A high-temperature molten metal full level monitoring system and method

Abstract

The present invention discloses a system and method for monitoring the full liquid level of a high-temperature molten metal. This system and method belong to the field of liquid level monitoring technology. Two industrial cameras are used to photograph the liquid surface of the high-temperature molten metal. The photographs taken by the two industrial cameras are processed to calculate the sum of the widths of the annular highlight areas of the high-temperature molten metal in the two photographs. The sum is then compared with target values ​​L1 and L2, respectively. When the sums are both greater than the target values ​​L1 and L2, it is determined that the high-temperature molten metal in the casting container has reached the full liquid level. The present invention utilizes two industrial cameras for full liquid level monitoring, achieving high detection accuracy and being unaffected by high temperatures.

Description

Technical Field

[0001] The present invention relates to the technical field of liquid level monitoring, and in particular to a system and method for monitoring the full liquid level of a high-temperature molten metal. Background Art

[0002] During metallurgical casting, liquid level monitoring is necessary to prevent overflow of high-temperature molten metal. Traditionally, liquid level monitoring is performed manually on-site or remotely. Prolonged visual observation of the high-temperature, brightly lit molten metal can be damaging to the eyes and easily lead to visual fatigue. For relatively low temperatures (700°C-800°C) of high-temperature aluminum melts, non-contact sensors, such as laser rangefinders, are often used for liquid level monitoring. Laser rangefinders determine the distance between the target object and the sensor by sending a laser pulse and measuring the time it takes for the pulse to reflect back. However, for molten metals at higher temperatures (above 1200°C), the resulting spectrum is cluttered, significantly interfering with the laser rangefinder, making accurate liquid level monitoring impossible. Therefore, the development of an accurate system and method for monitoring the liquid level of ultra-high-temperature molten metal is crucial. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a high-accuracy full liquid level monitoring system and method for high-temperature molten metal suitable for ultra-high temperatures.

[0004] In order to solve the above technical problems, the technical solution of the present invention is a method for monitoring the full liquid level of high-temperature molten metal, comprising the following steps:

[0005] S1. Install two industrial cameras vertically on one side of the pouring container. The first industrial camera at the bottom is represented by C1; the second industrial camera at the top is represented by C2.

[0006] S2: During the pouring process, C1 and C2 simultaneously take photos of the pouring container at a certain moment and transmit the photos to the visual controller;

[0007] S3, the visual controller calculates the width of the ring highlight area of ​​the high-temperature metal melt in the two photos taken by C1 and C2 at the same time. and ;

[0008] S4, when n consecutive moments and If all of the following conditions are met, it is determined that the high-temperature metal liquid in the pouring container has reached the full liquid level:

[0009] ,and ; Wherein, L1 and L2 are set values ​​respectively.

[0010] Further, ,and ;

[0011] Where V1 and V2 are the image distances of C1 and C2 respectively;

[0012] U1 and U2 represent the object distances, which are the distances between the target object and the optical centers of the C1 and C2 lenses, respectively;

[0013] b1 and b2 are the angles between the optical axis of the lenses C1 and C2 and the horizontal plane respectively;

[0014] Y is the set value.

[0015] Furthermore, the n is a natural number of a set value.

[0016] Furthermore, n=1 or 2 or 3.

[0017] Furthermore, Y is greater than or equal to the width of the mouth of the pouring container.

[0018] The present invention also provides a high-temperature molten metal full level monitoring system, comprising a display, a first industrial camera C1, a second industrial camera C2, and a visual controller connected to C1 and C2; the first industrial camera C1 and the second industrial camera C2 are installed in a vertical direction on one side of the pouring container, with C1 located below C2 (C1 performs low-angle photography, and C2 performs high-angle photography); the visual controller is used to receive photos taken by C1 and C2, and respectively calculate the width of the annular highlight area of ​​the high-temperature molten metal in the photos. and , when n consecutive moments and satisfy ,and , it is determined that the high-temperature metal liquid in the pouring container has reached the full liquid level; where L1 and L2 are the set values ​​respectively.

[0019] Further,

[0020] ,and ;

[0021] Where, and are the widths of the annular highlight areas of the high-temperature molten metal in the photos taken by C1 and C2, respectively;

[0022] V1 and V2 are the image distances of C1 and C2 respectively;

[0023] U1 and U2 are the distances between the target and the optical centers of C1 and C2 lenses, respectively;

[0024] b1 and b2 are the angles between the optical axis of the lenses C1 and C2 and the horizontal plane respectively;

[0025] Y is the set value.

[0026] Furthermore, n is a natural number of a set value, characterized in that n=1 or 2 or 3.

[0027] Furthermore, Y is greater than or equal to the width of the mouth of the pouring container.

[0028] Beneficial effects of the present invention:

[0029] The present invention uses two industrial cameras to take pictures of the liquid surface of the high-temperature molten metal, and processes the pictures taken by the two industrial cameras to calculate the width of the high-temperature molten metal ring highlight area in the two pictures. and ,Will and Compare with the target value respectively. and When both are greater than the target value, it is determined that the high-temperature metal liquid in the pouring container has reached the full liquid level. The present invention uses two industrial cameras to monitor the full liquid level, with high detection accuracy and is not affected by high temperature. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 These are photos taken by the first industrial camera C1 and the second industrial camera C2 displayed on the display at a certain moment in Example 2. DETAILED DESCRIPTION

[0031] The following is a further description of specific embodiments of the present invention in conjunction with the accompanying drawings. It should be noted that the description of these embodiments is intended to facilitate understanding of the present invention and does not constitute a limitation of the present invention. In addition, the technical features involved in the various embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.

[0032] Example 1

[0033] A method for monitoring the full liquid level of a high-temperature molten metal comprises the following steps:

[0034] S1. Install two industrial cameras vertically on one side of the pouring container. The first industrial camera at the bottom is represented by C1; the second industrial camera at the top is represented by C2.

[0035] S2: During the pouring process, C1 and C2 simultaneously take photos of the pouring container at a certain moment and transmit the photos to the visual controller;

[0036] S3, the visual controller calculates the width of the ring highlight area of ​​the high-temperature metal melt in the two photos taken by C1 and C2 at the same time. and ;

[0037] S4, when n consecutive moments and If all of the following conditions are met, it is determined that the high-temperature metal liquid in the pouring container has reached the full liquid level:

[0038] ,and ; Wherein, L1 and L2 are set values ​​respectively.

[0039] Further, ,and ;

[0040] Where V1 and V2 are the image distances of C1 and C2 respectively;

[0041] U1 and U2 represent the object distances, which are the distances between the target object and the optical centers of the C1 and C2 lenses, respectively;

[0042] b1 and b2 are the angles between the optical axis of the lenses C1 and C2 and the horizontal plane respectively;

[0043] Y is the set value.

[0044] Furthermore, the n is a natural number of a set value.

[0045] Furthermore, n=1 or 2 or 3.

[0046] Furthermore, Y is greater than or equal to the width of the mouth of the pouring container.

[0047] Example 2

[0048] A high-temperature molten metal full level monitoring system includes a display, a first industrial camera C1, and a second industrial camera C2; the first industrial camera C1 and the second industrial camera C2 are installed in the vertical direction of one side of the pouring container; and further includes a visual controller connected to the first industrial camera C1 and the second industrial camera C2; the visual controller is used to receive photos taken by C1 and C2 and calculate the width of the ring-shaped highlight area of ​​the high-temperature molten metal in the photos. and , when n consecutive moments and satisfy ,and , it is determined that the high-temperature metal liquid in the pouring container has reached the full liquid level; where L1 and L2 are set values. The display is used to display the photos taken by C1 and C2.

[0049] Further,

[0050] ,and ;

[0051] Where, and are the widths of the annular highlight areas of the high-temperature molten metal in the photos taken by C1 and C2, respectively;

[0052] V1 and V2 are the image distances of C1 and C2 respectively;

[0053] U1 and U2 are the distances between the target and the optical centers of C1 and C2 lenses, respectively;

[0054] b1 and b2 are the angles between the optical axis of the lenses C1 and C2 and the horizontal plane respectively;

[0055] Y is a set value, which needs to be reasonably set according to the size of the pouring container mouth in actual conditions.

[0056] Furthermore, n is a natural number of a set value, characterized in that n=1 or 2 or 3.

[0057] Furthermore, the Y is greater than or equal to the width of the mouth of the pouring container. Generally, Y is set to be equal to the width of the mouth of the pouring container, and the value of Y can also be set to be slightly greater than the width of the mouth of the pouring container.

[0058] In the images of the high-temperature liquid in the photos taken by C1 and C2, in addition to the pouring channel, the high-temperature liquid in the pouring container appears as a ring-shaped highlight area. Figure 1 The images of the high-temperature liquid in the photos taken at a certain moment C1 (right) and C2 (left). It can be seen that ring-shaped highlight areas are formed in both images at this time, and the width of the two ring-shaped highlight areas is and Both are greater than the set value, so the liquid level is full at this moment.

[0059] The embodiments of the present invention are described in detail above with reference to the accompanying drawings, but the present invention is not limited to the described embodiments. It is apparent to those skilled in the art that various changes, modifications, substitutions, and variations to these embodiments may be made without departing from the principles and spirit of the present invention, and the changes still fall within the scope of protection of the present invention.

Claims

1. A method for monitoring the full liquid level of a high-temperature molten metal, characterized by: The steps include: S1. Install two industrial cameras vertically on one side of the pouring container. The first industrial camera at the bottom is represented by C1; the second industrial camera at the top is represented by C2. S2: During the pouring process, C1 and C2 simultaneously take photos of the pouring container at a certain moment and transmit the photos to the visual controller; S3, the visual controller calculates the width of the ring highlight area of ​​the high-temperature metal melt in the two photos taken by C1 and C2 at the same time. and ; S4, when n consecutive moments and If the following conditions are met, it is determined that the high-temperature metal liquid in the pouring container has reached the full liquid level; ,and ; in, , ; Where V1 and V2 are the image distances of C1 and C2 respectively; U1 and U2 represent the object distances, which are the distances between the target object and the optical centers of the C1 and C2 lenses, respectively; b1 and b2 are the angles between the optical axis of the lenses C1 and C2 and the horizontal plane respectively; Y is a set value; Y is greater than or equal to the width of the mouth of the pouring container.

2. The method for monitoring the full liquid level of a high-temperature molten metal according to claim 1, characterized in that: The n is a natural number of a set value.

3. The method for monitoring the full liquid level of high-temperature molten metal according to claim 2, characterized in that: n=1 or 2 or 3.

4. A high-temperature molten metal full level monitoring system, characterized by: The system comprises a display, a first industrial camera C1 and a second industrial camera C2; the first industrial camera C1 and the second industrial camera C2 are installed in the vertical direction of one side of the pouring container; and further comprises a visual controller connected to the first industrial camera C1 and the second industrial camera C2; the visual controller is used to receive the photos taken by C1 and C2, and respectively calculate the width of the ring-shaped highlight area of ​​the high-temperature molten metal in the photos. and , when n consecutive moments and If the set conditions are met at the same time, it is determined that the high-temperature metal liquid in the pouring container has reached the full liquid level; ,and ; Where V1 and V2 are the image distances of C1 and C2 respectively; U1 and U2 are the distances between the target and the optical centers of C1 and C2 lenses, respectively; b1 and b2 are the angles between the optical axis of the lenses C1 and C2 and the horizontal plane respectively; Y is a set value; Y is greater than or equal to the width of the mouth of the pouring container.

5. The high-temperature molten metal full level monitoring system according to claim 4, characterized in that: The n is a natural number of a set value.

6. The high-temperature molten metal full level monitoring system according to claim 5, characterized in that: n=1 or 2 or 3.

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