A method and system for measuring the thickness of a layer of a mold powder for a round billet crystallizer

Abstract

The application provides a cross-section round billet crystallizer protective slag layer thickness measuring method and system, relates to the casting technical field, and is applied to a protective slag layer thickness measuring system.The measuring system comprises a crystallizer, a protective slag layer, a laser scanning measuring module, a liquid level detecting module and a data processing module.The measuring method comprises the following steps: height distribution data of the surface of the protective slag layer is acquired through the laser scanning measuring module, the surface height distribution data comprises height data corresponding to different positions; each height data is corrected according to a preset correction algorithm through the data processing module, and corresponding height correction data is obtained; liquid level height data is acquired through the liquid level detecting module, and the liquid level height data and the height data are one-to-one corresponding; and the thickness data of the protective slag layer of the crystallizer is determined according to the height correction data and the corresponding liquid level height data through the data processing module.The application significantly improves the measurement precision of the thickness of the protective slag layer through the laser scanning technology.

Description

Technical Field

[0001] This invention relates to the field of casting technology, and more specifically, to a method and system for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer. Background Technology

[0002] In the vertical semi-continuous casting process for ultra-large cross-section round billets, the mold flux plays a crucial role. The mold flux not only provides lubrication, reducing friction between the billet and the mold, but also acts as insulation, preventing the molten steel temperature from dropping too quickly. Simultaneously, the mold flux has the ability to absorb inclusions, contributing to improved billet quality. Properly controlling the thickness of the mold flux layer is of great significance for stabilizing billet surface quality, preventing mold leakage, and optimizing heat transfer conditions.

[0003] However, in actual continuous casting production, due to the large width of the crystallizer and the complex liquid surface conditions, the fluidity and melting rate of the protective slag are uneven, resulting in an uneven distribution of the slag layer thickness and thus affecting the overall quality of the cast billet. Currently, industrial practice mainly relies on manually inserting a metal wire and measuring at random single points to obtain the thickness of the protective slag layer. This method has several significant problems.

[0004] First, the limitations of manual measurement methods are obvious. Although traditional measurement methods such as manual probes or sampling analysis are still widely used, these methods are not only discontinuous and labor-intensive, but also prone to errors due to human intervention. Second, the practice of estimating slag layer thickness based on single-point temperature or liquid level sensors is constrained by the complexity of the liquid surface in the crystallizer, often failing to accurately reflect the thickness distribution of the entire slag layer, and thus unable to meet the requirements of refined control in ultra-large cross-section continuous casting. Furthermore, current measurement methods lack the ability to link with the production control system, and cannot provide real-time feedback of slag layer thickness data. This deficiency results in a lack of real-time control over the feeding of protective slag, and may lead to slag layers that are too thick or too thin, negatively impacting the quality of the cast billet. Summary of the Invention

[0005] The problem solved by this invention is one or more of the aforementioned related technical problems.

[0006] To address the above problems, this invention provides a method and system for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer.

[0007] In a first aspect, the present invention provides a method for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer, applied to a protective slag layer thickness measurement system. The protective slag layer thickness measurement system includes a crystallizer, a laser scanning measurement module, a liquid level detection module, and a data processing module. The measurement method includes:

[0008] The laser scanning measurement module acquires the height distribution data of the protective slag layer surface inside the crystallizer, and the surface height distribution data includes height data corresponding to different positions.

[0009] The data processing module corrects each height data according to a preset correction algorithm to obtain the corresponding height correction data.

[0010] The liquid level detection module acquires liquid level height data, and the liquid level height data corresponds one-to-one with the height data.

[0011] The data processing module determines the thickness of the protective slag layer in the crystallizer based on the height correction data and the corresponding liquid level height data.

[0012] Optionally, the protective slag layer thickness measurement system further includes a temperature acquisition module connected to the data processing module. The step of correcting the corresponding height data according to a preset correction algorithm to obtain corrected height data includes:

[0013] Ambient temperature data is acquired through the temperature acquisition module.

[0014] The refractive index of air is obtained based on the ambient temperature data, and the deviation of the corresponding laser path is determined based on the refractive index of air.

[0015] The height data is corrected by the deviation of each laser path to obtain first height correction data, and the first height correction data is used as the height correction data.

[0016] Optionally, the step of correcting the corresponding height data by the deviation of each laser path to obtain the corrected height data includes:

[0017] Using Equation 1, the corresponding height data is corrected based on the deviation of each laser path to obtain the corrected height data;

[0018] Equation 1 is as follows:

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

[0020] Among them, Z′ suface (x,y) represents height-corrected data, Z surface (x, y) represents the height data, and Δd represents the laser path deviation; where... n(T) is the air refractive index, L is the laser propagation path length, and T is the ambient temperature data.

[0021] Optionally, determining the thickness data of the protective slag layer of the crystallizer 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 angle of each laser in the laser scanning measurement module;

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

[0024] The thickness of the protective slag layer in the crystallizer is determined based on the target correction height data and the corresponding liquid level height data.

[0025] Optionally, determining the thickness data of the protective slag layer of the crystallizer based on 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, the liquid level height data are corrected to obtain corresponding liquid level correction data.

[0027] The thickness of the protective slag layer in the crystallizer is determined based on the target correction height data and the corresponding liquid level correction data.

[0028] Optionally, the thickness data of the protective slag layer of the crystallizer is determined based on the target correction height data and the corresponding liquid level height data, including:

[0029] Using the preset quadratic surface least squares method, the target correction height data of each target are smoothed to obtain the corresponding target correction data;

[0030] The thickness of the protective slag layer in the crystallizer is determined based on the target correction data and the corresponding liquid level height data.

[0031] Optionally, the step 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 the preset moving window size, and then correct each liquid level height data using Equation 2 to obtain the corresponding liquid level correction data;

[0033] Equation 2 shown is:

[0034]

[0035] Among them, Z′ steel，tThe liquid level correction data is given, where t is the current time point, ω is the preset moving window size, and Z is the value of the liquid level correction data. steel，i Let i be the liquid level height data, and i be the sequence number of the liquid level height data.

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

[0037] The synchronization module receives data from the laser scanning measurement module and the liquid level detection module respectively, and performs synchronization processing on the received data to obtain synchronized data.

[0038] The synchronized data is transmitted to the data processing module.

[0039] Secondly, the present invention provides a system for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer, comprising a memory and a processor; the memory is used to store a computer program; the processor is used to implement, when executing the computer program, the method for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer as described in the first aspect.

[0040] Thirdly, the present invention provides a computer-readable storage medium, characterized in that the storage medium stores a computer program, which, when executed by a processor, implements the method for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer as described in the first aspect.

[0041] The beneficial effects of the method for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer according to the present invention are:

[0042] The method for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer aims to achieve accurate measurement of the thickness of the protective slag layer inside the cross-sectional round billet crystallizer through a systematic measurement process.

[0043] First, a comprehensive scan of the protective slag layer surface inside the crystallizer is performed using a laser scanning measurement module applied to the protective slag layer thickness measurement system. This module uses a laser beam to acquire height distribution data of the slag layer surface. During the scanning process, the laser beam reflects at different locations, and the laser scanning measurement module records the time delay of these reflected lights, thereby calculating the height data at each location. The final surface height distribution data includes multiple sets of height values ​​corresponding to different locations, forming a height map.

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

[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 inside the crystallizer. This liquid level height data corresponds to each previously acquired height data point to ensure effective comparison and processing during subsequent calculations.

[0046] Finally, the data processing module combines each height correction data with the corresponding liquid level height data, and obtains the thickness measurement data of the protective slag layer through simple mathematical calculations.

[0047] In summary, this invention significantly improves the measurement accuracy of the protective slag layer thickness using laser scanning technology. Compared to traditional manual measurement methods, this high-resolution method can more comprehensively capture changes on the slag layer surface. Simultaneously, the automated measurement process enables real-time data acquisition, facilitating continuous monitoring and adjustment of the protective slag layer thickness during production, thereby avoiding billet quality problems caused by excessive thickness variations. Furthermore, because the machine automatically performs measurement and correction, errors caused by human operation are significantly reduced, ensuring more reliable data and further improving the accuracy of protective slag layer thickness measurement.

[0048] The high-distribution data obtained allows for further data analysis (such as fluidity studies and heat conduction simulations) that provides a rich data foundation for optimizing casting processes. The ability to monitor slag layer thickness in real time enables automated control of the protective slag, reducing adjustment time required due to excessively thick or thin slag layers and improving overall production efficiency. Attached Figure Description

[0049] Figure 1 This is a flowchart illustrating a method for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer according to an embodiment of the present invention.

[0050] Figure 2 This is a schematic diagram of a protective slag layer thickness measurement system according to an embodiment of the present invention;

[0051] Figure 3 This is a schematic diagram of a cross-sectional round billet crystallizer protective slag layer thickness measurement system according to an embodiment of the present invention.

[0052] Explanation of reference numerals in the attached figures:

[0053] 1-Crystallizer, 2-Protective slag 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. Detailed Implementation

[0054] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below 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 set forth herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the present invention. It should be understood that the accompanying drawings and embodiments of the present invention are for illustrative purposes only and are not intended to limit the scope of protection of the present invention.

[0055] It should be understood that the various steps described in the method embodiments of the present invention may be performed in different orders and / or in parallel. Furthermore, the method embodiments may include additional steps and / or omit the steps shown. The scope of the present invention is not limited in this respect.

[0056] The term "comprising" and its variations as used herein are open-ended, meaning "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"; and the term "optionally" means "optional embodiments". Definitions of other terms will be given in the following description. It should be noted that the concepts of "first," "second," etc., mentioned in this invention are used only to distinguish different devices, modules, or units, and are not intended to limit the order of functions performed by these devices, modules, or units or their interdependencies.

[0057] It should be noted that the terms "a" and "a plurality of" used in this invention are illustrative rather than restrictive. Those skilled in the art should understand that, unless otherwise expressly indicated in the context, they should be understood as "one or more".

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

[0059] To address the problems existing in the aforementioned related technologies, this embodiment provides a method and apparatus for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer.

[0060] like Figure 1As shown in the figure, an embodiment of the present invention provides a method for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer. This method is applied to a protective slag layer thickness measurement system, which includes a crystallizer 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: The height distribution data of the surface of the protective slag layer 2 inside the crystallizer 1 is obtained by the laser scanning measurement module 4. The surface height distribution data includes the height data corresponding to different positions.

[0062] Specifically, such as Figure 2 As shown, the protective slag layer thickness measurement system consists of multiple components, including a crystallizer 1.

[0063] The crystallizer 1 is a container used to cool molten metal into solid metal during the casting process. In this system, the crystallizer 1 contains molten metal, and a protective slag layer 2 is located above it to prevent oxidation and impurity intrusion.

[0064] The protective slag layer 2 is located on top of the molten metal, which reduces the contact between the metal and air, reduces oxidation and heat loss, and also adsorbs metal impurities to ensure the quality of the castings.

[0065] The laser dot array 3 is used to form multiple laser dots, that is, to cover the surface of the protective slag layer 2 inside the crystallizer 1. During the scanning process, the laser dot array 3 illuminates the slag layer surface with a laser beam, allowing the measurement system to acquire the height distribution data of the slag layer surface.

[0066] The laser scanning measurement module 4 is responsible for emitting a laser beam and receiving the reflected light signal. By measuring the laser time delay, the module can accurately calculate the height of the protective slag layer 2 surface 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 crystallizer 1. It monitors the liquid level changes 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] Synchronization module 6 coordinates the operation of laser scanning measurement module 4 and liquid level detection module 5. It ensures that the measurement data from the two systems are synchronized in time, enabling effective correlation during subsequent processing.

[0069] The data processing module 7 receives data from the laser scanning measurement module 4 and the liquid level detection module 5, and corrects and analyzes the height data using a preset algorithm. Finally, it outputs the thickness measurement data of the protective slag layer 2, ensuring the accuracy and reliability of the results.

[0070] Temperature acquisition module 8 is responsible for collecting ambient temperature data to perform necessary temperature compensation. Temperature changes may affect the accuracy of laser measurements, so temperature data can be used to specifically correct deviations in the laser path.

[0071] The display and feedback control module 9 displays the processed measurement results and provides a user interface for real-time data viewing and feedback control. Users can make necessary adjustments and operations based on the system feedback to ensure the efficiency and safety of the casting process. For example, the display interface can show the slag layer thickness distribution map in real-time in 2D / 3D format, with an update frequency ≥10Hz, allowing operators to intuitively monitor the status of the protective slag layer 2. Simultaneously, the system dynamically generates feedback control signals based on the thickness data to adjust the slag addition operation.

[0072] Specifically, the laser scanning measurement module 4 includes multiple lasers, such as a high-power semiconductor laser (wavelength 1550nm, strong steam penetration capability); in terms of laser layout, a preset number of laser emission points (lasers) can be arranged in a ring above the crystallizer 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; thereby obtaining the height data corresponding to different positions on the upper surface of the protective slag of the crystallizer 1, that is, the three-dimensional coordinate data of each laser point.

[0073] Laser scanning technology enables the acquisition of high-precision surface height distribution, accurately capturing minute changes in the slag layer and providing a reliable data foundation for subsequent processing. Simultaneously, the laser scanning system boasts rapid response capabilities, allowing for large-area surface measurements to be completed quickly, achieving real-time data acquisition. This system covers all areas within crystallizer 1, ensuring no blind spots and thus acquiring complete height distribution data, providing a more comprehensive reflection of the actual condition of the slag layer.

[0074] The acquired height distribution data provides crucial input for subsequent height correction, liquid level detection, and thickness calculation, helping to improve the overall accuracy and reliability of the measurement. Through this process, the laser scanning measurement module 4 can effectively and comprehensively acquire 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 height data according to a preset correction algorithm to obtain the corresponding height correction data;

[0076] Specifically, when the data processing module 7 receives the raw height data obtained from the laser scanning measurement module 4, this height data may be affected by various factors, such as temperature changes and environmental interference, and therefore needs to be corrected.

[0077] Based on different influencing factors, data processing module 7 employs preset correction algorithms. These algorithms may include: a temperature compensation algorithm: taking into account the impact of temperature changes on laser propagation speed, performing corresponding height corrections; a refractive index correction algorithm: since the refractive index of air or other media may affect laser measurements, corresponding adjustments are required; and environmental interference correction: correcting measurement errors caused by environmental factors such as wind speed and humidity.

[0078] Each piece of raw height data is fed into the selected correction algorithm. This process produces a new height correction dataset, where each value has been corrected to eliminate errors.

[0079] After correction, the module will generate a new height correction dataset that accurately reflects the true height of the slag layer surface and eliminates deviations caused by environmental influences.

[0080] Targeted corrections can eliminate the influence of various factors on altitude data, significantly improving the accuracy of measurement results. Corrected data is more reliable, reducing the risks associated with errors and ensuring that measurement results can be used for production decisions. The preset correction algorithm can be flexibly adjusted according to actual conditions to adapt to different environmental requirements, improving the system's versatility and applicability.

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

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

[0083] Step S300: The liquid level height data is obtained 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 begin measurement. This module typically consists of sensor components that monitor the molten metal level in real time. The liquid level detection module 5 can select different measurement methods depending on the application, such as ultrasonic, laser, float, or capacitive technologies. For example, an electromagnetic induction level gauge can be selected, with liquid level fluctuations required to be controlled within ±5mm. The choice of these methods depends on the specific measurement requirements and environmental conditions. The liquid level sensor measures the molten metal level in the crystallizer 1 in real time. The sensor continuously sends signals and receives return information to capture dynamic changes in the liquid surface position. Once the liquid level is measured, the liquid level detection module 5 performs preliminary processing to remove noise or irrelevant interference. Subsequently, the liquid level data is stored and output in the corresponding format. The key is to ensure a one-to-one correspondence between each liquid level measurement and the height data acquired by the laser scanning measurement module 4. To this end, the liquid level detection module 5 maintains time consistency with the synchronization module 6 of the laser measurement system, ensuring the accuracy and correlation of the liquid level data.

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

[0086] Real-time monitoring by the liquid level detection module 5 ensures the accuracy of the liquid level height data, thereby improving the overall measurement precision of the system. Simultaneously, each liquid level height data point corresponds one-to-one with the height data obtained from laser scanning, ensuring effective comparison and analysis during subsequent processing and reducing potential errors. Furthermore, the immediacy of liquid level monitoring enables the system to quickly respond to changes in the state of the molten metal, supporting accurate control of the production process.

[0087] Real-time monitoring of liquid level helps avoid safety hazards caused by excessively low or high levels, ensuring smooth production. Precise liquid level detection enables more efficient control of molten metal flow, improving material utilization and reducing production costs.

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

[0089] Step S400: The data processing module 7 determines the thickness data of the protective slag layer 2 of the crystallizer 1 based on the height correction data and the corresponding liquid level height data.

[0090] Specifically, all received data is organized into an ordered data structure, typically an array or table, ensuring that each set of height correction data matches the liquid level height data. This step provides a clear data foundation for subsequent calculations, where the thickness of the protective slag layer 2 is calculated using a formula, typically:

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

[0092] Among them, H s1ag (x,y) represents the thickness data of protective slag layer 2, Z′ suface (x,y) represents height-corrected data, Z steel This represents the liquid level height data. Where (x, y) are the coordinates of each laser point in laser dot matrix 3.

[0093] Data processing module 7 iterates through all height and liquid level data, calculating the thickness of each. This ensures data consistency and accuracy in each calculation. After calculation, the thickness data of the protective slag layer 2 is stored and output. Data processing module 7 typically transmits the output to the control system or user interface for subsequent decision-making and operation.

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

[0095] Ensuring casting quality: Ensure the thickness of the protective slag 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 and thickness of molten metal, improve overall production efficiency and reduce resource waste.

[0098] In this embodiment, the method for measuring the thickness of the protective slag layer in the cross-section round billet crystallizer aims to achieve accurate measurement of the thickness of the protective slag layer 2 inside the cross-section round billet crystallizer 1 through a systematic measurement process.

[0099] First, the surface of the protective slag layer 2 inside the crystallizer 1 is comprehensively scanned using the laser scanning measurement module 4, which is applied to the protective slag layer thickness measurement system. This module uses a laser beam to acquire the height distribution data of the slag layer surface. During the scanning process, the laser beam is reflected at different locations, and the laser scanning measurement module 4 records the time delay of these reflected lights, thereby calculating the height data at each location. The final surface height distribution data includes multiple sets of height values ​​corresponding to different locations, forming a height map.

[0100] Since the acquired 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 the height data one by one according to a preset correction algorithm (such as temperature compensation, refractive index correction, etc.) to obtain corrected height data. The correction algorithm aims to eliminate the influence of the external environment on laser measurement, thereby improving the accuracy of the measurement.

[0101] Meanwhile, the liquid level detection module 5 is responsible for acquiring liquid level height data, which reflects the actual liquid level of the molten metal inside the crystallizer 1. This liquid level height data corresponds to each previously acquired height data point to ensure effective comparison and processing during subsequent calculations.

[0102] Finally, the data processing module 7 combines each height correction data with the corresponding liquid level height data, and obtains the thickness measurement data of the protective slag layer 2 through simple mathematical calculations.

[0103] In summary, this invention significantly improves the measurement accuracy of the protective slag layer 2 thickness through laser scanning technology. Compared with traditional manual measurement methods, this high-resolution measurement method can more comprehensively capture changes on the slag layer surface. Simultaneously, the automated measurement process enables real-time data acquisition, facilitating continuous monitoring and adjustment of the protective slag layer 2 thickness during production, thereby avoiding billet quality problems caused by excessive thickness variations. Furthermore, because the machine automatically performs measurement and correction, errors caused by human operation are significantly reduced, ensuring more reliable data and further improving the accuracy of the protective slag layer 2 thickness measurement.

[0104] The high-distribution data obtained allows for further data analysis (such as fluidity studies and heat conduction simulations) that provides a rich data foundation for optimizing casting processes. The ability to monitor slag layer thickness in real time enables automated control of the protective slag, reducing adjustment time required due to excessively thick or thin slag layers and improving overall production efficiency.

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

[0106] Ambient temperature data is acquired through the temperature acquisition module 8.

[0107] The refractive index of air is obtained based on the ambient temperature data, and the deviation of the corresponding laser path is determined based on the refractive index of air.

[0108] The height data is corrected by the deviation of each laser path to obtain first height correction data, and the first height correction data is used as the height correction data.

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

[0110] Using Equation 1, the corresponding height data is corrected based on the deviation of each laser path to obtain the corrected height data;

[0111] Equation 1 is as follows:

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

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

[0114] Specifically, firstly, the temperature acquisition module 8 is activated to acquire ambient temperature data in real time. This module typically uses a temperature sensor, which is capable of accurately measuring the temperature of the surrounding environment.

[0115] The refractive index of air is determined based on the obtained ambient temperature data. The refractive index of air is affected by temperature and pressure, and can usually be calculated using 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 air refractive index.

[0118] Based on the calculated air refractive index, the deviation of the laser path is further determined. During laser measurement, changes in ambient temperature alter the speed of light transmission in the air, causing a deviation between the actual measured height and the theoretical value. The calculated laser path deviation is used to correct the corresponding height data.

[0119] Real-time temperature monitoring and refractive index calculation can significantly improve the accuracy of laser scanning measurements and eliminate temperature-induced measurement errors. Simultaneously, by correcting for 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 measurements under various operating conditions, increasing the system's versatility.

[0120] In complex working conditions such as casting, temperature fluctuations can be significant. In such cases, the temperature acquisition module 8 and its corresponding correction mechanism can effectively reduce the uncertainties caused by environmental changes. Accurate height correction data provides a reliable basis for measuring the thickness of the protective slag layer 2, helping operators make more scientific and rational decisions, thereby further optimizing the casting process.

[0121] Optionally, the step of determining the thickness data of the protective slag layer 2 of the crystallizer 1 by the data processing module 7 based on each of the height correction data and the corresponding liquid level height data includes:

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

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

[0124] The thickness data of the protective slag layer 2 of the crystallizer 1 is determined based on the target correction height data and the corresponding liquid level height data.

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

[0126] For each first height correction data point, data processing module 7 corrects it based on the acquired offset angle, calculating the second height correction data. The correction process can typically be represented by the following formula:

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

[0128] Where Z1(x,y) is the first height correction data, Z″ suface (x,y) represents the second altitude correction data, θ x θ y These represent the offset angles of the laser, i.e., the tilt angles around the X and Y axes, respectively.

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

[0130] By acquiring and correcting the laser's offset angle, the accuracy of height data was significantly improved, reducing measurement deviations caused by equipment errors. Further processing the height data using Kalman filtering effectively reduced data noise, improved the accuracy of the target corrected height data, and ensured the reliability of the final measurement results. The obtained high-precision thickness data of the protective slag layer 2 provides operators with more reliable data support, facilitating more scientific production decisions and improving the optimization level of the casting process.

[0131] This process can adapt to different working conditions and laser configurations, enhancing the system's adaptability and flexibility in various environments. Precise data on the thickness of the protective slag layer 2 effectively monitors the casting process, ensuring the stability of the molten metal, thereby reducing casting defects and improving finished product quality.

[0132] Optionally, determining the thickness data of the protective slag layer 2 of the crystallizer 1 based on the target correction height data and the corresponding liquid level height data includes:

[0133] Based on a preset liquid level fluctuation correction algorithm, the liquid level height data are corrected to obtain corresponding liquid level correction data.

[0134] The thickness data of the protective slag layer 2 of the crystallizer 1 is determined based on the target correction height data and the corresponding liquid level correction data.

[0135] Optionally, the step 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:

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

[0137] Equation 2 shown is:

[0138]

[0139] Among them, Z′ steel，t The liquid level correction data is given, where t is the current time point, ω is the preset moving window size, and Z is the value of the liquid level correction data. steel，i Let i be the liquid level height data, and i be the sequence number of the liquid level height data.

[0140] Specifically, the data processing module 7 first uses a preset liquid level fluctuation correction algorithm to smooth the liquid level data using the moving average method, thereby reducing the impact of short-term fluctuations on thickness calculation.

[0141] In the liquid level detection module 5, a real-time sequence of liquid level measurement data is acquired, typically plotted with time on the horizontal axis and the liquid level measurement value on the vertical axis. The moving average method is a simple smoothing technique that reduces data fluctuations and noise by calculating the mean of data within a specific time window, thus obtaining a more stable average value.

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

[0143] Real-time liquid level measurement data is collected and recorded as a time series dataset Z. steel，i Determine the window size ω for the moving average. The window size should be selected based on the volatility characteristics of the data and real-time requirements, such as choosing 3 or 5 for use in subsequent averaging calculations.

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

[0145] Perform the following steps for each time point:

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

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

[0148] For t=3, the smoothing value is calculated using the above formula, i.e.

[0149]

[0150] By correcting the liquid level height data, the influence of liquid level fluctuations can be effectively considered, significantly improving the accuracy of the protective slag layer 2 thickness measurement and reducing measurement errors caused by liquid level changes. After fully considering liquid level fluctuations, the final thickness data of the protective slag layer 2 is more reliable, helping to ensure operational safety during the casting process. Simultaneously, the high-precision measurement results of the protective slag layer 2 thickness provide operators with more accurate data support, helping them make more scientific and reasonable production decisions, further improving the efficiency and effectiveness of the casting process.

[0151] The system is designed to adapt to varying environmental conditions and liquid level changes, efficiently and accurately acquiring the thickness data of the protective slag layer 2 under all operating conditions. Precise data on the thickness of the protective slag layer 2 effectively monitors the state of the molten metal, helping operators adjust process parameters in a timely manner, thereby reducing casting defects and improving finished product quality.

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

[0153] Optionally, the thickness data of the protective slag layer 2 of the crystallizer 1 is determined based on the target correction height data and the corresponding liquid level height data, including:

[0154] Using the preset quadratic surface least squares method, the target correction height data of each target are smoothed to obtain the corresponding target correction data;

[0155] The thickness data of the protective slag layer 2 of the crystallizer 1 is determined based on the target correction data and the corresponding liquid level height data.

[0156] Specifically, data processing module 7 employs a preset quadratic surface least squares method to smooth the target correction height data. The core of this method is to reduce the impact of data fluctuations on the measurement results by fitting a quadratic surface, thereby obtaining the corresponding target correction data.

[0157] In some embodiments, the basic steps of the quadratic surface least squares method may include: constructing a quadratic surface model using the target correction height data as the independent variable; minimizing the error between the model prediction and the actual data to obtain smoothed target correction data for subsequent calculations; and using the smoothed target correction data and the corresponding liquid level height data, the data processing module 7 calculates the thickness data of the protective slag layer 2 of the crystallizer 1.

[0158] By smoothing the target correction height data using the quadratic surface least squares method, random noise and outliers in the data are reduced, thus significantly improving the measurement accuracy of the protective slag layer 2 thickness. The smoothed target correction data is more stable, which helps to maintain the consistency of measurement results under different environmental conditions and reduces the impact of liquid level changes on the final measurement results.

[0159] Furthermore, the high-precision measurement of the protective slag layer 2 thickness provides operators with reliable data support, enabling them to make more scientific and rational production decisions, thereby optimizing the casting process. This process design is highly adaptable, effectively addressing different environmental conditions and measurement requirements, ensuring accurate protective slag layer 2 thickness data under various operating conditions. Simultaneously, precise protective slag layer 2 thickness data can effectively monitor the state of the molten metal, allowing for timely adjustments to process parameters, thereby reducing casting defects and improving finished product quality.

[0160] Optionally, the protective slag layer thickness measurement system further 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, respectively. The measurement method further includes:

[0161] The synchronization module 6 receives data from the laser scanning measurement module 4 and the liquid level detection module 5 respectively, and performs synchronization processing on the received data to obtain synchronized data.

[0162] The synchronized data is transmitted to the data processing module 7.

[0163] Specifically, the protective slag 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 synchronous data processing.

[0164] The specific steps are as follows:

[0165] The synchronization module 6 receives data from the laser scanning measurement module 4 and the liquid level detection module 5, respectively. These two modules acquire the height data of the protective slag layer 2 and the liquid level height data, which are used for subsequent thickness calculations.

[0166] The received data may have time deviations due to different measurement times, which may lead to inconsistencies. Synchronization module 6 performs synchronization processing on these received data to ensure data consistency in time.

[0167] In some embodiments, the data synchronization process includes: time stamping: adding a timestamp to each received set of data in order 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 laser measurement data and liquid level data correspond to the same time points. This can be done using methods such as linear interpolation or spline interpolation to obtain more accurate synchronization data.

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

[0170] Synchronization module 6 synchronizes laser scanning measurement data and liquid level detection data, ensuring data consistency over time, which is crucial for providing accurate thickness measurement results. Simultaneously, synchronization eliminates data inconsistencies caused by measurement time differences, reduces measurement errors due to delays, and helps improve overall measurement accuracy and reliability. This process integrates data from different modules, providing a unified and accurate foundation for subsequent data processing and analysis, enhancing the overall system efficiency.

[0171] The introduction of Synchronization Module 6 improves the system's intelligence level, enabling it to automatically process and adjust data from different sources, making operators more efficient in analysis and decision-making, thereby reducing the need for manual intervention. Furthermore, by providing synchronous and high-precision data support, operators can make more scientific and rational production decisions, further optimizing the casting process.

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

[0173] Optionally, before outputting the calculation results, the data processing module 7 may also perform a validity check on the results, such as checking whether the thickness is within the expected range. If an anomaly is found, an alarm may be triggered or the calculation may be recalculated.

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

[0175] like Figure 3 As shown in the figure, an embodiment of the present invention provides a system for measuring the thickness of the protective slag layer in a cross-section round billet crystallizer, 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 protective slag layer in a cross-section round billet crystallizer as described above when the computer program is executed.

[0176] Alternatively, a system for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer 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 the computer program is executed:

[0177] The laser scanning measurement module 4 acquires the height distribution data of the surface of the protective slag layer 2 inside the crystallizer 1, and the surface height distribution data includes the height data corresponding to different positions.

[0178] The data processing module 7 corrects each height data according to a preset correction algorithm to obtain the corresponding height correction data.

[0179] The liquid level detection module 5 acquires liquid level height data, and the liquid level height data corresponds one-to-one with the height data.

[0180] The data processing module 7 determines the thickness data of the protective slag layer 2 of the crystallizer 1 based on the height correction data and the corresponding liquid level height data.

[0181] This invention provides a computer-readable storage medium storing a computer program. When the computer program is executed by a processor, it implements the method for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer as described above.

[0182] Alternatively, a non-volatile computer-readable storage medium storing a computer program that, when executed by a processor, causes the processor to perform the following operations:

[0183] The laser scanning measurement module 4 acquires the height distribution data of the surface of the protective slag layer 2 inside the crystallizer 1, and the surface height distribution data includes the height data corresponding to different positions.

[0184] The data processing module 7 corrects each height data according to a preset correction algorithm to obtain the corresponding height correction data.

[0185] The liquid level detection module 5 acquires liquid level height data, and the liquid level height data corresponds one-to-one with the height data.

[0186] The data processing module 7 determines the thickness data of the protective slag layer 2 of the crystallizer 1 based on the height correction data and the corresponding liquid level height data.

[0187] A system for measuring the thickness of the protective slag layer in a cross-section round billet crystallizer, which can serve as a server or client of the present invention, is described below. This system is an example of hardware devices applicable to various aspects of the present invention. The system is intended to represent various forms of digital electronic computer devices, such as laptop computers, desktop computers, workbenches, personal digital assistants, servers, blade servers, mainframe computers, and other suitable computers. It can also represent various forms of mobile devices, such as personal digital processors, cellular phones, smartphones, wearable devices, and other similar computing devices. The components shown herein, their connections and relationships, and their functions are merely illustrative and are not intended to limit the implementation of the invention described and / or claimed herein.

[0188] The cross-sectional round billet crystallizer protective slag layer thickness measurement system includes a computing unit, which can perform various appropriate actions and processes based on a computer program stored in read-only memory (ROM) or a computer program loaded from a storage unit into random access memory (RAM). The RAM can also store various programs and data required for device operation. The computing unit, ROM, and RAM are interconnected via a bus. Input / output (I / O) interfaces are also connected to the bus.

[0189] Those skilled in the art will understand that all or part of the processes in the above embodiments can be implemented by a computer program instructing related hardware. The program can be stored in a computer-readable storage medium, and when executed, it can include the processes of the embodiments of the above methods. The storage medium can be a magnetic disk, optical disk, read-only memory (ROM), or random access memory (RAM), etc. In this application, the units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of the embodiments of the present invention according to actual needs. Furthermore, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated units can be implemented in hardware or as software functional units.

[0190] While the present invention has been disclosed above, its scope of protection 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 all such changes and modifications will fall within the scope of protection of the present invention.

Claims

1. A method for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer, characterized in that, An application is made in a protective slag layer thickness measurement system, which includes a crystallizer (1), a protective slag layer (2), a laser scanning measurement module (4), a liquid level detection module (5), and a data processing module (7). The measurement method includes: The laser scanning measurement module (4) obtains the height distribution data of the surface of the protective slag layer (2) inside the crystallizer (1), and the surface height distribution data includes the height data corresponding to different positions; The data processing module (7) corrects each height data according to a preset correction algorithm to obtain the corresponding height correction data; The liquid level height data is obtained through the liquid level detection module (5), and the liquid level height data corresponds one-to-one with the height data; The thickness data of the protective slag layer (2) of the crystallizer (1) is determined by the data processing module (7) based on the height correction data and the corresponding liquid level height data. The protective slag layer thickness measurement system further includes a temperature acquisition module (8), which is connected to the data processing module (7). The step of correcting the corresponding height data according to a preset correction algorithm to obtain corrected height data includes: Ambient temperature data is acquired through the temperature acquisition module (8). The refractive index of air is obtained based on the ambient temperature data, and the deviation of the corresponding laser path is determined based on the refractive index of air. The height data is corrected by the deviation of each laser path to obtain first height correction data, and the first height correction data is used as the height correction data.

2. The method for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer according to claim 1, characterized in that, The step of correcting the corresponding height data by the deviation of each laser path to obtain height correction data includes: Using Equation 1, the corresponding height data is corrected based on the deviation of each laser path to obtain the corrected height data; Equation 1 is as follows: ； in, For the height correction data, For the height data, This represents the laser path deviation; where, , is the air refractive index, L is the laser propagation path length, T is the ambient temperature data, and (x, y) are the coordinates of each laser point in the laser array (3) on the XY plane.

3. The method for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer according to claim 1, characterized in that, The process of determining the thickness data of the protective slag layer (2) of the crystallizer (1) by the data processing module (7) based on the height correction data and the corresponding liquid level height data includes: Obtain the offset angle of each laser in the laser scanning measurement module (4); For each of the first height correction data, it is corrected by the corresponding offset angle to obtain the second height correction data, and the second height correction data is filtered based on a preset Kalman filter to obtain the target corrected height data; The thickness data of the protective slag layer (2) of the crystallizer (1) is determined based on the target correction height data and the corresponding liquid level height data.

4. The method for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer according to claim 3, characterized in that, The determination of the thickness data of the protective slag layer (2) of the crystallizer (1) based on the target correction height data and the corresponding liquid level height data includes: Based on a preset liquid level fluctuation correction algorithm, the liquid level height data are corrected to obtain corresponding liquid level correction data. The thickness data of the protective slag layer (2) of the crystallizer (1) is determined based on the target correction height data and the corresponding liquid level correction data.

5. The method for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer according to claim 4, characterized in that, The determination of the thickness data of the protective slag layer (2) of the crystallizer (1) based on the target correction height data and the corresponding liquid level height data includes: Using the preset quadratic surface least squares method, the target correction height data of each target are smoothed to obtain the corresponding target correction data; The thickness data of the protective slag layer (2) of the crystallizer (1) is determined based on the target correction data and the corresponding liquid level height data.

6. The method for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer according to claim 4, characterized in that, The method of correcting each liquid level height data based on a preset liquid level fluctuation correction algorithm to obtain corresponding liquid level correction data includes: Obtain the preset moving window size, and then correct each liquid level height data using Equation 2 to obtain the corresponding liquid level correction data; Equation 2 shown is: ； in, The liquid level correction data is given, where t is the current time point. To preset the movable window size, Let i be the liquid level height data, and i be the sequence number of the liquid level height data.

7. The method for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer according to claim 1, characterized in that, The protective slag layer thickness measurement system further 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), respectively. The measurement method further includes: The synchronization module (6) receives data from the laser scanning measurement module (4) and the liquid level detection module (5) respectively, and performs synchronization processing on the received data to obtain synchronized data; The synchronized data is transmitted to the data processing module (7).

8. A system for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer, characterized in that, It includes a memory and a processor; the memory is used to store a computer program; the processor is used to implement, when executing the computer program, the method for measuring the thickness of the protective slag layer in a cross-section round billet crystallizer as described in any one of claims 1 to 7.

9. A computer-readable storage medium, characterized in that, The storage medium stores a computer program, which, when executed by a processor, implements the method for measuring the thickness of the protective slag layer in a cross-sectional round billet crystallizer as described in any one of claims 1 to 7.

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