Converter dangerous area risk management and control system and method based on Internet of Things

Abstract

The invention discloses a converter dangerous area risk management and control system based on the Internet of Things, the system comprises a video sensing module, a data acquisition module, a risk management module, an early warning module and a data transmission module, and the invention further discloses a converter dangerous area risk management and control method based on the Internet of Things. According to the method, the heterogeneous data and the parameter data are systematically collected, logic judgment is carried out on the heterogeneous data and the parameter data, all-area risk monitoring coverage in front of, behind, below and above the converter is achieved, risk monitoring of all stages of converter steelmaking is achieved, the accident pre-prediction capacity is improved, and the risk monitoring efficiency is improved. And systematic control of converter area safety risks by enterprises is facilitated.

Description

Technical Field

[0001] The present invention belongs to the technical field of smelting, and specifically relates to a risk control method for dangerous areas of a converter based on the Internet of Things, and also includes a risk control system for dangerous areas of a converter based on the Internet of Things. Background Technique

[0002] In iron and steel enterprises, the converter equipment is an important equipment for steelmaking. There are many risk factors in the converter area, the working environment is complex, and various casualties occur from time to time, making it difficult to control risks. Common accidents in converters include: explosion accidents caused by the leakage of the converter oxygen lance encountering molten metal; splash and scalding accidents during converter steel tapping; explosion caused by accumulated water in the slag channel encountering molten metal; explosion accidents during converter hot metal charging; splashing and scalding accidents during converter smelting; converter gas poisoning; other accidents, such as mechanical injury accidents of the converter charging belt, lifting injury accidents of the overhead crane, forklift injury accidents, object hitting accidents, etc.

[0003] Currently, the main methods for risk control in the converter area of iron and steel enterprises are: monitoring of the oxygen lance (sub-lance) water cooling system, which uses pressure, flow, and temperature sensors to input the collected data into a computer system for program determination. When the parameters reach the set threshold, an alarm is given on the computer and the interlock is started; video monitoring in front of the furnace, and the traditional method of video monitoring in front of the furnace is to manually observe the video monitoring screen to check if there are non-staff members entering, and give a voice prompt; physical isolation in front of the furnace, which mainly uses fences to safely isolate the area in front of the furnace to prevent non-staff members from entering; setting warning lines for the standing positions of hot metal charging commanders, which are mainly set when adding scrap steel or charging hot metal, and personnel stand within the warning line outside the 120° hot metal charging fan-shaped area; safety warning signs are set to remind that it is prohibited for personnel to pass through in front of the furnace during converter blowing; a small number of enterprises use video monitoring and digital twin technology to establish a three-dimensional model for the converter area to automatically identify whether there are personnel entering, etc.

[0004] Currently, for the risk control in the converter area, traditional methods are mostly adopted. For example, the monitoring range of the cameras installed in front of the furnace is limited, and the risk cannot be predicted in relation to the production operation. The setting of safety warning signs, the physical isolation of the railing in front of the furnace, and the positioning of the molten iron charging commanders have problems such as slow manual judgment of early warnings, inability to monitor in real time, and unreliability. Non-traditional methods are also used, such as collecting the parameters of pressure, flow rate, and temperature of the cooling water in the water-cooling system of the converter oxygen lance (sub-lance) and alarming to prevent explosion accidents caused by water leakage of the oxygen lance (sub-lance); collecting the pressure of the oil pump that supplies lubricating oil to the converter tilting motor to monitor and prevent wear and failure of the tilting motor due to lack of oil. These IoT monitoring parameters mainly focus on production, and the data has not been effectively applied to risk control. The safety warning is relatively single. The risk control in the converter area does not consider the areas in front of the furnace, behind the furnace, under the furnace, and above the furnace from a systematic perspective. The IoT-collected data has not been effectively integrated and associated, and the systems are isolated from each other and cannot achieve interlocking disposal actions, which is not a systematic design. Summary of the Invention

[0005] The purpose of the present invention is to provide a risk control method for dangerous areas of converters based on the Internet of Things and a risk control system for dangerous areas of converters based on the Internet of Things in view of the above problems existing in the prior art.

[0006] The above object of the present invention is achieved by the following technical means:

[0007] A risk control method for dangerous areas of converters based on the Internet of Things includes the following steps:

[0008] Step 1: Conduct safety detection during the charging stage of converter steelmaking;

[0009] Step 2: Conduct safety detection during the blowing stage of converter steelmaking;

[0010] Step 3: Conduct safety detection during the steel tapping stage of converter steelmaking;

[0011] Step 4: Conduct safety detection during the slag cleaning stage of converter steelmaking;

[0012] Step 5: Conduct safety detection on the 4th - 8th floors of the converter.

[0013] As described above, Step 1 includes the following steps:

[0014] Step 1.1: Before adding scrap steel to the converter, if the edge server identifies that the height of the scrap steel in the scrap steel tank exceeds the height of the tank, the central control host sends a warning signal of excessive scrap steel loading amount to the controller. The controller controls the sound and light alarm to give a sound and light alarm, and controls the speaker to give a voice prompt to the dispatcher that the scrap steel in the scrap steel tank is too high;

[0015] Step 1.2: When scrap steel is fed into the converter, if the edge server recognizes that the position of the personnel in front of the furnace is not outside the electronic fence marked by the set fan-shaped area, the central control host sends a warning signal of the forward position of the personnel in front of the furnace to the controller. The controller controls the sound and light alarm to give an audible and visual alarm, and controls the electronic fence marked by the fan-shaped area to give a voice prompt to the personnel in front of the furnace to move outside the fan-shaped area marking;

[0016] Step 1.3: During the process of adding scrap steel to the converter, if the central control host obtains the rotation speed of the dust removal fan collected by the sensor, and if the rotation speed of the dust removal fan is lower than the set rotation speed, the central control host sends a warning signal of low rotation speed of the dust removal fan to the controller. The controller adjusts the rotation speed of the fan to the set rotation speed;

[0017] Step 1.4: When the crane hooks the ladle, if the edge server recognizes that there are no post personnel in the defined areas on both sides of the hot metal ladle or the post personnel do not stay in the defined areas, the central control host sends a warning signal for hook unhooking inspection to the controller. The controller controls the sound and light alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt to the post personnel to check and confirm whether the trunnions on both sides of the hot metal ladle are hooked;

[0018] Step 1.5: Before the overhead crane starts, if the edge server recognizes that the hot metal ladle does not pause, and if it recognizes that the hot metal ladle does not pause, the central control host sends a warning message to the controller. The controller controls the sound and light alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt to the crane driver to pause the ladle body to test whether the overhead crane brake is in good condition;

[0019] Step 1.6: Before pouring hot metal into the converter, if the edge processor recognizes that the accumulated water area in front of the converter furnace is larger than the set area, the central control host sends a warning signal of excessive accumulated water area in front of the furnace to the controller. The controller controls the sound and light alarm to give an audible and visual alarm, and controls the speaker to announce that the accumulated water area in front of the furnace is excessive;

[0020] Step 1.7: Before pouring hot metal into the converter, the edge server recognizes that the position of the personnel in front of the furnace is not outside the electronic fence marked by the set fan-shaped area. The central control host sends a warning signal of the forward position of the personnel in front of the furnace to the controller. The controller controls the sound and light alarm to give an audible and visual alarm, and controls the electronic fence to give a voice prompt to the personnel in front of the furnace to move outside the fan-shaped area marking;

[0021] Step 1.8: After the edge server recognizes that there is no accumulated water in front of the furnace and the positions of the personnel in front of the furnace are all outside the electronic fence marked by the fan-shaped area, it starts to pour molten iron into the converter. The central control host obtains the parameters of the converter tilting angle and the gap between the molten iron ladle and the converter collected by the sensors. If the converter tilting angle or the gap between the molten iron ladle and the converter does not meet the set values, the central control host sends a hook release warning signal to the controller. The controller controls the sound and light alarm to give an alarm, and controls the speaker to give a voice prompt that the converter tilting angle exceeds the limit, which may cause the molten iron ladle to be placed on the converter mouth and pose a risk of hook release;

[0022] Step 1.9: During the process of pouring molten iron into the converter, if the central control host obtains the rotation speed of the dust removal fan collected by the sensor, and if the rotation speed of the dust removal fan is lower than the set speed, the central control host sends a low rotation speed warning signal of the dust removal fan to the controller. The controller adjusts the fan speed to the set speed.

[0023] As described above, Step 2 specifically includes the following steps:

[0024] Step 2.1: After pouring molten iron and before blowing, the edge server recognizes whether the explosion-proof door is closed. If it is recognized that the explosion-proof door is not closed, the central control host sends a warning signal of the explosion-proof door not closed to the controller. The controller controls the sound and light alarm to give an alarm, and controls the speaker to give a voice prompt to the post employees to close the explosion-proof door;

[0025] Step 2.2: During blowing, the edge server recognizes whether the position of the personnel in front of the furnace is outside the marked fan-shaped area. If the recognition result is that the position of the personnel in front of the furnace is not outside the electronic fence of the fan-shaped area, the central control host sends a warning signal of the personnel in front of the furnace standing too close to the controller. The controller controls the sound and light alarm to give an alarm, and controls the speaker to give a voice prompt to the personnel in front of the furnace to move outside the electronic fence of the fan-shaped area;

[0026] Step 2.3: During blowing, the edge server recognizes the temperature of the converter shell. If it is recognized that the difference between the temperature of the converter shell and the adjacent temperature exceeds the set value, the central control host sends a warning signal of the converter shell damage to the controller. The controller controls to stop oxygen blowing and raise the lance, controls the sound and light alarm to give an alarm, and controls the speaker to give a voice prompt of the converter shell damage;

[0027] Step 2.4: During blowing, the central control host obtains the limit states of the water cooling systems of the furnace mouth, the trunnion, the oxygen lance, the hood, the limit state of the oxygen lance reel, and the parameter data of the hydraulic station, the oxygen main pipeline, and the steam drum, and judges whether to stop oxygen blowing and raise the lance;

[0028] Step 2.5: During the operation of opening the furnace mouth during the smelting interval, if the edge server recognizes that the monitoring personnel are not outside the set safety distance marking line of the furnace mouth, the central control host sends a warning signal to the controller. The controller controls the sound and light alarm to emit sound and light alarms, and controls the speaker to give a voice prompt for the monitoring personnel to move outside the safety distance marking line of the furnace mouth;

[0029] Step 2.6: When personnel work in the area under the converter during the converter smelting period, the converter is not allowed to tilt. If the central control host recognizes that the output current of the tilting motor is zero, the central control host sends a warning signal that there are people working in the area under the furnace but the converter is tilting to the controller. The controller controls to stop tilting the converter.

[0030] As described above, Step 3 specifically includes the following steps:

[0031] Step 3.1: Before tapping in the converter steelmaking stage, the edge server recognizes the lining thickness of the converter. If it is recognized that the lining thickness is less than the set ratio of the initial thickness, the central control host sends a warning signal of lining damage to the controller. The controller controls the converter tilting interlock, controls the sound and light alarm to emit sound and light alarms, and controls the speaker to give a voice prompt of lining damage;

[0032] Step 3.2: Before tapping in the converter steelmaking stage, the edge server recognizes whether all the personnel on the fan-shaped surface of the platform behind the furnace are post employees. If it is recognized that they are all post employees, then the furnace is tilted for tapping; if it is recognized that they are non-post employees, the central control host sends a warning signal to the controller. The controller controls the converter tilting interlock, controls the sound and light alarm to emit sound and light alarms, and controls the electronic fence to give a voice prompt for the non-post employees to leave the fan-shaped surface of the platform behind the furnace as soon as possible; until it is recognized that all the personnel on the fan-shaped surface of the platform behind the furnace are post employees, the controller controls to release the interlock and tilt the furnace for tapping;

[0033] Step 3.3: During the tapping operation, if the edge processor recognizes that the distance between the molten steel level in the ladle and the ladle mouth is less than the set distance, the central control host sends a warning signal of overfilled molten steel to the controller. The controller controls to stop tilting the furnace, controls the sound and light alarm to emit sound and light alarms, and controls the speaker to give a voice prompt of overfilled molten steel;

[0034] Step 3.4: During the tapping operation, when the converter is tilting, the central control host obtains the limit states of the water cooling systems of the furnace mouth, the trunnion, the oxygen lance, and the hood, the limit state of the oxygen lance drum, and the parameter data of the hydraulic station, the oxygen main pipeline, and the steam drum, and judges whether to stop oxygen blowing and raise the lance.

[0035] As described above, the judgment of whether to stop oxygen blowing and raise the lance is specifically as follows:

[0036] The central control host obtains the water inlet and outlet flow difference and the outlet water temperature of the oxygen lance water cooling system through sensors. If it is identified that the water inlet and outlet flow difference of the oxygen lance water cooling system is greater than the set value or the outlet water temperature of the oxygen lance water cooling system is higher than the set temperature, the central control host sends an abnormal warning signal for the water inlet and outlet flow difference or an abnormal warning signal for the outlet water temperature of the oxygen lance water cooling system to the controller. The controller stops the oxygen lance from blowing oxygen and controls the hydraulic station to lift the oxygen lance out of the converter. The controller controls the sound and light alarm to give a sound and light alarm and controls the speaker to give a voice prompt for the abnormal water inlet and outlet flow difference of the oxygen lance water cooling system and the abnormal outlet water temperature of the oxygen lance water cooling system;

[0037] The central control host obtains the water inlet and outlet flow difference and the outlet water temperature of the hood water cooling system and the trunnion water cooling system through sensors. If it is identified that the water inlet and outlet flow difference of the hood water cooling system is greater than or equal to the set value or the water inlet and outlet flow difference of the trunnion water cooling system is greater than or equal to the set temperature, the central control host sends an abnormal warning signal for the water inlet and outlet flow difference of the hood water cooling system or an abnormal warning signal for the water inlet and outlet flow difference of the trunnion water cooling system to the controller. The controller controls the oxygen lance to stop blowing oxygen and controls the hydraulic station to lift the oxygen lance out of the converter. The controller controls the sound and light alarm to give a sound and light alarm and controls the speaker to give a voice prompt for the abnormal water inlet and outlet flow difference of the hood water cooling system and the abnormal water inlet and outlet flow difference of the trunnion water cooling system;

[0038] The central control host obtains the limit states of the hood and the oxygen lance reel respectively. When the central control host receives the upper limit signal or the lower limit signal of the hood, or the upper limit signal or the lower limit signal of the oxygen lance reel, the central control host sends an abnormal warning signal for the hood limit state or an abnormal warning signal for the oxygen lance reel limit state to the controller. The controller controls the oxygen lance to stop blowing oxygen and controls the hydraulic station to lift the oxygen lance out of the converter. The controller controls the sound and light alarm to give a sound and light alarm and controls the speaker to give a voice prompt for the abnormal hood limit state or the abnormal oxygen lance reel limit state;

[0039] The central control host obtains the oil supply pressure of the hydraulic station and the oxygen pressure of the oxygen main pipeline respectively. When the oil supply pressure of the hydraulic station is less than the set pressure, the central control host sends an abnormal warning signal for the oil supply pressure of the hydraulic station to the controller. The controller controls the oxygen lance to stop blowing oxygen. The controller controls the sound and light alarm to give a sound and light alarm and controls the speaker to give a voice prompt for the abnormal oil supply pressure of the hydraulic station. When the oxygen pressure after the oxygen main pipeline cut-off valve is less than the set pressure, the central control host sends an abnormal warning signal for the oxygen pressure to the controller. The controller controls the oxygen lance to stop blowing oxygen and controls the hydraulic station to lift the oxygen lance out of the converter. The controller controls the sound and light alarm to give a sound and light alarm and controls the speaker to give a voice prompt for the abnormal oxygen pressure;

[0040] The central control host respectively obtains the pressure and water level of the steam drum. When the pressure of the steam drum is lower than the set pressure or the water level of the steam drum is lower than the set water level, the central control host sends an abnormal warning signal of the steam drum pressure or an abnormal warning signal of the steam drum water level to the controller. The controller controls the oxygen lance to stop blowing oxygen, and controls the hydraulic station to lift the oxygen lance out of the converter. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt that the steam drum pressure is abnormal or the steam drum water level is abnormal.

[0041] Step 4 as described above specifically includes the following steps:

[0042] Step 4.1: The edge server identifies whether the inside of the slag ladle of the slag ladle truck is dry. If it is identified that there is water accumulation inside the slag ladle, the central control host sends a warning signal of water accumulation inside the slag ladle to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt to the slag cleaning staff to clean the slag ladle.

[0043] Step 4.2: Before the slag ladle truck moves forward, if the edge server identifies that there is accumulated slag on the ladle track, the central control host sends a warning signal of accumulated slag on the ladle track to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt to the slag cleaning staff to clean the accumulated slag on the ladle track.

[0044] Step 4.3: When performing the operation of cleaning the accumulated slag on the ladle track, the edge server identifies the standing position of the slag cleaning staff. If it is identified that the standing position of the slag cleaning staff is within the set safety position marking line, the central control host sends a warning signal to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt to the slag cleaning staff to move outside the set safety position marking line.

[0045] Step 4.4: The edge server identifies the water accumulation area in the slag channel pit. If the identification result is that the water accumulation area in the slag channel pit is larger than the set water accumulation area, the central control host sends a warning signal of excessive water accumulation area in the slag channel pit to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt that the water accumulation area in the slag channel pit is excessive.

[0046] Step 5 as described above specifically includes the following steps:

[0047] Step 5.1: The edge server identifies the number of operating personnel working on the 4th - 8th floors of the converter. If the identification result is single - person operation, the central control host sends a warning signal of lack of joint guarantee and mutual guarantee to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt to the employees to carry out joint guarantee and mutual guarantee.

[0048] Step 5.2: The edge server identifies whether the employees working on the 4th - 8th floors of the converter are wearing gas alarms. If the identification result is that they are not wearing gas alarms, the central control host sends a warning signal of personnel not wearing gas alarms to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt for the employees to wear gas alarms.

[0049] Step 5.3: The edge server identifies whether the protective cover is in good condition. If the identification result is that the protective cover is not in good condition, the central control host sends a warning signal of the protective cover not being in good condition to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt for the mechanical maintenance staff to repair the protective cover in time.

[0050] Step 5.4: The edge server identifies the standing positions of the personnel working on the 4th - 8th floors of the converter. If the identification result is that the standing positions of the personnel are not outside the marked area, the central control host sends a warning signal of personnel standing in a dangerous area to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt for the employees to move outside the marked area.

[0051] A converter dangerous area risk control system based on the Internet of Things includes a video perception module and a data acquisition module, and also includes a risk management module, an early warning module, and a data transmission module. The video perception module includes a camera and an infrared thermal imaging module. The data acquisition module includes sensors. The risk management module includes a central control host, an edge server, and a controller. The early warning module includes a mobile phone terminal, an optoelectronic alarm, an electronic fence, and a speaker. The central control host is connected to the camera, infrared thermal imaging module, sensors, edge server, and controller through the data transmission module. The camera and infrared thermal imaging module are also connected to the edge server. The controller is connected to the mobile phone terminal, optoelectronic alarm, electronic fence, speaker, and disposal equipment. The data transmission module includes a data acquisition gateway and an Internet of Things gateway.

[0052] As described above, the edge server receives heterogeneous data from the camera and infrared thermal imaging module through the data transmission module, and performs edge algorithm processing on the video heterogeneous data to measure the standing positions of personnel, the water accumulation area, the pause of the tank body, the distance measurement, the equipment movement, the thickness measurement, and the identification of personnel identities, and sends the identification results to the central control host.

[0053] The central control host receives the identification results from the edge server, and sends corresponding warning signals to the controller according to the identification results of the edge server. The central control host also obtains the parameter data of the sensors through the data transmission module, compares and identifies the obtained parameter data with the thresholds of each set parameter data, and sends corresponding warning signals to the controller according to the identification results.

[0054] The camera and the infrared thermal imaging module are used to obtain heterogeneous data, which includes video data and thermal imaging data; both the camera and the infrared thermal imaging module include multiple probes;

[0055] The sensor is used to collect the parameter data of the device in real time. The parameter data of the device includes temperature, pressure, flow rate, rotational speed, current, and liquid level;

[0056] The audible and visual alarm receives the early warning signal sent by the central control host and gives an audible and visual alarm. The speaker and the electronic fence receive the early warning signal sent by the central control host and emit corresponding alarm voices.

[0057] It also includes a background data entry module and a display module. Both the background data entry module and the display module are connected to the central control host. The background data entry module is used to enter the list of personnel, facial information, relevant certificate information, and threshold information of each parameter; it is also used to enter the annual inspection and annual inspection date of the vehicle, the annual inspection and annual inspection date of the ladle, the annual inspection and annual inspection date of the slag pot trunnion, the obtaining of gas special operation certificates, the obtaining of certificates for overhead crane operators, and the annual inspection and annual inspection date of the metallurgical casting crane; the risk management module also includes a display module, which is used for the parameter data of the device.

[0058] The present invention has the following beneficial effects compared with the prior art:

[0059] (1) By systematically collecting heterogeneous data and parameter data and making logical judgments for each heterogeneous data and parameter data respectively, the present invention realizes full-area risk monitoring coverage in front of, behind, below, and above the converter furnace, improves the accident prediction ability before the event, and is conducive to the enterprise's systematic management and control of the safety risks in the converter area.

[0060] (2) The system of the present invention extends the single-index alarm to the associated system, improving the dynamic accuracy and efficiency of monitoring. BRIEF DESCRIPTION OF THE DRAWINGS

[0061] Figure 1 It is a schematic structural diagram of the system of the present invention;

[0062] Figure 2 It is a working flow chart of the system of the present invention;

[0063] Figure 3 It is a flow chart of the charging stage of the converter of the present invention;

[0064] Figure 4 It is a flow chart of the steel tapping stage of the converter of the present invention;

[0065] Figure 5 It is a flow chart of the slag cleaning stage of the converter of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0066] To facilitate the understanding and implementation of the present invention by those of ordinary skill in the art, the present invention will be further described in detail below in conjunction with embodiments. The embodiments described herein are only for the purpose of illustrating and explaining the present invention and are not intended to limit the present invention.

[0067] Embodiment 1:

[0068] A risk control system for dangerous areas of a converter based on the Internet of Things includes a risk management system, a data transmission module, a video perception module, a data acquisition module, and an early warning module.

[0069] The video perception module includes a camera and an infrared thermal imaging module. The video perception module is used to obtain heterogeneous data, which includes video data and thermal imaging data. The camera includes multiple probes that obtain video data in real time; the infrared thermal imaging module includes multiple probes that obtain thermal imaging data in real time;

[0070] The data acquisition module includes sensors for collecting parameter data. The sensors obtain parameter data related to the equipment in the converter area in real time, including temperature, pressure, flow rate, rotational speed, current, and liquid level;

[0071] In this embodiment, the parameter data includes the difference in the inlet and outlet water flow rates of the oxygen lance water cooling system, the difference in the inlet and outlet water flow rates of the furnace mouth water cooling system, the difference in the inlet and outlet water flow rates of the trunnion water cooling system, the difference in the inlet and outlet water flow rates of the hood water cooling system, the outlet water temperature of the oxygen lance, the limit state of the hood, the limit state of the oxygen lance reel, the oil supply pressure of the hydraulic station, the oxygen pressure in the oxygen main pipeline, the drum pressure, the drum water level, the tilting angle of the converter, the gap between the hot metal ladle and the converter, the rotational speed of the dust removal fan, and the output current value of the tilting motor.

[0072] Among them, the furnace mouth area is in direct contact with high-temperature molten steel and slag. The water cooling system of the furnace mouth is used to reduce the temperature of the furnace mouth. When operating the water cooling system of the furnace mouth, it is necessary to detect whether the difference in the inlet and outlet water flow rates of the water cooling system of the furnace mouth is within the set difference threshold. If it is higher than the set difference threshold, it indicates that the water cooling system of the furnace mouth has a fault; similarly, both the trunnion and the hood are provided with water cooling systems, and when operating, it is necessary to check the difference in the inlet and outlet water flow rates; the limit state of the hood is the position or state of the hood during operation, which is detected and monitored by sensors. The setting of the limit state is to ensure that the hood operates within a safe range, avoid collisions with the converter or other equipment, and at the same time ensure that the hood can effectively collect flue gas and dust; the limit state of the oxygen lance reel refers to the position or state of the oxygen lance reel during operation, which is usually detected and monitored by limit switches or sensors. The setting of the limit state is to ensure that the oxygen lance reel operates within a safe range; the hydraulic station is a device that provides power for the lifting, horizontal movement, or other mechanical actions of the oxygen lance system, and realizes the precise movement control of the oxygen lance through the circulation and pressure transmission of hydraulic oil; the oxygen main pipeline is used to transport oxygen to the oxygen lance and provide an oxygen source for the oxygen lance.

[0073] The data transmission module includes a data acquisition gateway and an Internet of Things gateway. In some embodiments, the data acquisition gateway can be a DCS (Distributed Control System), or an NVS (Network Video System), or a PC (Computer). The data acquisition gateway obtains perception data from the video perception module and the data acquisition module. The data acquisition gateway interface uses Ethernet, serial port, CAN port, IO port, or 4G / 5G network access mode; the Internet of Things gateway centrally manages data metrics with different protocols through a unified protocol standard, and has functions of conversion, control management, and data filtering. The Internet of Things gateway obtains various protocol data from the data acquisition gateway to form a data acquisition pool.

[0074] In some embodiments, the risk management system includes an edge server and a central control host. The edge server receives heterogeneous data from the camera and the infrared thermal imaging module through the data transmission module, and performs edge algorithm processing on the video heterogeneous data to measure the personnel standing position, water accumulation area, tank pause, distance, equipment movement, thickness, and identify the personnel identity, and sends the identification result to the central control host;

[0075] In some embodiments, the risk management module further includes a display module for the parameter data of the equipment.

[0076] The central control host receives the identification result of the edge server, and issues a corresponding warning signal to the warning module according to the identification result of the edge server; the central control host also obtains the parameter data of the sensor through the data transmission module, compares and identifies the obtained parameter data with the threshold values set for each parameter data, and issues a corresponding warning signal according to the identification result; the central control host is also connected to the warning module, and the central control host issues a warning signal to the controller, audible and visual alarm, and electronic fence of the warning module.

[0077] The warning module includes an audible and visual alarm, a speaker, and an electronic fence. The audible and visual alarm receives the warning signal issued by the central control host and gives an audible and visual alarm. The speaker and the electronic fence receive the warning signal issued by the central control host and issue corresponding alarm voices;

[0078] In some embodiments, there is also a background data entry module for entering personnel lists, facial information, relevant certificate information, and threshold information; it is also used to enter the annual inspection and annual inspection date of the vehicle, the inspection and annual inspection date of the ladle, the annual inspection and annual inspection date of the slag pot trunnion, the acquisition of gas special operation certificates, the acquisition of certificates for overhead crane operators, the annual inspection and annual inspection date of metallurgical casting cranes, and the inspection dates of plate hooks, lifting hooks, wire ropes, drums, and end fixing parts.

[0079] Embodiment 2:

[0080] A risk control method for dangerous areas of converters based on the Internet of Things, including the following steps:

[0081] Step 1. Conduct safety inspections during the charging stage of converter steelmaking: The edge server obtains heterogeneous data collected by cameras and infrared thermal imaging modules, and performs edge computing. Sequentially identify the scrap height in the scrap steel tank, the positions of personnel in front of the furnace, whether the trunnions on both sides of the molten iron ladle are hooked when the crane hangs the ladle, whether the crane brake is tested before the crane starts, the accumulated water in front of the furnace and the area of the accumulated water. The edge processor sends the identification results to the central control host, and the central control host determines whether to send corresponding warning signals based on the identification results; at the same time, the central control host judges according to the parameter data of the rotation speed of the dust removal fan obtained in real time by the sensor. The specific steps are as follows:

[0082] Step 1.1. Before adding scrap steel to the converter, the edge server identifies the scrap height in the scrap steel tank. If the edge server identifies that the scrap height in the scrap steel tank exceeds the tank height, the central control host sends a warning signal of excessive scrap steel loading amount to the controller, and the controller controls the sound and light alarm to give a sound and light alarm, and controls the speaker to give a voice prompt to the dispatcher that the scrap steel in the scrap steel tank is too high.

[0083] Step 1.2. When scrap steel enters the converter, the edge server identifies whether the position of the personnel in front of the furnace is outside the electronic fence marked by the set 120-degree fan-shaped area. If the identification result is that the position of the personnel in front of the furnace is not outside the electronic fence marked by the 120-degree fan-shaped area, the central control host sends a warning signal of the forward position of the personnel in front of the furnace to the controller, and the controller controls the sound and light alarm to give a sound and light alarm, and controls the electronic fence marked by the 120-degree fan-shaped area to give a voice prompt to the personnel in front of the furnace to move outside the electronic fence marked by the 120-degree fan-shaped area.

[0084] Step 1.3. During the process of adding scrap steel to the converter, the central control host obtains the rotation speed parameter data of the dust removal fan collected by the dust removal fan sensor. If the rotation speed of the dust removal fan is lower than the set rotation speed, the central control host sends a warning signal of low rotation speed of the dust removal fan to the controller, and the controller adjusts the fan rotation speed to the set rotation speed (such as 2300 revolutions per minute), so as to increase the dust removal air volume and prevent a large amount of flames from bursting out and scalding people.

[0085] Step 1.4. When the crane hangs the ladle, the edge server identifies whether there are personnel in the designated areas on both sides of the molten iron ladle and whether they stay in the designated areas. If the identification result is that there are no personnel in the designated areas on both sides of the molten iron ladle, the central control host sends a warning signal for hook inspection to the controller, and the controller controls the sound and light alarm to give a sound and light alarm, and controls the speaker to give a voice prompt for personnel to check and confirm whether the trunnions on both sides of the molten iron ladle are hooked and unhooked.

[0086] Step 1.5: Before the overhead crane starts, the edge server identifies whether the molten iron ladle is in a stationary state. If it is identified that the molten iron ladle is not stationary, the central control host sends a warning message to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt to the crane driver to pause the ladle body to test whether the overhead crane brake is in good condition.

[0087] Step 1.6: Before pouring molten iron into the converter, in order to ensure that there is no accumulated water in front of the furnace and prevent the molten iron from splashing and encountering accumulated water on the ground, resulting in an explosion of molten metal encountering accumulated water, it is necessary to control the area of accumulated water on the ground not to be too large. Therefore, it is necessary to detect the accumulated water and the area of accumulated water in front of the furnace: The edge processor identifies the area of accumulated water in front of the converter. If the identification result shows that the area of accumulated water in front of the converter is greater than the set area (such as 1m 2 ), the central control host sends a warning signal of excessive accumulated water area in front of the furnace to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the voice prompt to indicate that the accumulated water area in front of the furnace is too large.

[0088] Step 1.7: Before pouring molten iron into the converter, the edge server identifies whether the standing position of the personnel in front of the furnace is outside the electronic fence marked by the set 120-degree fan-shaped area. If the identification result shows that the standing position of the personnel in front of the furnace is not outside the electronic fence marked by the 120-degree fan-shaped area, the central control host sends a warning signal of the forward standing position of the personnel in front of the furnace to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the electronic fence to give a voice prompt to the personnel in front of the furnace to move outside the electronic fence marked by the 120-degree fan-shaped area.

[0089] Step 1.8: After the edge server identifies that there is no accumulated water in front of the furnace and the standing position of the personnel in front of the furnace is outside the electronic fence marked by the fan-shaped area, start pouring molten iron into the converter. The central control host obtains the parameters of the tilting angle of the converter and the gap between the molten iron ladle and the converter collected by the sensor. If it does not meet the set tilting angle of the converter or the set gap between the molten iron ladle and the converter, the central control host sends a hook release warning signal to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt that the tilting angle of the converter exceeds the limit, which may cause the risk of hook release due to the molten iron ladle being placed on the converter mouth.

[0090] Step 1.9: During the process of pouring molten iron into the converter, if the central control host obtains the rotation speed of the dust removal fan collected by the sensor, and if the rotation speed of the dust removal fan is lower than the set rotation speed, the central control host sends a warning signal of low rotation speed of the dust removal fan to the controller. The controller adjusts the rotation speed of the fan to the set rotation speed;

[0091] In some embodiments, 3 AI intelligent cameras are set on the working platform in front of the furnace, namely 41-a, 41-b, and 41-c.

[0092] Table 1 is the camera position, heterogeneous data and index table of the working platform in front of the furnace

[0093]

[0094]

[0095] In some embodiments, 2 AI intelligent cameras are set on the post-furnace working platform, namely 42-a and 42-b.

[0096] Table 2 is the camera position, heterogeneous data and index table of the post-furnace working platform

[0097]

[0098] Step 2: After adding scrap steel and charging molten iron into the converter, enter the blowing stage and conduct safety inspections during the blowing stage, which specifically includes the following steps:

[0099] Step 2.1: After the molten iron is charged and before blowing, the explosion-proof door needs to be closed. The edge server identifies whether the explosion-proof door is closed. If the identification result is that the explosion-proof door is not closed, the central control host sends a warning signal of the unclosed explosion-proof door to the controller. The controller controls the sound and light alarm to give a sound and light alarm, and controls the speaker to give a voice prompt to the post employees to close the explosion-proof door;

[0100] Step 2.2: During the blowing period, the edge server identifies whether the standing position of the front-furnace personnel is outside the electronic fence marked by the set 120-degree fan-shaped area. If the identification result is that the standing position of the front-furnace personnel is not outside the electronic fence marked by the 120-degree fan-shaped area, the central control host sends a warning signal of the forward standing position of the front-furnace personnel to the controller. The controller controls the sound and light alarm to give a sound and light alarm, and controls the speaker to give a voice prompt to the front-furnace personnel to move outside the electronic fence marked by the 120-degree fan-shaped area.

[0101] Step 2.3: During the blowing period, the edge server identifies the temperature of the converter shell. If the identification result is that the difference between the temperature of the converter shell and the adjacent temperature exceeds the set value, the central control host sends a warning signal of the damaged shell to the controller. The controller controls to stop oxygen blowing and raise the lance, controls the sound and light alarm to give a sound and light alarm, and controls the speaker to give a voice prompt of the damaged shell.

[0102] Step 2.4: During the blowing period, the central control host obtains the limit states of the water-cooling system of the furnace mouth, the water-cooling system of the trunnion ring, the water-cooling system of the oxygen lance, the hood, the limit state of the oxygen lance drum, the parameters of the hydraulic station, the oxygen main pipeline, and the steam drum, and judges whether to stop oxygen blowing and raise the lance. Specifically:

[0103] This embodiment takes a 130t converter as an example;

[0104] Step 2.4.1: The central control host obtains the difference between the inlet and outlet water flow rates and the outlet water temperature of the oxygen lance water-cooling system. If it is identified that the difference between the inlet and outlet water flow rates of the oxygen lance water-cooling system is greater than 20m3 When the water outlet temperature of the oxygen lance water cooling system is higher than 50 °C or the water inlet and outlet flow difference of the oxygen lance water cooling system is abnormal, the central control host sends an abnormal warning signal for the water inlet and outlet flow difference or an abnormal warning signal for the water outlet temperature of the oxygen lance water cooling system to the controller. The controller stops the oxygen lance from blowing oxygen, controls the hydraulic station to lift the oxygen lance out of the converter, controls the sound and light alarm to give a sound and light alarm, and controls the speaker to give a voice prompt for the abnormal water inlet and outlet flow difference of the oxygen lance water cooling system and the abnormal water outlet temperature of the oxygen lance water cooling system;

[0105] Step 2.4.2: The central control host respectively obtains the water inlet and outlet flow difference and the water outlet temperature of the hood water cooling system and the trunnion water cooling system. If it is identified that the water inlet and outlet flow difference of the hood water cooling system is greater than or equal to 15 m 3 / h or the water inlet and outlet flow difference of the trunnion water cooling system is greater than or equal to 15 m 3 / h, the central control host sends an abnormal warning signal for the water inlet and outlet flow difference of the hood water cooling system or an abnormal warning signal for the water inlet and outlet flow difference of the trunnion water cooling system to the controller. The controller stops the oxygen lance from blowing oxygen, controls the hydraulic station to lift the oxygen lance out of the converter, controls the sound and light alarm to give a sound and light alarm, and controls the speaker to give a voice prompt for the abnormal water inlet and outlet flow difference of the hood water cooling system and the abnormal water inlet and outlet flow difference of the trunnion water cooling system;

[0106] Step 2.4.3: The central control host respectively obtains the limit states of the hood and the oxygen lance reel. When the central control host receives the upper limit signal or the lower limit signal of the hood, or the upper limit signal or the lower limit signal of the oxygen lance reel, the central control host sends an abnormal warning signal for the hood limit state or an abnormal warning signal for the oxygen lance reel limit state to the controller. The controller stops the oxygen lance from blowing oxygen, controls the hydraulic station to lift the oxygen lance out of the converter, controls the sound and light alarm to give a sound and light alarm, and controls the speaker to give a voice prompt for the abnormal hood limit state or the abnormal oxygen lance reel limit state;

[0107] Step 2.4.4: The central control host respectively obtains the oil supply pressure of the hydraulic station and the oxygen pressure of the oxygen main pipeline. When the oil supply pressure of the hydraulic station is less than 0.15 Mpa, the central control host sends an abnormal warning signal for the oil supply pressure of the hydraulic station to the controller. The controller stops the oxygen lance from blowing oxygen, controls the sound and light alarm to give a sound and light alarm, and controls the speaker to give a voice prompt for the abnormal oil supply pressure of the hydraulic station; when the oxygen pressure after the oxygen main pipeline cut-off valve is less than 0.6 Mpa, the central control host sends an abnormal warning signal for the oxygen pressure to the controller. The controller stops the oxygen lance from blowing oxygen, controls the hydraulic station to lift the oxygen lance out of the converter, controls the sound and light alarm to give a sound and light alarm, and controls the speaker to give a voice prompt for the abnormal oxygen pressure;

[0108] Step 2.4.5: The central control host respectively obtains the pressure and water level of the steam drum. When the pressure of the steam drum is lower than 0.5 Mpa or the water level of the steam drum is lower than 1 m, the central control host sends an early warning signal of abnormal steam drum pressure or an early warning signal of abnormal steam drum water level to the controller. The controller controls the oxygen lance to stop blowing oxygen, and controls the hydraulic station to lift the oxygen lance out of the converter. The controller controls the sound and light alarm to give out sound and light alarm, and controls the speaker to give voice prompt of abnormal steam drum pressure or abnormal steam drum water level.

[0109] Step 2.5: Before smelting and during the smelting interval, the operation of opening the furnace mouth is required. When opening the furnace mouth, it is necessary to detect whether the standing position of the monitoring personnel is outside the set safety distance marking line. Specifically: The edge server identifies whether the monitoring personnel are outside the set safety distance marking line (such as 5 meters outside the marking line) of the furnace mouth. If the identification result is that the monitoring personnel are not outside the set safety distance marking line (5 meters), the central control host sends an early warning signal to the early warning module. The early warning module gives out sound and light alarm, and gives voice prompt for the personnel to move outside the safety distance marking line of the furnace mouth.

[0110] Step 2.6: When personnel go to work in the area under the converter during the converter smelting period, the converter is not allowed to tilt. The edge server identifies the magnitude of the output current of the tilting motor. If the identification result is that the output current of the tilting motor is not 0, indicating that the converter is tilting, the central control host sends an early warning signal of someone working in the area under the converter but the converter is tilting to the early warning module. The early warning module gives out sound and light alarm, and gives voice prompt that there are people working in the area under the converter, and the post employees are not allowed to tilt the converter.

[0111] Step 3: After smelting is completed and entering the stage of converter steel tapping, safety detection during converter steel tapping is required: Identify the thickness of the furnace lining, identify the identity of the personnel behind the furnace, identify the identity of the personnel on the fan-shaped surface of the platform behind the furnace, identify the standing position of the personnel behind the furnace, and identify the height of the molten steel in the ladle in sequence. Specifically:

[0112] Step 3.1: In order to avoid the risk of the furnace lining collapsing during the process of tilting the furnace body, it is necessary to detect and ensure whether the converter lining is damaged. The specific operation is: The edge server identifies the thickness of the converter furnace lining. If the identification result is that the furnace lining thickness is greater than 10% of the initial thickness, it indicates that the furnace lining is normal; if the identification result is that the furnace lining thickness is less than 10% of the initial thickness, the central control host sends an early warning signal of furnace lining damage to the early warning module. The early warning module gives out sound and light alarm, and gives voice prompt of furnace lining damage.

[0113] Step 3.2. Before steel tapping in the converter steelmaking stage, the edge server identifies whether all the personnel on the fan-shaped surface of the platform behind the furnace are employees in their positions. If all are identified as employees in their positions, the converter is tilted for steel tapping; if non-position employees are identified, the central control host sends a warning signal to the controller. The controller controls the interlock of the converter tilting, controls the sound and light alarm to give out sound and light alarms, and controls the voice prompt of the electronic fence to prompt the non-position employees to leave the fan-shaped surface of the platform behind the furnace as soon as possible; until all the personnel on the fan-shaped surface of the platform behind the furnace are identified as employees in their positions, the controller controls the release of the interlock and tilts the converter for steel tapping;

[0114] Step 3.3. During the steel tapping operation, in order not to overfill the ladle, it is also necessary to keep the distance between the molten steel level in the ladle and the ladle mouth greater than the set distance. The edge processor identifies the distance between the molten steel level in the ladle and the ladle mouth. If the identification result shows that the distance between the height of the molten steel level in the ladle and the ladle mouth is less than the set distance (such as 300 mm), the central control host sends an overfilling warning signal of the molten steel to the warning module. The warning module gives out sound and light warnings and voice prompts that the molten steel is overfilled, and the employees in their positions stop tilting the converter.

[0115] Step 3.4. During the steel tapping operation, when the converter is tilted, the central control host obtains the limit states of the water-cooling systems of the furnace mouth, the trunnion, the oxygen lance, and the hood, the limit state of the oxygen lance reel, and the parameter data of the hydraulic station, the oxygen main pipeline, and the steam drum, and judges whether to stop tilting and interlock. Specifically:

[0116] Step 3.4.1. The central control host obtains the difference in the inlet and outlet water flow rates and the outlet water temperature of the oxygen lance water-cooling system. If it is identified that the difference in the inlet and outlet water flow rates of the oxygen lance water-cooling system is greater than 20 m 3 / h or the outlet water temperature of the oxygen lance water-cooling system is higher than 50 °C, the central control host sends an abnormal warning signal of the difference in the inlet and outlet water flow rates or an abnormal warning signal of the outlet water temperature of the oxygen lance water-cooling system to the controller. The controller stops the oxygen blowing of the oxygen lance and controls the hydraulic station to lift the oxygen lance out of the converter. The controller controls the sound and light alarm to give out sound and light alarms and controls the speaker to voice prompt that the difference in the inlet and outlet water flow rates of the oxygen lance water-cooling system is abnormal and the outlet water temperature of the oxygen lance water-cooling system is abnormal;

[0117] Step 3.4.2. The central control host respectively obtains the difference in the inlet and outlet water flow rates and the outlet water temperature of the water-cooling systems of the furnace mouth and the trunnion. If it is identified that the difference in the inlet and outlet water flow rates of the water-cooling system of the furnace mouth is greater than 15 m 3 / h or the difference in the inlet and outlet water flow rates of the trunnion water-cooling system is greater than 15 m 3When the flow rate difference between the inlet and outlet water of the ladle water cooling system or the flow rate difference between the inlet and outlet water of the trunnion water cooling system is abnormal per hour, the central control host sends an early warning signal of abnormal flow rate difference between the inlet and outlet water of the ladle water cooling system or an early warning signal of abnormal flow rate difference between the inlet and outlet water of the trunnion water cooling system to the controller. The controller controls the oxygen lance to stop blowing oxygen, controls the hydraulic station to lift the oxygen lance out of the converter, controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt that the flow rate difference between the inlet and outlet water of the ladle water cooling system is abnormal and the flow rate difference between the inlet and outlet water of the trunnion water cooling system is abnormal;

[0118] Step 3.4.3: The central control host respectively obtains the limit states of the hood and the oxygen lance reel. When the central control host receives the upper limit signal or the lower limit signal of the hood, or the upper limit signal or the lower limit signal of the oxygen lance reel, the central control host sends an early warning signal of abnormal hood limit state or an early warning signal of abnormal oxygen lance reel limit state to the controller. The controller controls the oxygen lance to stop blowing oxygen, controls the hydraulic station to lift the oxygen lance out of the converter, controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt that the hood limit state is abnormal or the oxygen lance reel limit state is abnormal;

[0119] Step 3.4.4: The central control host respectively obtains the oil supply pressure of the hydraulic station and the oxygen pressure of the oxygen main pipeline. When the oil supply pressure of the hydraulic station is less than 0.15 Mpa, the central control host sends an early warning signal of abnormal oil supply pressure of the hydraulic station to the controller. The controller controls the oxygen lance to stop blowing oxygen, controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt that the oil supply pressure of the hydraulic station is abnormal; When the oxygen pressure after the oxygen main pipeline cut-off valve is less than 0.6 Mpa, the central control host sends an early warning signal of abnormal oxygen pressure to the controller. The controller controls the oxygen lance to stop blowing oxygen, controls the hydraulic station to lift the oxygen lance out of the converter, controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt that the oxygen pressure is abnormal;

[0120] Step 3.4.5: The central control host respectively obtains the pressure and water level of the steam drum. When the pressure of the steam drum is lower than 0.5 Mpa or the water level of the steam drum is lower than 1 m, the central control host sends an early warning signal of abnormal steam drum pressure or an early warning signal of abnormal steam drum water level to the controller. The controller controls the oxygen lance to stop blowing oxygen, controls the hydraulic station to lift the oxygen lance out of the converter, controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt that the steam drum pressure is abnormal or the steam drum water level is abnormal;

[0121] Step 4: After the converter has finished steelmaking, slag cleaning operations are carried out, and safety inspections for slag cleaning operations are required. The specific steps are as follows:

[0122] Step 4.1: The edge server identifies whether the inside of the slag pot of the slag pot truck is dry. If it is identified that there is water accumulation inside the slag pot, the central control host sends an early warning signal of water accumulation inside the slag pot to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt for the slag cleaning staff to clean the slag pot;

[0123] Step 4.2: Before the slag ladle truck moves forward, it is necessary to detect whether there is any accumulated slag on the ladle track. The edge server identifies whether there is accumulated slag on the ladle track. If it is identified that there is accumulated slag on the ladle track, the central control host sends a warning signal of accumulated slag on the ladle track to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt to the slag cleaning staff to clean the accumulated slag on the ladle track;

[0124] Step 4.3: When performing the operation of cleaning the accumulated slag on the ladle track, the edge server identifies the standing position of the slag cleaning staff. If it is identified that the standing position of the slag cleaning staff is within the set safety position marking line, the central control host sends a warning signal to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt to the slag cleaning staff to move outside the set safety position marking line;

[0125] Step 4.4: The water accumulation area in the slag channel pit should not be too large. It is necessary to detect the water accumulation area in the slag channel pit. Specifically: The edge server identifies the water accumulation area in the slag channel pit. If the identification result is that the water accumulation area in the slag channel pit is larger than the set water accumulation area (such as 1m 2 ), the central control host sends a warning signal of excessive water accumulation area in the slag channel pit to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt that the water accumulation area in the slag channel pit is too large, reminding the post staff to clean it in time.

[0126] After the ladle track is cleaned, the slag ladle truck collects the slag from the converter and transports it through the ladle track to the slag treatment area for dumping.

[0127] In some embodiments, the perception of the slag channel platform under the furnace mainly depends on setting 1 AI intelligent camera on the converter slag channel wall, denoted as 43-a.

[0128] Table 3 is the camera position, heterogeneous data and index table of the slag channel platform under the furnace

[0129]

[0130] Step 5: For the high-rise belt on the 4th - 8th floors of the converter, it is necessary to perform regular cleaning operations, fixed-point inspection operations, and maintenance operations. Regular cleaning operations, fixed-point inspection operations, and maintenance operations all require more than two people to work together so as to carry out joint guarantee and mutual protection. It is also necessary to carry a gas alarm. Therefore, it is necessary to conduct safety inspections for regular cleaning, fixed-point inspection, and maintenance: successively conduct personnel quantity detection, detection of whether a gas alarm is worn, the standing position of the operating personnel, and safety detection of whether the protective cover is in good condition. Specifically:

[0131] Step 5.1: The edge server identifies the number of operators working on the 4th - 8th floors of the converter. If the identification result is single - person operation, the central control host sends a warning signal of lack of joint guarantee and mutual protection to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt to the employees to carry out joint guarantee and mutual protection.

[0132] Step 5.2: The edge server identifies whether the employees working on the 4th - 8th floors of the converter are wearing gas alarms. If the identification result is that they are not wearing gas alarms, the central control host sends a warning signal of employees not wearing gas alarms to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt to the employees to wear gas alarms.

[0133] Step 5.3: The edge server identifies whether the protective cover is in good condition. If the identification result is that the protective cover is not in good condition, the central control host sends a warning signal of the protective cover not being in good condition to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt to the employees in the mechanical maintenance position to repair the protective cover in time.

[0134] Step 5.4: The edge server identifies the standing positions of the operators working on the 4th - 8th floors of the converter. If the identification result is that the standing positions of the personnel are not outside the marked area, the central control host sends a warning signal of the personnel standing in a dangerous area to the controller. The controller controls the audible and visual alarm to give an audible and visual alarm, and controls the speaker to give a voice prompt to the employees to move outside the marked area.

[0135] Table 4 is the table of camera positions, heterogeneous data and indicators above the fourth - floor platform of the converter

[0136]

[0137] Two carbon monoxide alarms are set on each floor at the stairs of the 4th - 8th floors, with a total of 10 for alarm.

[0138] According to the embodiments of the present invention, the data acquisition module, the tilting system mainly collects the following parameters. The tilting system of the converter is interlocked with the following settings. When the following abnormal situations occur in the data, the tilting should be stopped in time and interlocked.

[0139] Table 5 is the table of parameter data and indicators of the tilting system

[0140]

[0141] According to the embodiments of the present invention, the data acquisition module, the oxygen lance system mainly uses various sensors to obtain the temperature, pressure and cooling water of the water - cooling system. For the Internet of Things data of the water - cooling parameters of the oxygen lance system, during the oxygen blowing of the converter, when abnormal situations occur in the collected parameters, logical judgment is carried out, and the lance should be lifted and the blowing should be stopped in time. Taking the 130t furnace building as an example, the judgment indicators in the judgment module are as shown in the table.

[0142] Table 7 is the parameter data and index table of the oxygen lance system

[0143]

[0144] According to the embodiments of the present invention, the dynamic factors of basic management of work safety, potential accident hazards, daily data, data acquisition modules, and main heterogeneous data and indexes of emergency equipment in the Internet of Things are shown in the table below.

[0145] The safety inspection of emergency equipment includes the equipment status signals of the independent high-voltage power supply in the substation, the equipment status signals of the standby water pumps in the pump house, the equipment status signals of the oxygen lance drive device and the oxygen lance emergency power supply, the replacement dates of various wire ropes of the overhead crane, and the annual inspection dates of the metallurgical casting crane.

[0146] Table 8 is the data and index table entered in the background

[0147]

[0148] In one embodiment, a computer device is further provided, including a memory and a processor. A computer program is stored in the memory, and when the processor executes the computer program, the steps in the above method embodiments are implemented.

[0149] In one embodiment, a computer-readable storage medium is provided, on which a computer program is stored. When the computer program is executed by a processor, the steps in the above method embodiments are implemented.

[0150] In one embodiment, a computer program product is provided, including a computer program. When the computer program is executed by a processor, the steps in the above method embodiments are implemented.

[0151] It should be noted that the embodiments described in the present invention are only examples of the spirit of the present invention. Those skilled in the art of the present invention can make various modifications or supplements to the described embodiments or use similar methods to replace them, but will not deviate from the spirit of the present invention or exceed the scope defined by the appended claims.

Claims

1. A converter dangerous area risk management method based on the Internet of Things, characterized in that: The following steps are involved: Step 1: Conduct safety testing during the charging phase of converter steelmaking. Step 2: Conduct safety testing of the blowing stage of converter steelmaking; Step 3: Conduct safety testing of the tapping stage of converter steelmaking; Step 4: Conduct safety testing of the slag removal stage of converter steelmaking; Step 5: Conduct safety inspections on converter floors 4-8.

2. The method for risk control of converter hazardous areas based on the Internet of Things according to claim 1, characterized in that: The step 1 comprises the following steps: Step 1.1: Before adding scrap steel to the converter, if the edge server detects that the scrap steel in the scrap steel trough exceeds the trough height, the central control host sends a scrap steel loading excessive high warning signal to the controller. The controller controls the sound and light alarm to sound a sound and light alarm, and controls the speaker to voice-prompt the dispatcher that the scrap steel in the scrap steel trough is excessively high. Step 1.2: When feeding scrap steel into the converter, if the edge server identifies that the person in front of the furnace is not outside the electronic fence marked by the sector area, the central control host sends a warning signal to the controller that the person in front of the furnace is standing too far forward. The controller controls the sound and light alarm to sound an audible alarm and controls the electronic fence marked by the sector area to voice prompt the person in front of the furnace to move outside the sector area. Step 1.3: During the process of adding scrap steel to the converter, if the central control host obtains the dust removal fan speed collected by the sensor and the dust removal fan speed is lower than the set speed, the central control host sends a dust removal fan low speed warning signal to the controller, and the controller adjusts the fan speed to the set speed; Step 1.4: When the crane is hooking the ladle, if the edge server detects that there are no personnel on duty within the designated areas on both sides of the ladle or that the personnel on duty are not staying within the designated areas, the central control host sends a warning signal for hook unhooking to the controller. The controller controls the audible and visual alarm to sound an audible and visual alarm, and controls the loudspeaker to voice prompt the personnel on duty to check and confirm whether the trunnions on both sides of the ladle are hooked. Step 1.5: Before the crane starts, if the edge server identifies that the molten iron ladle is not stopped, the central control host sends a warning message to the controller. The controller controls the sound and light alarm to sound an audible and visual alarm, and controls the loudspeaker to voice prompt the crane driver to stop the ladle to test whether the crane brake is in good condition. Step 1.6: Before adding molten iron to the converter, if the edge processor identifies that the water accumulation area in front of the converter is larger than the set area, the central control host sends a warning signal of excessive water accumulation in front of the converter to the controller. The controller controls the sound and light alarm to sound a sound and light alarm, and controls the speaker to indicate that the water accumulation area in front of the converter is too large. Step 1.7: Before adding molten iron to the converter, the edge server detects that the person in front of the furnace is not outside the electronic fence of the sector area. The central control host sends a warning signal to the controller that the person in front of the furnace is too far forward. The controller controls the sound and light alarm to sound an audible alarm and controls the electronic fence to voice prompt the person in front of the furnace to move outside the sector area. In step 1.8, after the edge server detects that there is no water in front of the furnace and that all personnel are outside the electronic fence marked in the fan-shaped area, it begins adding molten iron to the converter. The central control host obtains the parameter data of the converter tilt angle and the gap between the molten iron ladle and the converter collected by the sensor. If the converter tilt angle or the gap between the molten iron ladle and the converter do not meet the set values, the central control host sends a decoupling warning signal to the controller. The controller controls the audible and visual alarm to sound an audible and visual alarm, and controls the speaker to voice prompt that the converter tilt angle exceeds the limit, which may cause the molten iron ladle to be placed on the converter mouth, posing a risk of decoupling. Step 1.9: During the process of adding molten iron to the converter, if the central control host obtains the dust removal fan speed collected by the sensor and the dust removal fan speed is lower than the set speed, the central control host sends a dust removal fan low speed warning signal to the controller, and the controller adjusts the fan speed to the set speed.

3. The method for risk control of converter dangerous areas based on the Internet of Things according to claim 1, characterized in that: The step 2 specifically includes the following steps: Step 2.1: After adding molten iron and before blowing, the edge server identifies whether the explosion-proof door is closed. If so, the central control host sends a warning signal to the controller. The controller then controls the audible and visual alarm to sound an audible and visual alarm, and controls the speaker to voice prompt the staff on duty to close the explosion-proof door. Step 2.2: During the blowing process, the edge server identifies whether the furnace personnel are outside the designated sector area. If the identification result indicates that the furnace personnel are not outside the electronic fence of the sector area, the central control host sends a warning signal indicating that the furnace personnel are too far forward to the controller. The controller controls the sound and light alarm to sound a sound and light alarm, and controls the speaker to voice prompt the furnace personnel to move outside the electronic fence of the sector area. Step 2.3: During the blowing process, the edge server identifies the temperature of the converter shell. If the difference between the converter shell temperature and the adjacent temperature is greater than the set value, the central control host sends a shell damage warning signal to the controller. The controller stops blowing oxygen and raises the oxygen gun. The controller also controls the sound and light alarm to sound a sound and light alarm, and controls the speaker to issue a voice prompt indicating the shell is damaged. Step 2.4: During the blowing period, the central control host obtains parameter data of the furnace mouth water cooling system, the support ring water cooling system, the oxygen lance water cooling system, the smoke hood limit status, the oxygen lance drum limit status, the hydraulic station, the oxygen main network, and the steam drum, and determines whether to stop blowing oxygen and raise the lance; Step 2.5: During the furnace opening operation during the smelting interval, if the edge server identifies that the supervisor is not outside the set safety distance line of the furnace opening, the central control host sends a warning signal to the controller. The controller controls the sound and light alarm to sound an audible and visual alarm, and controls the speaker to voice prompt the supervisor to move outside the safety distance line of the furnace opening; Step 2.6: During converter smelting, when personnel go to the area under the furnace to work, the converter is not allowed to tilt. If the central control host recognizes that the output current of the tilting motor is zero, the central control host sends a warning signal to the controller that there are people working in the area under the furnace but the converter is tilting, and the controller controls to stop tilting the converter.

4. The method for risk control of converter hazardous areas based on the Internet of Things according to claim 1, characterized in that: The step 3 specifically includes the following steps: Step 3.1: Before tapping the converter, the edge server identifies the converter lining thickness. If the lining thickness is less than a set percentage of the initial thickness, the central control host sends a lining damage warning signal to the controller. The controller controls the converter tilt interlock, the controller controls the sound and light alarm to sound a sound and light alarm, and controls the speaker to voice prompt that the lining is damaged. Step 3.2: Before tapping steel from the converter, the edge server identifies whether all personnel on the square sector of the platform behind the furnace are on-duty employees. If so, the furnace is shaken to tap steel. If non-staff are identified, the central control host sends an early warning signal to the controller, which controls the converter tilt interlock, controls the sound and light alarm to sound a sound and light alarm, and controls the electronic fence to voice prompt non-staff to leave the square sector of the platform behind the furnace as soon as possible. The controller controls the release of the interlock and the shaking of the furnace to tap steel until all personnel on the square sector of the platform behind the furnace are identified as on-duty employees. Step 3.3: During the steel tapping operation, if the edge processor identifies that the distance between the molten steel level in the molten steel tank and the tank opening is less than the set distance, the central control host sends a molten steel overfill warning signal to the controller, which controls the furnace to stop shaking, controls the sound and light alarm to sound an audible and visual alarm, and controls the speaker to voice prompt that the molten steel is overfilled; Step 3.4: During the steel tapping operation, when the converter is tilting, the central control host obtains parameter data of the furnace mouth water cooling system, the support ring water cooling system, the oxygen lance water cooling system, the smoke hood limit status, the oxygen lance drum limit status, the hydraulic station, the oxygen main network, and the steam drum to determine whether to stop oxygen blowing and lift the lance.

5. The method for risk control of converter dangerous areas based on the Internet of Things according to claim 3 or claim 4, characterized in that: The specific judgment of whether to stop blowing oxygen and lift the gun is as follows: The central control host obtains the inlet and outlet water flow difference and outlet water temperature of the oxygen lance water cooling system through sensors. If it is identified that the inlet and outlet water flow difference of the oxygen lance water cooling system is greater than the set value or the outlet water temperature of the oxygen lance water cooling system is higher than the set temperature, the central control host sends an abnormal inlet and outlet water flow difference warning signal or an abnormal outlet water temperature warning signal to the controller. The controller stops blowing oxygen at the oxygen lance and controls the hydraulic station to lift the oxygen lance out of the converter. The controller controls the sound and light alarm to sound an sound and light alarm, and controls the speaker to voice prompt that the inlet and outlet water flow difference of the oxygen lance water cooling system is abnormal or the outlet water temperature of the oxygen lance water cooling system is abnormal. The central control host obtains the difference in inlet and outlet water flow and the outlet water temperature of the furnace mouth water cooling system and the support ring water cooling system through sensors. If it is identified that the difference in inlet and outlet water flow of the furnace mouth water cooling system is greater than or equal to the set value or the difference in inlet and outlet water flow of the support ring water cooling system is greater than or equal to the set temperature, the central control host sends an abnormal warning signal of the difference in inlet and outlet water flow of the furnace mouth water cooling system or an abnormal warning signal of the difference in inlet and outlet water flow of the support ring water cooling system to the controller. The controller controls the oxygen lance to stop blowing oxygen and controls the hydraulic station to lift the oxygen lance out of the converter. The controller controls the sound and light alarm to sound an sound and light alarm and controls the speaker to give a voice prompt that the difference in inlet and outlet water flow of the furnace mouth water cooling system and the difference in inlet and outlet water flow of the support ring water cooling system are abnormal. The central control host obtains the limit status of the smoke hood and the oxygen lance drum respectively. When the central control host receives the upper limit signal or lower limit signal of the smoke hood, or the upper limit signal or lower limit signal of the oxygen lance drum, the central control host sends a smoke hood limit status abnormality warning signal or an oxygen lance drum limit status abnormality warning signal to the controller. The controller controls the oxygen lance to stop blowing oxygen and controls the hydraulic station to lift the oxygen lance out of the converter. The controller controls the sound and light alarm to emit a sound and light alarm and controls the speaker to give a voice prompt of the smoke hood limit status abnormality or the oxygen lance drum limit status abnormality. The central control host obtains the oil supply pressure of the hydraulic station and the oxygen pressure of the oxygen main network respectively. When the oil supply pressure of the hydraulic station is lower than the set pressure, the central control host sends an abnormal oil supply pressure warning signal of the hydraulic station to the controller. The controller controls the oxygen lance to stop blowing oxygen, the controller controls the sound and light alarm to sound an audible and visual alarm, and controls the loudspeaker to voice prompt that the oil supply pressure of the hydraulic station is abnormal. When the oxygen pressure after the shut-off valve of the oxygen main network is lower than the set pressure, the central control host sends an abnormal oxygen pressure warning signal to the controller. The controller controls the oxygen lance to stop blowing oxygen, and controls the hydraulic station to lift the oxygen lance out of the converter. The controller controls the sound and light alarm to sound an audible and visual alarm, and controls the loudspeaker to voice prompt that the oxygen pressure is abnormal. The central control host obtains the pressure and water level of the steam drum respectively. When the pressure of the steam drum is lower than the set pressure or the water level of the steam drum is lower than the set water level, the central control host sends a warning signal of abnormal steam drum pressure or abnormal steam drum water level to the controller. The controller controls the oxygen lance to stop blowing oxygen and controls the hydraulic station to lift the oxygen lance out of the converter. The controller controls the sound and light alarm to emit a sound and light alarm and controls the speaker to voice prompt that the steam drum pressure or steam drum water level is abnormal.

6. The method for risk control of converter dangerous areas based on the Internet of Things according to claim 1, characterized in that: The step 4 specifically includes the following steps: Step 4.1: The edge server identifies whether the inside of the slag tank of the slag tank truck is dry. If water is detected inside the slag tank, the central control host sends a water accumulation warning signal to the controller. The controller controls the sound and light alarm to sound an audible and visual alarm, and controls the speaker to voice prompt the slag cleaning staff to clean the slag tank. Step 4.2: Before the slag tank car moves, if the edge server detects slag accumulation on the ladle track, the central control host sends a slag accumulation warning signal to the controller. The controller controls the sound and light alarm to sound an audible and visual alarm, and controls the speaker to voice prompt the slag cleaning staff to clean the slag on the ladle track. Step 4.3: When cleaning the ladle track, the edge server identifies the position of the slag cleaning worker. If the position of the slag cleaning worker is identified as being within the set safety position line, the central control host sends a warning signal to the controller. The controller controls the sound and light alarm to sound an audible and visual alarm, and controls the speaker to voice prompt the slag cleaning worker to move outside the set safety position line. Step 4.4: The edge server identifies the water accumulation area in the slag pit. If the identification result shows that the water accumulation area in the slag pit is larger than the set water accumulation area, the central control host sends a warning signal indicating that the water accumulation area in the slag pit is too large to the controller. The controller controls the sound and light alarm to emit a sound and light alarm, and controls the speaker to give a voice prompt indicating that the water accumulation area in the slag pit is too large.

7. The method for risk management and control of converter dangerous areas based on the Internet of Things according to claim 1, characterized in that: The step 5 specifically includes the following steps: Step 5.1: The edge server identifies the number of workers on converter floors 4-8. If the identification result indicates a single worker, the central control host sends a warning signal to the controller indicating that the workers are not working together to provide mutual protection. The controller then controls the audible and visual alarm to sound an audible and visual alarm, and controls the loudspeaker to voice prompt the workers to provide mutual protection. Step 5.2: The edge server identifies whether the employee working on the 4th to 8th floors of the converter is wearing a gas alarm. If the identification result is that the employee is not wearing a gas alarm, the central control host sends a warning signal to the controller indicating that the employee is not wearing a gas alarm. The controller controls the sound and light alarm to sound a sound and light alarm, and controls the speaker to voice prompt the employee to wear a gas alarm. Step 5.3: The edge server identifies whether the protective cover is intact. If the identification result is that the protective cover is not intact, the central control host sends a warning signal of the protective cover being not intact to the controller. The controller controls the sound and light alarm to sound an audible and visual alarm, and controls the speaker to voice prompt the mechanical maintenance staff to repair the protective cover in time. In step 5.4, the edge server identifies the positions of personnel working on the 4th to 8th floors of the converter. If the identification result shows that the personnel are not located outside the marked area, the central control host sends a warning signal to the controller indicating that the personnel are in a dangerous area. The controller controls the sound and light alarm to sound a sound and light alarm, and controls the speaker to voice prompt the employee to move outside the marked area.

8. A converter dangerous area risk management and control system based on the Internet of Things, including a video perception module and a data acquisition module, characterized in that: It also includes a risk management module, an early warning module, and a data transmission module. The video perception module includes a camera and an infrared thermal imaging module. The data acquisition module includes a sensor. The risk management module includes a central control host, an edge server, and a controller. The early warning module includes a mobile phone, a photoelectric alarm, an electronic fence, and a speaker. The central control host is connected to the camera, infrared thermal imaging module, sensor, edge server, and controller through the data transmission module. The camera and infrared thermal imaging module are also connected to the edge server. The controller is connected to the mobile phone, photoelectric alarm, electronic fence, speaker, and disposal equipment. The data transmission module includes a data acquisition gateway and an Internet of Things gateway.

9. The converter dangerous area risk management and control system based on the Internet of Things according to claim 8 is characterized in that: The edge server receives heterogeneous data from the camera and infrared thermal imaging module through the data transmission module, and performs edge algorithm processing on the video heterogeneous data to perform personnel position, water accumulation area measurement, tank pause, distance measurement, equipment movement, thickness measurement, and personnel identity recognition, and sends the recognition results to the central control host; The central control host receives the recognition results from the edge server and sends a corresponding warning signal to the controller based on the recognition results of the edge server. The central control host also obtains the parameter data of the sensor through the data transmission module, and compares the obtained parameter data with the set thresholds of each parameter data, and sends a corresponding warning signal to the controller based on the recognition results. The camera and infrared thermal imaging module are used to obtain heterogeneous data, including video data and thermal imaging data; the camera and infrared thermal imaging module each include multiple probes; Sensors are used to collect equipment parameter data in real time, including temperature, pressure, flow, speed, current, and liquid level; The sound and light alarm receives the warning signal from the central control host and issues a sound and light alarm. The speaker and electronic fence receive the warning signal from the central control host and issue a corresponding alarm voice.

10. The converter dangerous area risk management and control system based on the Internet of Things according to claim 9, characterized in that: It also includes a background data entry module and a display module, both of which are connected to the central control host. The background data entry module is used to enter personnel lists, facial information, relevant certificate information, and threshold information of various parameters; it is also used to enter the annual inspection and annual inspection date of the crane, the annual inspection and annual inspection date of the ladle, the annual inspection and annual inspection date of the slag pot ear shaft, the evidence collection of special gas operations, the evidence collection of overhead crane commanders, and the annual inspection and annual inspection date of metallurgical casting cranes; the risk management module also includes a display module for equipment parameter data.

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