten metal flow rate can be achieved, improving the utilization rate of materials and thus reducing production costs.

[0088] Through this process, the liquid level detection module 5 provides the necessary liquid level height data basis for the measurement of the thickness of the mold powder layer 2, ultimately contributing to the optimization and quality improvement of the casting process.

[0089] Step S400, the data processing module 7 determines the thickness data of the mold powder layer 2 of the mold 1 according to each of the height correction data and the corresponding liquid level height data.

[0090] Specifically, all received data will be organized into an ordered data structure, usually an array or a table, to ensure that each set of corresponding height correction data matches the liquid level height data. This step provides a clear data basis for subsequent calculations. The thickness of the mold powder layer 2 is calculated according to the formula, usually as follows:

[0091] H slag (x,y) = Z surface (x,y) - Z steel ;.

[0092] Where, H s1ag (x,y) is the thickness data of the mold powder layer 2, Z' suface (x,y) is the height correction data, and Z steel is the liquid level height data. Among them, (x, y) are the coordinates of each laser point in the laser dot matrix 3.

[0093] The data processing module 7 will traverse all height data and liquid level data and calculate the thickness one by one. Ensure the consistency and accuracy of the data during each calculation. After the calculation is completed, the obtained thickness data of the mold powder layer 2 will be stored and output. The data processing module 7 usually passes the output result to the control system or the user interface for subsequent decision-making and operation.

[0094] Through this process, the data processing module 7 can provide high-precision thickness data of the mold powder layer 2, providing important support for the optimization of the casting process. These measurement results are of great significance in the following aspects:

[0095] Guarantee casting quality: Ensure that the thickness of the mold powder layer 2 is within a reasonable range, thereby reducing the risk of production defects.

[0096] Optimize control decisions: Provide real-time data support for production operations to help operators make more accurate judgments.

[0097] Improve production efficiency: By precisely managing the flow rate and thickness of the molten metal, improve the overall production efficiency and reduce resource waste.

[0098] In this embodiment, the method for measuring the thickness of the mold powder layer of the cross-section round billet mold aims to achieve precise measurement of the thickness of the mold powder layer 2 in the cross-section round billet mold 1 through a set of systematic measurement processes.

[0099] First, the surface of the mold powder layer 2 inside the mold 1 is comprehensively scanned by the laser scanning measurement module 4 applied to the mold powder layer thickness measurement system. This module uses a laser beam to obtain the height distribution data of the slag layer surface. During the scanning process, the laser beam is reflected at different positions, and the laser scanning measurement module 4 records the time delay of these reflected lights, thereby calculating the height data of each position. The finally obtained surface height distribution data includes multiple groups of height values corresponding to different positions, forming a height map.

[0100] Since the obtained height data may be affected by various factors (such as temperature, environmental interference, etc.), each height data needs to be corrected by the data processing module 7. Specifically, the data processing module 7 corrects each height data one by one according to a preset correction algorithm (such as temperature compensation, refractive index correction, etc.) to obtain height-corrected data. The correction algorithm aims to eliminate the influence of the external environment on laser measurement, thereby improving the measurement accuracy.

[0101] Meanwhile, the liquid level detection module 5 is responsible for obtaining liquid level height data, which reflects the actual liquid level situation of the molten metal in the mold 1. This liquid level height data corresponds to each previously obtained height data to ensure effective comparison and processing during subsequent calculations.

[0102] Finally, through the data processing module 7, each height-corrected data is combined with the corresponding liquid level height data, and the thickness measurement data of the mold powder layer 2 is obtained through simple mathematical operations.

[0103] In summary, the present invention significantly improves the measurement accuracy of the thickness of the mold powder layer 2 through laser scanning technology. Compared with the traditional manual measurement method, this high-resolution measurement method can capture the changes on the surface of the slag layer more comprehensively. At the same time, the automated measurement process realizes real-time data acquisition, which helps to continuously monitor and adjust the thickness of the mold powder layer 2 during the production process, thereby avoiding slab quality problems caused by excessive thickness changes. In addition, since the machine automatically performs measurement and correction, it can significantly reduce the errors caused by human operation, ensure the reliability of the obtained data, and further improve the measurement accuracy of the thickness of the mold powder layer 2.

[0104] Through the obtained height distribution data, further data analysis (such as fluidity research, heat conduction simulation, etc.) can provide a rich data basis for optimizing the casting process. The ability to monitor the thickness of the slag layer in real time makes it possible to automate the control of the mold powder, reduces the adjustment time required due to too thick or too thin slag layer, and improves the overall production efficiency.

[0105] Optionally, the mold powder layer thickness measurement system further includes a temperature acquisition module 8, which is connected to the data processing module 7. The corresponding height data is corrected according to a preset correction algorithm to obtain height correction data, including:

[0106] Obtain ambient temperature data through the temperature acquisition module 8,

[0107] Obtain the refractive index of air based on the ambient temperature data, and determine the deviation amount of the corresponding laser path according to the refractive index of air;

[0108] Correct the corresponding height data through the deviation amounts of each laser path to obtain first height correction data, and use the first height correction data as the height correction data.

[0109] Optionally, the step of correcting the corresponding height data through the deviation amounts of each laser path to obtain the height correction data includes:

[0110] Correct the corresponding height data through Equation 1 according to the deviation amounts of each laser path to obtain the height correction data;

[0111] Equation 1 is:

[0112] Z′ suface (x,y)=Z surface (x,y)-Δd;

[0113] where, Z′ suface (x,y) is the height correction data, Z surface (x,y) is the height data, and Δd is the deviation amount of the laser path; where, n(T) is the refractive index of air, L is the laser propagation path length, and T is the ambient temperature data.

[0114] Specifically, first, the temperature acquisition module 8 is activated to obtain ambient temperature data in real time. This module usually uses a temperature sensor and can accurately measure the temperature of the surrounding environment.

[0115] Obtain the refractive index of air based on the acquired ambient temperature data. The refractive index of air is affected by temperature and pressure, and can usually be calculated through known formulas:

[0116]

[0117] where, T is the current temperature (current ambient temperature data), T0 is the standard temperature, and k is the temperature coefficient of the refractive index of air.

[0118] According to the calculated air refractive index, the deviation of the laser path is further determined. During laser measurement, due to the change in ambient temperature, the transmission speed of light in the air changes, resulting in a deviation between the actual measured height and the theoretical value. The corresponding height data is corrected using the calculated laser path deviation.

[0119] Real-time monitoring of temperature and calculation of refractive index can significantly improve the accuracy of laser scanning measurement and eliminate measurement errors caused by temperature. At the same time, by correcting the laser path deviation, the accuracy of each height data point is ensured, thereby improving the reliability of the entire measurement system. This process can adapt to different ambient temperatures and maintain high-precision measurement under various operating conditions, increasing the versatility of the system.

[0120] Under complex working conditions such as casting, the temperature fluctuation may be large. At this time, the temperature acquisition module 8 and the corresponding correction mechanism can effectively reduce the uncertainty brought by environmental changes. The accurate height correction data provides a reliable basis for the measurement of the thickness of the mold powder layer 2, helping the operator to make more scientific and reasonable decisions, thereby further optimizing the casting process.

[0121] Optionally, the data processing module 7 determines the thickness data of the mold powder layer 2 of the mold 1 according to each of the height correction data and the corresponding liquid level height data, including:

[0122] Obtain the offset angles of each laser in the laser scanning measurement module 4;

[0123] For each of the first height correction data, correct it through the corresponding offset angle to obtain the second height correction data, and filter the second height correction data based on a preset Kalman filter to obtain the target correction height data;

[0124] Determine the thickness data of the mold powder layer 2 of the mold 1 according to each of the target correction height data and the corresponding liquid level height data.

[0125] Specifically, the data processing module 7 first obtains the offset angles of each laser from the laser scanning measurement module 4. These offset angles are usually caused by the position error during laser installation, environmental factors, or improper equipment calibration, and they will directly affect the measurement accuracy.

[0126] For each first height correction data, the data processing module 7 corrects it according to the obtained offset angle to calculate the second height correction data. The correction process can usually be expressed by the following formula:

[0127] Z″ suface (x,y)=Z1(x,y)cosθ x cosθy ;

[0128] Among them, Z1(x,y) is the first height correction data, and Z″ suface (x,y) is the second height correction data, and θ x , θ y respectively represent the offset angles of the laser, that is, the tilting angles around the X and Y axes.

[0129] For the obtained second height correction data, the data processing module 7 filters it based on a preset Kalman filtering algorithm. Kalman filtering is an effective estimation method that can optimize the current measurement value according to historical data and the measurement noise model, improving the accuracy and reliability of the data. The processing result is the target correction height data.

[0130] By obtaining and correcting the offset angle of the laser, the accuracy of the height data is significantly improved, and the measurement deviation caused by equipment errors is reduced. Then, by applying Kalman filtering to process the height data, the data noise can be effectively reduced, the accuracy of the target correction height data can be improved, and the reliability of the final measurement result can be ensured. The obtained high-precision thickness data of the mold powder layer 2 provides more reliable data support for the operator, helps to make more scientific production decisions, and improves the optimization level of the casting process.

[0131] This process can adapt to different working conditions and laser configurations, enhancing the adaptability and flexibility of the system in various environments. The accurate thickness data of the mold powder layer 2 can effectively monitor the casting process, ensure the stability of the molten metal, thereby reducing casting defects and improving the quality of the finished product.

[0132] Optionally, the determining the thickness data of the mold powder layer 2 of the mold 1 according to each of the target correction height data and the corresponding liquid level height data includes:

[0133] Based on a preset liquid level fluctuation correction algorithm, each of the liquid level height data is corrected to obtain corresponding liquid level correction data;

[0134] According to each of the target correction height data and the corresponding liquid level correction data, the thickness data of the mold powder layer 2 of the mold 1 is determined.

[0135] Optionally, the based on a preset liquid level fluctuation correction algorithm, correcting each of the liquid level height data to obtain corresponding liquid level correction data includes:

[0136] Obtain a preset moving window size, and correct each of the liquid level height data through Equation 2 to obtain corresponding liquid level correction data;

[0137] The shown Equation 2 is:

[0138]

[0139] Among them, Z′ steel，t is the liquid level correction data, t is the current time point, ω is the preset moving window size, and Z steel，i is the liquid level height data, and i is the serial number of the liquid level height data.

[0140] Specifically, the data processing module 7 first uses the preset liquid level fluctuation correction algorithm, that is, the moving average method can be used to smooth the liquid level data and reduce the influence of short-term fluctuations on thickness calculation.

[0141] In the liquid level detection module 5, the measurement data sequence of the liquid level is collected in real time. Usually, the time is the horizontal axis and the liquid level measurement value is the vertical axis. The moving average method is a simple smoothing technique that reduces data fluctuations and noise by calculating the mean value of data within a specific time window to obtain a more stable average value.

[0142] In some embodiments, the moving window size (ω) is selected: the moving window size determines the time span of the average. The larger the window, the more obvious the smoothing effect, but it may cause lag and reduce the response speed.

[0143] Collect the measurement data of the liquid level in real time and record it as a time series data set Z steel，i , and determine the window size ω of the moving average. The window size should be selected according to the fluctuation characteristics and real-time requirements of the data. For example, 3 or 5 can be selected for use in subsequent average calculations.

[0144] For example, the measured values corresponding to the time points t(1, 2, 3) are: 100, 102, 101.

[0145] The following steps are performed for each time point:

[0146] For t = 1, since there is not enough data, keep the original value Z′ steel，1 = Z steel，1 ;

[0147] For t = 2, since there is not enough data, keep the original value Z′ steel，2 = Z steel，2 ;

[0148] For t = 3, apply the above formula to calculate the smoothed value, that is

[0149]

[0150] By correcting the liquid level height data, it is possible to effectively consider the liquid level fluctuation factor, significantly improve the accuracy of the measurement of the thickness of the mold powder layer 2, and reduce the measurement error caused by the liquid level change. After fully considering the liquid level fluctuation, the finally obtained thickness data of the mold powder layer 2 is more reliable, which helps to ensure the operation safety during the casting process. At the same time, the high-precision measurement result of the thickness of the mold powder layer 2 provides more accurate data support for the operator, helps them make more scientific and reasonable production decisions, and further improves the efficiency and effect of the casting process.

[0151] The design of this process enables the system to cope with different environmental conditions and liquid level changes. Under any working conditions, it can efficiently and accurately obtain the thickness data of the mold powder layer 2. The accurate thickness data of the mold powder layer 2 can effectively monitor the state of the molten metal, help the operator adjust the process parameters in a timely manner, thereby reducing casting defects and improving the finished product quality.

[0152] Through the above steps, this process ensures the accurate measurement of the thickness of the mold powder layer in the mold, providing important support for the effective control and optimization of the casting process.

[0153] Optionally, determining the thickness data of the mold powder layer 2 of the mold 1 according to each of the target corrected height data and the corresponding liquid level height data includes:

[0154] Using the preset least squares method for quadratic surface to smooth each of the target corrected height data to obtain the corresponding target corrected data;

[0155] Determining the thickness data of the mold powder layer 2 of the mold 1 according to each of the target corrected data and the corresponding liquid level height data.

[0156] Specifically, the data processing module 7 uses the preset least squares method for quadratic surface to smooth each target corrected height data. The core of this method is to reduce the influence of data fluctuation on the measurement result by fitting a quadratic surface, so as to obtain the corresponding target corrected data.

[0157] In some embodiments, the basic steps of the least squares method for quadratic surface may include: using the target corrected height data as the independent variable to construct a quadratic surface model. Minimizing the error between the model prediction value and the actual data to obtain the smoothed target corrected data for subsequent calculation. Using the smoothed target corrected data and the corresponding liquid level height data, the data processing module 7 calculates the thickness data of the mold powder layer 2 of the mold 1.

[0158] The target corrected height data is smoothed by the quadratic surface least squares method, reducing random noise and outliers in the data, thus significantly improving the measurement accuracy of the thickness of the mold powder layer 2. The smoothed target corrected data is more stable, helping to maintain the consistency of measurement results under different environmental conditions and reducing the impact of liquid level height changes on the final measurement results.

[0159] In addition, the high-precision measurement results of the thickness of the mold powder layer 2 provide reliable data support for the operator, enabling them to make more scientific and reasonable production decisions, thereby optimizing the casting process. The process design has strong adaptability and can effectively respond to different environmental conditions and measurement requirements, ensuring accurate data on the thickness of the mold powder layer 2 under various working conditions. At the same time, the accurate data on the thickness of the mold powder layer 2 can effectively monitor the state of the molten metal and timely adjust the process parameters, thereby reducing casting defects and improving the quality of the finished product.

[0160] Optionally, the mold powder layer thickness measurement system further includes a synchronization module 6, which is respectively connected to the laser scanning measurement module 4, the liquid level detection module 5, and the data processing module 7. The measurement method further includes:

[0161] Receiving the data from the laser scanning measurement module 4 and the liquid level detection module 5 respectively through the synchronization module 6, and performing synchronization processing on the received data to obtain the synchronized data;

[0162] Transmitting the synchronized data to the data processing module 7.

[0163] Specifically, the mold powder layer thickness measurement system includes a synchronization module 6, which is connected to the laser scanning measurement module 4, the liquid level detection module 5, and the data processing module 7 to achieve synchronization processing of the data.

[0164] The specific steps are as follows:

[0165] Receiving the data from the laser scanning measurement module 4 and the liquid level detection module 5 respectively through the synchronization module 6. These two modules respectively obtain the height data of the mold powder layer 2 and the liquid level height data for subsequent thickness calculation.

[0166] The received data may have a time deviation due to different measurement times, which may lead to inconsistencies. The synchronization module 6 performs synchronization processing on these received data to ensure the temporal consistency of the data.

[0167] In some embodiments, the process of data synchronization processing includes: time marking: adding a time stamp to each group of received data to identify the temporal relationship between the data.

[0168] Data interpolation or insertion: If necessary, use interpolation methods to fill or adjust the data so that the time points of the laser measurement data and the liquid level data are consistent. This can be achieved by methods such as linear interpolation and spline interpolation to obtain more accurate synchronized data.

[0169] Data transmission: The synchronized data is then transmitted to the data processing module 7. This module will further analyze and calculate the synchronized data to determine the thickness measurement data of the mold powder layer 2.

[0170] By synchronizing the laser scan measurement data and the liquid level detection data through the synchronization module 6, the consistency of the data in time is ensured, which is crucial for providing accurate thickness measurement results. At the same time, the synchronization process eliminates the data inconsistency caused by the measurement time difference, reduces the measurement error caused by delay, and helps to improve the overall measurement accuracy and reliability. This process integrates data from different modules, provides a unified and accurate basis for subsequent data processing and analysis, and enhances the overall efficiency of the system.

[0171] The introduction of the synchronization module 6 improves the intelligent level of the system, which can automatically process and adjust data from different sources, making the operators more efficient in analysis and decision-making, thus reducing the need for manual intervention. In addition, by providing synchronized and high-precision data support, the operators can make more scientific and reasonable production decisions, further optimizing the casting process.

[0172] In summary, by introducing the synchronization module 6, the mold powder layer thickness measurement system not only improves the accuracy and consistency of data processing, but also helps to enhance the intelligent level of the system and the scientific nature of production decisions.

[0173] Optionally, before the calculation result is output, the data processing module 7 may also perform a rationality verification of the result, such as checking whether the thickness is within the expected range. If an abnormality is found, an alarm may be issued or a recalculation may be performed.

[0174] It should be noted that in the coordinate system set in the present invention, the plane of the XY axis is parallel to the horizontal plane, generally being the upper end face of the copper tube of the mold 1.

[0175] As Figure 3 shown, an embodiment of the present invention provides a cross-sectional round billet mold powder layer thickness measurement system, including a memory and a processor; the memory is used to store a computer program; the processor is used to, when executing the computer program, implement the cross-sectional round billet mold powder layer thickness measurement method as described above.

[0176] That is to say, a measurement system for the thickness of the mold powder layer of a round bloom continuous casting mold includes a memory and a processor coupled to the memory; the memory is configured to store a computer program; the processor is configured to perform the following operations when executing the computer program:

[0177] Obtain the height distribution data of the surface of the mold powder layer 2 in the mold 1 through the laser scanning measurement module 4, where the surface height distribution data includes height data corresponding to different positions;

[0178] Correct each of the height data according to a preset correction algorithm through the data processing module 7 to obtain corresponding height correction data;

[0179] Obtain the liquid level height data through the liquid level detection module 5, and the liquid level height data corresponds to the height data one by one;

[0180] Determine the thickness data of the mold powder layer 2 of the mold 1 according to each of the height correction data and the corresponding liquid level height data through the data processing module 7.

[0181] A computer-readable storage medium provided by an embodiment of the present invention, on which a computer program is stored, and when the computer program is executed by a processor, the method for measuring the thickness of the mold powder layer of the round bloom continuous casting mold as described above is implemented.

[0182] That is to say, a non-volatile computer-readable storage medium, on which a computer program is stored, and when the computer program is executed by a processor, the processor is caused to perform the following operations:

[0183] Obtain the height distribution data of the surface of the mold powder layer 2 in the mold 1 through the laser scanning measurement module 4, where the surface height distribution data includes height data corresponding to different positions;

[0184] Correct each of the height data according to a preset correction algorithm through the data processing module 7 to obtain corresponding height correction data;

[0185] Obtain the liquid level height data through the liquid level detection module 5, and the liquid level height data corresponds to the height data one by one;

[0186] Determine the thickness data of the mold powder layer 2 of the mold 1 according to each of the height correction data and the corresponding liquid level height data through the data processing module 7.

[0187] A cross-section round bloom mold powder layer thickness measurement system that can be used as a server or client of the present invention will now be described. It is an example of a hardware device that can be applied to various aspects of the present invention. The cross-section round bloom mold powder layer thickness measurement system is intended to represent various forms of digital electronic computer devices, such as laptop computers, desktop computers, workstations, personal digital assistants, servers, blade servers, mainframe computers, and other suitable computers. The cross-section round bloom mold powder layer thickness measurement system can also represent various forms of mobile devices, such as personal digital processors, cellular phones, smart phones, wearable devices, and other similar computing devices. The components shown herein, their connections and relationships, and their functions are merely examples and are not intended to limit the implementation of the present invention described and / or claimed herein.

[0188] The cross-section round bloom mold powder layer thickness measurement system includes a computing unit that can perform various appropriate actions and processes according to a computer program stored in a read-only memory (ROM) or a computer program loaded from a storage unit into a random access memory (RAM). In the RAM, various programs and data required for device operation can also be stored. The computing unit, ROM, and RAM are connected to each other via a bus. An input / output (I / O) interface is also connected to the bus.

[0189] Those of ordinary skill in the art can understand that all or part of the processes of implementing the methods in the above embodiments can be completed by instructing relevant hardware through a computer program. The program can be stored in a computer-readable storage medium. When the program is executed, it can include the processes of the embodiments of the above methods. Among them, the storage medium can be a magnetic disk, an optical disk, a read-only memory (ROM), or a random access memory (RAM), etc. In this application, the units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they can be located in one place or distributed to multiple network units. Part or all of the units can be selected according to actual needs to achieve the purpose of the solution of the embodiments of the present invention. In addition, the functional units in various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically alone, or two or more units can be integrated into one unit. The above integrated units can be implemented in the form of hardware or in the form of software functional units.

[0190] Although the present invention is disclosed as above, the scope of protection of the present invention is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention, and these changes and modifications will all fall within the scope of protection of the present invention.

Claims

1. A method for measuring the thickness of the mold powder layer of a round bloom mold, characterized in that, Applied to the measuring system for the thickness of the mold powder layer, the measuring system for the thickness of the mold powder layer includes a mold (1), a mold powder layer (2), a laser scanning measurement module (4), a liquid level detection module (5), and a data processing module (7). The measuring method includes: Obtaining height distribution data of the surface of the mold powder layer (2) inside the mold (1) through the laser scanning measurement module (4), where the surface height distribution data includes height data corresponding to different positions; Correcting each of the height data according to a preset correction algorithm through the data processing module (7) to obtain corresponding height correction data; Obtaining liquid level height data through the liquid level detection module (5), where the liquid level height data corresponds one-to-one with the height data; Determining the thickness data of the mold powder layer (2) of the mold (1) through the data processing module (7) according to each of the height correction data and the corresponding liquid level height data.

2. The method for measuring the thickness of the mold powder layer of a round bloom continuous casting mold according to claim 1, wherein The measuring system for the thickness of the mold powder layer further includes a temperature acquisition module (8), and the temperature acquisition module (8) is connected to the data processing module (7). Correcting the corresponding height data according to the preset correction algorithm to obtain height correction data includes: Obtaining ambient temperature data through the temperature acquisition module (8); Obtaining the refractive index of air according to the ambient temperature data, and determining the deviation amount of the corresponding laser path according to the refractive index of air; Correcting each of the height data through each of the laser path deviation amounts to obtain first height correction data, and using the first height correction data as the height correction data.

3. The method for measuring the thickness of the mold powder layer of a round bloom continuous casting mold according to claim 2, characterized in that, The correcting each of the height data through each of the laser path deviation amounts to obtain height correction data includes: Correcting each of the height data according to each of the laser path deviation amounts through Equation 1 to obtain the height correction data; Equation 1 is: Z ′ SUFAce (x,y) = Z surface (x,y) - Δd; Among them, Z ′ SUface (x, y) is the height correction data, Z surface (x, y) is the height data, and Δd is the laser path deviation amount; among them, n(T) is the air refractive index, L is the laser propagation path length, and T is the ambient temperature data.

4. The method for measuring the thickness of the mold powder layer of the cross-section round billet mold according to claim 2, wherein, Determining the thickness data of the mold powder layer (2) of the mold (1) through the data processing module (7) according to each of the height correction data and the corresponding liquid level height data includes: Obtaining the offset angles of the lasers in the laser scanning measurement module (4); For each of the first height correction data, correcting it through the corresponding offset angle to obtain second height correction data, and filtering the second height correction data based on a preset Kalman filter to obtain target corrected height data; Determining the thickness data of the mold powder layer (2) of the mold (1) according to each of the target corrected height data and the corresponding liquid level height data.

5. The method for measuring the thickness of the mold powder layer of a round bloom mold according to claim 4, characterized in that, Determining the thickness data of the mold powder layer (2) of the mold (1) according to each of the target corrected height data and the corresponding liquid level height data includes: Correcting each of the liquid level height data based on a preset liquid level fluctuation correction algorithm to obtain corresponding liquid level correction data; Determining the thickness data of the mold powder layer (2) of the mold (1) according to each of the target corrected height data and the corresponding liquid level correction data.

6. The method for measuring the thickness of the mold powder layer of the cross-sectional round billet mold according to claim 5, wherein Determining the thickness data of the mold powder layer (2) of the mold (1) according to each of the target corrected height data and the corresponding liquid level height data includes: Smoothing each of the target corrected height data by using a preset quadratic surface least squares method to obtain corresponding target correction data; Determining the thickness data of the mold powder layer (2) of the mold (1) according to each of the target correction data and the corresponding liquid level height data.

7. The method for measuring the thickness of the mold powder layer of a round bloom continuous casting mold according to claim 5, wherein Based on a preset liquid level fluctuation correction algorithm, correcting each of the liquid level height data to obtain corresponding liquid level correction data, including: Obtaining a preset moving window size, and correcting each of the liquid level height data through Equation 2 to obtain corresponding liquid level correction data; The so-called Equation 2 is: Among them, Z′ steel，t is the liquid level correction data, t is the current time point, ω is the preset moving window size, and Z steel，i is the liquid level height data, and i is the serial number of the liquid level height data.

8. The method for measuring the thickness of the mold powder layer of a cross-sectional round billet mold according to claim 1, characterized in that, The mold powder layer thickness measurement system further includes a synchronization module (6). The synchronization module (6) is respectively connected to the laser scanning measurement module (4), the liquid level detection module (5), and the data processing module (7). The measurement method further includes: Receiving the data of the laser scanning measurement module (4) and the liquid level detection module (5) respectively through the synchronization module (6), and performing synchronization processing on the received data to obtain the data after synchronization processing; Transmitting the data after synchronization processing to the data processing module (7).

9. A measuring system for the thickness of the mold powder layer of a round bloom continuous casting mold, characterized in that, Including a memory and a processor; the memory is used for storing a computer program; the processor is used for, when executing the computer program, implementing the cross-section round billet mold powder layer thickness measurement method according to any one of claims 1 to 8.

10. A computer-readable storage medium, characterized in that, A computer program is stored on the storage medium. When the computer program is executed by the processor, the cross-section round billet mold powder layer thickness measurement method according to any one of claims 1 to 8 is implemented.

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