Converter installation and pushing system and method

Abstract

The present invention discloses a system and method for pushing and positioning a converter, belonging to the technical field of converter positioning. The pushing and positioning system of the present invention includes a ladle car, an intelligent pushing mechanism, a position detection mechanism, and a control system. The intelligent pushing mechanism pushes the ladle car to move along the rails. The position detection mechanism detects whether the running trajectory of the ladle car has been laterally offset or deflected during movement, as well as the alignment of the bolt holes of the converter bearing seat and the bolt holes on the converter base, and feeds back to the control system. The control system controls the intelligent pushing mechanism to perform timely deviation correction or parking brake. This effectively ensures the installation and positioning accuracy of the converter, and its positioning efficiency is relatively high.

Description

Technical Field

[0001] The present invention belongs to the technical field of converter positioning, and more specifically, relates to a system and method for installing and pushing a converter into position. Background Art

[0002] Ladle cars are the primary means of transporting large industrial equipment such as steel converters and ladle tanks. They come in two types: heavy and light. Light ladle cars, which can be evacuated at any time by passengers, are called light ladle cars; heavy ladle cars, which cannot be evacuated at any time, are called heavy ladle cars. Ladle cars are long and can travel in both directions.

[0003] When a ladle car is used to transport the converter body, the position of the ladle car needs to be monitored in real time through a positioning system. The existing positioning system mainly obtains the position coordinates of the satellite receiving device by installing a GNSS satellite receiving device on the ladle car. However, since the length of the ladle car body is 15m to 20m or longer, when locating the position of the ladle car, only the single-point installation position of the satellite receiving device is used to represent the position of the entire ladle car. The positioning accuracy is relatively low, and effective positioning cannot be achieved. It is even more impossible to detect and provide feedback in real time whether the running trajectory of the ladle car has deviated. Therefore, it is impossible to effectively ensure the accurate installation of the converter, and the cost is also high.

[0004] Therefore, how to effectively ensure the precise positioning of the ladle car during the converter transportation process and to perform real-time detection and timely correction of whether the ladle car's running trajectory deviates is of great significance to ensure the accurate installation of the converter. Summary of the Invention

[0005] To address the relatively low positioning accuracy of ladle cars in existing technologies, particularly the difficulty in real-time detection and adjustment of deviations in the running trajectories of the ladle cars and converters, the present invention provides a system and method for pushing and positioning a converter. This system uses a position detection mechanism to accurately locate the real-time positions of the ladle cars and converters during operation, and detects deviations in the ladle car's running trajectory in real time. This information is then fed back to a control system, which then controls an intelligent pushing mechanism to promptly correct the deviation or apply parking brakes, thereby ensuring converter installation accuracy.

[0006] In order to achieve the above object, the technical solution adopted by the present invention is as follows:

[0007] A first aspect of the present invention provides a converter installation and pushing system, comprising:

[0008] A ladle car, which is used to transport the converter to the converter base for installation;

[0009] An intelligent pushing mechanism, which is used to push the ladle car along the rails, and includes a pushing trolley. The left and right sides of the front portion of the pushing trolley frame are connected to the ladle car via a left pushing hydraulic cylinder and a right pushing hydraulic cylinder, respectively. A clamping mechanism is provided on both sides of the pushing trolley frame between the front and rear wheels. The clamping mechanism clamps the rails, thereby fixing the intelligent pushing mechanism relative to the rails; and

[0010] A position detection mechanism, comprising a first distance measuring sensor and a second distance measuring sensor spaced apart on one side of the ladle car body along the length direction of the ladle car, and a visual camera mounted on the converter base;

[0011] The first and second distance measuring sensors are used to detect in real time whether the running track of the ladle car has undergone lateral deviation or deflection during its movement; the visual camera is used to perform point cloud scanning on the bolt holes of the converter bearing seat on the ladle car and the bolt holes on the converter base to obtain the alignment of the above bolt holes;

[0012] The intelligent pushing mechanism and position detection mechanism are both connected to the control system. Based on the feedback from the position detection mechanism, the control system achieves precise positioning of the converter by differentially controlling the left and right pushing hydraulic cylinders or controlling the brakes of the ladle car.

[0013] According to the technical solution described in the first aspect of the present invention, the left-side pushing hydraulic cylinder is connected to the hydraulic pump through the left-side three-position four-way electromagnetic reversing valve and the left-side proportional flow valve; the right-side pushing hydraulic cylinder is connected to the hydraulic pump through the right-side three-position four-way electromagnetic reversing valve and the right-side proportional flow valve.

[0014] According to the technical solution described in the first aspect of the present invention, the clamping mechanism includes a clamping hydraulic cylinder and a hydraulic clamp, wherein the clamping hydraulic cylinder is connected to the hydraulic pump through a clamping hydraulic cylinder flow valve and a clamping hydraulic cylinder reversing valve.

[0015] According to the technical solution described in the first aspect of the present invention, pressure sensors are provided on the oil inlet pipelines of the left pushing hydraulic cylinder, the right pushing hydraulic cylinder and the clamping hydraulic cylinder.

[0016] According to the technical solution described in the first aspect of the present invention, the first ranging sensor and the second ranging sensor are both laser ranging sensors, which are both installed on the ladle car body through a fixed bracket and a magnetic adsorption component.

[0017] The second aspect of the present invention further provides a method for installing and pushing a converter into position, using the system for installing and pushing a converter into position described in the first aspect of the present invention, the method comprising:

[0018] During the process of transporting the ladle car to the converter, the first and second distance measuring sensors are used to detect the lateral distance between the two sensors and the outer side of the rail in real time and feed back to the control system to determine whether the running track of the ladle car has been laterally offset or deflected;

[0019] If there is lateral deviation or deflection in the running track of the ladle car, the control system will control the differential speed of the left and right pushing hydraulic cylinders to achieve preliminary lateral deviation correction of the ladle car and converter;

[0020] When the ladle car moves to the point where the bolt holes on the converter bearing seat reach the working range of the visual camera, the visual camera will further photograph the bolt holes on the converter base and the converter bearing seat. After point cloud data processing and calculation, the alignment between the corresponding bolt holes on the converter base and the converter bearing seat is obtained and fed back to the control system in real time.

[0021] If the center distance deviation between the corresponding bolt holes on the converter base and the converter bearing seat does not meet the lateral alignment requirement during converter installation, the left and right pushing hydraulic cylinders are further differentially controlled to achieve lateral alignment correction between the bolt holes on the converter bearing seat and the corresponding bolt holes on the converter base;

[0022] When the longitudinal distance between the center of the bolt hole on the converter bearing seat and the corresponding bolt hole on the converter base is equal to the braking distance of the ladle car, the ladle car is braked to align the bolt hole on the converter bearing seat with the corresponding bolt hole on the converter base longitudinally, thereby achieving precise installation of the converter.

[0023] According to the technical solution described in the second aspect of the present invention, when the converter is transported by a ladle car, the initial distance between it and the rail is first detected by the first distance measuring sensor as l1, and the initial distance between it and the rail is detected by the second distance measuring sensor as l2. During the movement of the ladle car, the lateral distances x1 and x2 between the first distance measuring sensor and the second distance measuring sensor and the rail are respectively detected in real time. By comparing the values ​​of x1 and x2 with the initial distances l1 and l2, the lateral offset or deflection of the ladle car's running trajectory can be obtained.

[0024] According to the technical solution described in the second aspect of the present invention, point cloud data of the corresponding bolt holes on the converter base and the converter bearing seat are obtained based on a visual camera, so as to judge the alignment of the bolt holes on the converter base and the corresponding bolt holes on the converter bearing seat. The specific operations are as follows:

[0025] S1. Before the ladle car transports the converter, a visual camera is used to scan the bolt holes on the front side of the converter base to obtain their point cloud data.

[0026] S2. Preprocessing the collected point cloud data, wherein the preprocessing includes mean filtering and image enhancement;

[0027] S3, using a circle-based template matching method to identify circles in the preprocessed image;

[0028] S4. Use the gen_area_center() operator to extract the center coordinates of the circle, and then mark the center coordinates of the bolt hole on the front side of the converter base as the origin of the world coordinate system (0, 0);

[0029] S5. When the ladle car moves forward to the point where the bolt hole on the converter bearing seat reaches the working range of the visual camera, the visual camera is used to photograph the bolt hole on the front side of the converter bearing seat to obtain its point cloud data. Then, steps S2 to S4 are repeated to obtain the center coordinates (x3, y3) of the bolt hole on the front side of the converter bearing seat, thereby obtaining the lateral distance deviation and longitudinal spacing between the bolt hole on the front side of the converter bearing seat and the corresponding bolt hole on the front side of the converter base.

[0030] According to the technical solution described in the second aspect of the present invention, the initial lateral deviation correction of the ladle car and the lateral alignment and deviation correction process of the corresponding bolt holes on the converter bearing seat and the converter base are both controlled by the PID algorithm.

[0031] According to the technical solution described in the second aspect of the present invention, the PID control output value u(t) = Kp×e(t) + Ki×∫(e(t)dt) + Kd×(de(t) / dt), where u(t) is the output correction amount; e(t) is the difference between the set value and the actual value of the center distance between the corresponding bolt holes on the converter bearing seat and the converter base; kp is the proportional coefficient, which is 0.5; ki is the integral coefficient, which is 0.05; and kd is the differential coefficient, which is 0.

[0032] Compared with other existing technologies, the present invention can achieve the following beneficial effects:

[0033] (1) The present invention provides a converter installation and pushing system, which drives the ladle car to move along the rails through an intelligent pushing mechanism, thereby transporting the converter to the converter base for installation; during the transportation process, the first distance measuring sensor and the second distance measuring sensor can be set to detect in real time whether the running track of the ladle car has undergone lateral offset or deflection and feedback to the control system, and the differential speed control of the left pushing hydraulic cylinder and the right pushing hydraulic cylinder can achieve timely lateral correction of the ladle car and the converter; and when the ladle car advances to the point where the bolt hole on the converter bearing seat reaches the working range of the visual camera, the visual camera can further obtain the point cloud data of the bolt hole on the converter base and the converter bearing seat, and based on this, the alignment of the bolt hole on the converter bearing seat and the converter base can be obtained, thereby controlling the lateral alignment correction again, or controlling the ladle car to brake in time to achieve longitudinal alignment. The solution of the present invention can not only improve the positioning accuracy of the ladle car, but also can timely detect and adjust the lateral offset or deflection in the converter transportation process, thereby effectively ensuring the installation positioning accuracy of the converter, and its positioning efficiency is relatively high.

[0034] (2) The present invention uses two proportional flow valves to perform differential control on the left-side pushing hydraulic cylinder and the right-side pushing hydraulic cylinder to eliminate the lateral error between the bolt holes on the converter base and the bolt holes on the converter bearing seat and the deflection angle of the ladle car, so that the ladle car moves forward facing the converter base. At the same time, PID algorithm control is used to perform lateral correction, which is conducive to further ensuring the precise matching of the positioning bolt holes on the converter bearing seat and the converter base. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In the drawings, the sizes and proportions do not represent the sizes and proportions of actual products. The drawings are merely illustrative and some non-essential elements or features are omitted for clarity.

[0036] Figure 1 This is a schematic diagram of the overall structure of a converter installation and pushing system according to an embodiment of the present invention;

[0037] Figure 2 This is a schematic structural diagram of an intelligent pushing mechanism according to an embodiment of the present invention;

[0038] Figure 3 Schematic diagram of the installation structure of the first and second laser ranging sensors in an embodiment of the present invention;

[0039] Figure 4 Schematic diagram of the installation structure of the third laser ranging sensor in an embodiment of the present invention;

[0040] Figure 5 This is a flow chart of aligning and positioning the bolt holes on the converter base and the converter bearing seat in an embodiment of the present invention;

[0041] Figure 6 Schematic diagram of the detection principle of the position detection mechanism in an embodiment of the present invention;

[0042] Figure 7 This is a point cloud image of the bolt holes on the converter base after processing in an embodiment of the present invention;

[0043] Figure 8 This is a point cloud image of the bolt holes on the converter base and the bolt holes on the converter bearing seat in an embodiment of the present invention after point cloud splicing;

[0044] Figure 9 The trend of the speed, acceleration and displacement of the ladle car changing with time during one working stroke of the hydraulic cylinder in the embodiment of the present invention;

[0045] Figure 10 Schematic diagram of the structure of the hydraulic system of the intelligent pushing mechanism in an embodiment of the present invention.

[0046] In the picture:

[0047] 1. Intelligent pushing mechanism;

[0048] 11. Pushing trolley; 12. Wheels; 13. Clamping mechanism; 131. Clamping hydraulic cylinder; 132. Clamping hydraulic cylinder flow valve; 133. Clamping hydraulic cylinder reversing valve; 14. Left-side pushing hydraulic cylinder; 141. Left-side three-position four-way solenoid reversing valve; 142. Left-side proportional flow valve; 15. Right-side pushing hydraulic cylinder; 151. Right-side three-position four-way solenoid reversing valve; 152. Right-side proportional flow valve; 16. Pressure sensor; 17. Fuel tank; 18. Filter; 19. Hydraulic pump;

[0049] 2. Ladle car;

[0050] 31. First distance measuring sensor; 32. Second distance measuring sensor; 33. Third distance measuring sensor; 34. Fixed bracket; 35. Magnetic adsorption element; 36. Reflective baffle; 37. Visual camera;

[0051] 4. Converter; 401. Bolt hole on the front side of converter bearing seat;

[0052] 5. Converter base; 501. Bolt hole on the front side of converter base;

[0053] 6. Rails. DETAILED DESCRIPTION

[0054] In order to further understand the content of the present invention, the present invention is now described in detail with reference to the accompanying drawings and specific embodiments.

[0055] It should be noted that the terms "first," "second," and the like in the specification and claims of this application and the accompanying drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or precedence. It should be understood that the terms used in this manner are interchangeable where appropriate, for the purposes of describing the embodiments of the present application herein.

[0056] In the present application, the terms "upper", "lower", "left", "right", "front", "back", "top", "bottom", "inside", "outside", "middle", "vertical", "horizontal", "transverse", "longitudinal" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings. These terms are mainly intended to better describe the present application and its embodiments, and are not intended to limit the indicated devices, elements or components to having a specific orientation, or to be constructed and operated in a specific orientation. Moreover, in addition to being used to indicate orientations or positional relationships, some of the above terms may also be used to indicate other meanings. For example, the term "upper" may also be used to indicate a certain dependency or connection relationship in certain circumstances. For those of ordinary skill in the art, the specific meanings of these terms in the present application can be understood according to the specific circumstances.

[0057] Furthermore, the terms "installed," "disposed," "equipped with," and "connected" as used in this application should be interpreted broadly. For example, they may refer to fixed connections, removable connections, or integral structures; mechanical connections or electrical connections; direct connections, indirect connections through an intermediary, or internal communication between two devices, elements, or components. Those skilled in the art will understand the specific meanings of these terms in this application based on the specific circumstances.

[0058] The embodiment of the present invention provides a converter installation and pushing system, such as Figure 1 As shown, it includes a ladle car 2, an intelligent pushing mechanism 1, a position detection mechanism and a control system, wherein:

[0059] The ladle car 2 is used to transport the converter 4 to the converter base 5 for installation, wherein the converter base 5 and the converter bearing seat are respectively provided with four bolt holes for converter installation;

[0060] like Figure 2As shown, the intelligent pushing mechanism 1 includes a pushing trolley 11. Wheels 12 that can move along the rails 6 on both sides are respectively provided on both sides of the bottom of the frame of the pushing trolley 11. The left and right sides of the front part of the frame of the pushing trolley 11 are connected to the ladle car 2 through the left pushing hydraulic cylinder 14 and the right pushing hydraulic cylinder 15 respectively. The ladle car 2 is pushed to move along the rails 6 by the left pushing hydraulic cylinder 14 and the right pushing hydraulic cylinder 15. A clamping mechanism 13 is provided on both sides of the frame of the pushing trolley 11 between the front and rear wheels 12. The rails 6 are clamped by the clamping mechanism 13, so that the intelligent pushing mechanism can be fixed to the rails.

[0061] Combine Figure 1 、 Figure 3 and Figure 4 As shown, the position detection mechanism includes a first ranging sensor 31 and a second ranging sensor 32 spaced apart on one side of the ladle car body along the length direction of the ladle car 2, a third ranging sensor 33 installed at the bolt hole of the converter bearing seat, and a visual camera 37 installed on the converter base 5.

[0062] Among them, the first distance measuring sensor 31 and the second distance measuring sensor 32 are respectively used to detect the lateral (perpendicular to the direction of the rail) distance between the corresponding distance measuring sensor and the outer side of the rail 6 during the movement of the ladle car in real time and feed it back to the control system, so as to determine whether the running trajectory of the ladle car has undergone lateral offset or deflection; if lateral offset or deflection occurs, the control system will differentially control the left pushing hydraulic cylinder 14 and the right pushing hydraulic cylinder 15 of the intelligent pushing mechanism, thereby achieving preliminary lateral correction of the ladle car 2 and the converter.

[0063] The third distance measuring sensor 33 is used to detect the longitudinal distance between the bolt holes on the converter bearing seat and the corresponding bolt holes on the converter base 5 in real time during the movement of the ladle car, so as to obtain the real-time position of the converter.

[0064] When the ladle car 2 moves forward to the bolt hole on the converter bearing seat and reaches the working range of the visual camera 37, the more precise visual camera 37 is further used to obtain point cloud data of the bolt hole on the converter base and the corresponding bolt hole on the converter bearing seat on the ladle car. After data processing and calculation, the center distance between the above-mentioned corresponding bolt holes is obtained and fed back to the control system in real time. If the center distance deviation value (lateral deviation) between the bolt hole on the converter bearing seat and the corresponding bolt hole on the converter base does not meet the requirements, the left-side pushing hydraulic cylinder 14 and the right-side pushing hydraulic cylinder 15 are further differentially controlled to achieve precise lateral alignment between the bolt hole on the converter bearing seat and the corresponding bolt hole on the converter base; when the longitudinal distance between the center points of the bolt hole on the converter bearing seat and the corresponding bolt hole on the converter base is equal to the braking distance of the ladle car, the ladle car 2 is controlled to brake, so that the bolt hole on the converter bearing seat on the ladle car is longitudinally aligned with the corresponding bolt hole on the converter base, thereby achieving precise installation of the converter.

[0065] As a preferred embodiment, the first distance measuring sensor 31 , the second distance measuring sensor 32 and the third distance measuring sensor 33 are all laser distance measuring sensors.

[0066] During the advancement of the ladle car, the ladle car 2 is pushed forward by the left and right pushing hydraulic cylinders 14 and 15. When the pushing hydraulic cylinders are in operation, the clamping mechanism 13 is controlled to clamp the rail, thereby fixing the intelligent pushing mechanism 1 relative to the rail 6. The clamping mechanism 13 includes a clamping hydraulic cylinder 131 and a hydraulic clamp. That is, the clamping hydraulic cylinder 131 controls the hydraulic clamp to clamp the rail 6. However, it should be noted that the present application does not limit the specific structure of the hydraulic clamp, and an existing hydraulic clamp structure can be directly adopted.

[0067] like Figure 10 As shown, in the embodiment of the present invention, the direction and speed of the left pushing hydraulic cylinder 14 are controlled by the left three-position four-way electromagnetic reversing valve 141 and the left proportional flow valve 142, and the direction and speed of the right pushing hydraulic cylinder 15 are controlled by the right three-position four-way electromagnetic reversing valve 151 and the right proportional flow valve 152. The forward direction of the ladle car 2 is corrected by the differential control of the pushing hydraulic cylinders on both sides; the hydraulic clamp is controlled to clamp or release the rail by the clamping hydraulic cylinder flow valve 132 and the clamping hydraulic cylinder reversing valve 133.

[0068] The oil outlet pipe of the oil tank 17 is connected to the above-mentioned left three-position four-way solenoid reversing valve 141, right three-position four-way solenoid reversing valve 151 and clamping hydraulic cylinder reversing valve 133 after passing through the filter 18 and the hydraulic pump 19 in sequence. The oil circuit pressure entering the left and right pushing hydraulic cylinders and the clamping hydraulic cylinder 131 is respectively detected in real time through the pressure sensor 16 and fed back to the control system. The control system controls the actions of the left pushing hydraulic cylinder 14, the right pushing hydraulic cylinder 15 and the clamping hydraulic cylinder according to the data fed back by the automatic control program, the pressure sensor 16 and the position detection mechanism.

[0069] Specifically, in a working cycle, the clamping hydraulic cylinder reversing valve 133 switches to the oil inlet position, so that the piston rod of the clamping hydraulic cylinder 131 extends, and the clamping mechanism 13 clamps the rail. The oil circuit pressure data is fed back to the control system through the pressure sensor 16 in the oil circuit. When the pressure reaches the set value, it is considered that the clamping mechanism 13 clamps the rail. At this time, the clamping hydraulic cylinder reversing valve 133 switches to the locking position, and the intelligent pushing mechanism is fixed on the rail through the clamping mechanism 13; the left-hand three-position four-way solenoid reversing valve 141 and the right-hand three-position four-way solenoid reversing valve 151 switch to the oil inlet position, and the piston rods of the pushing hydraulic cylinders on both sides extend, thereby pushing the ladle car forward.

[0070] When the maximum stroke of the pushing hydraulic cylinder is reached, the left three-position four-way solenoid reversing valve 141 and the right three-position four-way solenoid reversing valve 151 are switched to the locking position, and the pushing hydraulic cylinder stops working; the clamping hydraulic cylinder reversing valve 133 is switched to the return oil position, so that the piston rod of the clamping hydraulic cylinder 131 is shortened. After the clamping mechanism 13 releases the rail, the left three-position four-way solenoid reversing valve 141 and the right three-position four-way solenoid reversing valve 151 are switched to the return oil position, and the piston rod of the pushing hydraulic cylinder is shortened. Since the mass of the ladle car is much greater than the mass of the pushing trolley 11, the ladle car does not move at this time, and the pushing trolley 11 moves forward, causing the piston rods of the pushing hydraulic cylinders on both sides to return to their initial positions.

[0071] In one working cycle, the forward process of the ladle car 2 is the working stroke of the hydraulic cylinders on both sides. Assume that one working stroke of the hydraulic cylinder is l In order to avoid the impact on positioning accuracy during the forward movement of the ladle car 2, the embodiment of the present invention preferably adopts the sinusoidal acceleration motion law to achieve precise control of the motion process. The trend of the ladle car speed, acceleration and displacement changing with time during a working cycle of the hydraulic cylinder is as follows: Figure 9 As shown. Assume that the acceleration of ladle car 2 in a working stroke is a, the travel time is t, the travel speed is v, and the displacement is s, then v= ,s= The acceleration and speed of the ladle car are measured in real time during its movement. When the intelligent pushing mechanism stops, the ladle car will continue to roll forward for a distance due to its large inertia. Assuming that the ladle car brakes at a speed of v1 and an acceleration of a0, the required braking distance is s1, and the calculation yields s1= Where Q1 is the flow rate input to the hydraulic cylinder's oil inlet, which can be detected by a flow sensor, and A is the cross-sectional area of ​​the hydraulic cylinder's internal oil chamber. Therefore, when the longitudinal distance y1 between the front bolt holes of the converter base 5 and the corresponding front bolt holes on the converter bearing seat and the braking distance s1 of the ladle car meet the required accuracy (i.e., y1 - s1 < 1 mm), the ladle car brakes are controlled to align the bolt holes of the converter bearing seat with the bolt holes of the converter base.

[0072] like Figure 3 As shown, in the embodiment of the present invention, the first and second distance measuring sensors 31 and 32 are both mounted on the ladle car body via a fixing bracket 34 and a magnetic adsorption member 35. Since the converter body is already aligned with the bolt holes on the converter base when it is hoisted onto the ladle car, it is necessary to ensure that the relative position of the ladle car with respect to the rail remains unchanged during its movement. The initial distance l1 between the first and second distance measuring sensors 31 and 32 is detected, while the initial distance l2 between the first and second distance measuring sensors 31 and 32 is detected, respectively. As the ladle car moves, the lateral spacings x1 and x2 between the first and second distance measuring sensors 31 and 32 and the rail are measured in real time. By comparing the values ​​of x1 and x2 with the initial distances l1 and l2, the lateral offset or deflection of the ladle car's trajectory can be determined.

[0073] If it is detected that the running track of the ladle car has undergone lateral displacement or deflection during operation, the flow of the left pushing hydraulic cylinder 14 and the right pushing hydraulic cylinder 15 are controlled by two proportional flow valves respectively to achieve differential control, thereby realizing lateral deviation correction of the ladle car.

[0074] Furthermore, the first and second distance sensors 31, 32 are preferably installed at two trisection points on the left side of the ladle car, respectively, with the first distance sensor 31 positioned near the front of the ladle car (near the converter base) and the second distance sensor 32 positioned near the rear. Specifically, when x1 < l1 and x2 > l2 are detected, indicating that the ladle car has deviated to the right, the left and right pushing hydraulic cylinders 14, 15 are synchronously controlled to push the ladle car at a low speed, forcing it to continue moving in that direction. When the data x1 measured by the first distance sensor 31 and the data x2 measured by the second distance sensor 32 satisfy l1 - x1 = 2 (x2 - l2), the pushing is stopped, the clamping mechanism is controlled to release the rail, and the two pushing hydraulic cylinders return to their initial positions. At this point, the clamping mechanism 13 re-clamps the rail, and the piston rod of the right pushing hydraulic cylinder 15 is independently controlled to extend. Deflection correction is complete when the first distance sensor detects x1 = l1.

[0075] When x1>l1 and x2<l2, meaning the ladle car is deflecting to the left, the left and right push cylinders 14 and 15 are synchronously controlled to push the ladle car at a low speed. When x2>l2 and the data x1 measured by the first distance sensor 31 and the data x2 measured by the second distance sensor 32 satisfy x1-l1=2(l2-x2), the pushing stops, the clamping mechanism 13 is controlled to release, and the push cylinders on both sides return to their initial positions. At this point, the clamping mechanism 13 clamps the track, and the piston rod of the left push cylinder is independently controlled to extend. When the second distance sensor detects x2=l2, the deviation correction is complete.

[0076] When x1>l1 and x2>l2, that is, the overall trajectory of the ladle car moves to the left, if x1-l1>x2-l2, when x1-l1<2(x2-l2), the clamping mechanism releases the rail, and the piston rods of the pushing hydraulic cylinders on both sides extend a stroke to make the pushing trolley 11 move backward, and then the clamping mechanism clamps the rail, and the piston rods of the pushing hydraulic cylinders on both sides shorten to make the ladle car move backward. When the data x1 measured by the first distance measuring sensor 31 and the data x2 measured by the second distance measuring sensor 32 satisfy x1-l1=2(x2-l2), the pushing hydraulic cylinders on both sides stop working, the clamping mechanism is released, and the pushing hydraulic cylinders on both sides return to the initial position. At this point, the clamping mechanism 13 clamps the track, independently controlling the piston rod extension of the left-side push hydraulic cylinder 14. When the first distance sensor detects x1 = l1, the deviation correction is complete. When x1 - l1 > 2 (x2 - l2), the left and right push hydraulic cylinders 14 and 15 are synchronously controlled to push the ladle car at a low speed, causing it to continue moving in this direction until x1 - l1 = 2 (x1 - l1). The clamping mechanism then releases, and the push hydraulic cylinders on both sides return to their initial positions. At this point, the clamping mechanism 13 clamps the track, independently controlling the piston rod extension of the left-side push hydraulic cylinder 14. When the first distance sensor detects x1 = l1, the deviation correction is complete.

[0077] When x1>l1 and x2>l2, meaning the ladle car's overall trajectory shifts to the left, and if x1-l1<x2-l2, the left and right push cylinders 14 and 15 are synchronously controlled to push the ladle car at a low speed, continuing the car forward in this direction until l1-x1=2(l2-x2). The clamping mechanism then releases, and the two push cylinders return to their initial positions. The clamping mechanism 13 now clamps the track, and the piston rod of the right push cylinder 15 is independently controlled to extend. Correction is complete when the first distance sensor detects x1=l1.

[0078] When x1<l1 and x2<l2, that is, the overall trajectory of the ladle car moves to the right, if l1-x1>l2-x2, when l1-x1<2(l2-x2), the clamping mechanism is released, and the piston rods of the hydraulic cylinders on both sides extend a stroke to make the driving mechanism retreat, and then the clamping mechanism clamps the track, and the piston rods of the hydraulic cylinders on both sides shorten to make the ladle car retreat. When the data x1 measured by the first distance measuring sensor 31 and the data x2 measured by the second distance measuring sensor 32 satisfy l1-x1=2(l2-x2), the hydraulic cylinders on both sides stop working, the clamping mechanism is released, and the hydraulic cylinders on both sides return to their initial positions. At this point, the clamping mechanism clamps the track, independently controlling the piston rod extension of the right-side push hydraulic cylinder 15. Correction is complete when the first distance sensor detects x1 = l1. When l1 - x1 > 2 (l2 - x2), the left and right push hydraulic cylinders 14 and 15 are synchronously controlled to push the ladle car at a low speed, continuing in this direction until l1 - x1 = 2 (l2 - x2). The clamping mechanism then releases, and the push hydraulic cylinders on both sides return to their initial positions. At this point, the clamping mechanism clamps the track, independently controlling the piston rod extension of the right-side push hydraulic cylinder 15. Correction is complete when the first distance sensor detects x1 = l1.

[0079] When x1 < l1 and x2 < l2, meaning the ladle car's overall trajectory shifts to the right, and if l1 - x1 < 2 (l2 - x2), the left and right push cylinders 14 and 15 are synchronously controlled to push the ladle car forward at a low speed until x1 - l1 = 2 (x2 - l2). The clamping mechanism then releases, and the push cylinders on both sides return to their initial positions. The clamping mechanism now clamps the track, and the piston rod of the left push cylinder 14 is independently extended. Correction is complete when the first distance sensor detects x1 = l1.

[0080] like Figure 4 As shown, the third distance measuring sensor 33 is installed at the bolt hole on the front side of the converter bearing seat on the ladle car, and a reflective baffle 36 is correspondingly provided on the front side of the converter base. By real-time detection of the distance between the third distance measuring sensor 33 and the reflective baffle 36, and subtracting the distance between the reflective baffle 36 and the bolt hole on the front side of the converter base (which can be measured in advance), the real-time longitudinal distance of the ladle car and the converter relative to the converter base is obtained.

[0081] As a preferred embodiment, the point cloud data of the bolt holes on the converter base and the corresponding bolt holes on the converter bearing seat on the ladle car are obtained based on the visual camera 37, so as to judge the alignment of the bolt holes on the converter base and the corresponding bolt holes on the converter bearing seat. The specific operation is as follows:

[0082] Before the ladle car transports the converter, the visual camera 37 is used to photograph the bolt hole 501 on the front side of the converter base, and the coordinates of the projection point of the center of the bolt hole 501 on the horizontal plane are calculated and used as the origin of the coordinate system (0, 0);

[0083] When the ladle car 2 advances until the bolt hole on the converter bearing seat reaches the working range of the visual camera 37, the visual camera 37 photographs the front bolt hole 401 of the converter bearing seat, calculates the coordinates of the projection point of the center of the front bolt hole 401 on the horizontal plane, and thus determines the relative distance between the bolt hole on the converter base and the corresponding bolt hole on the converter bearing seat. This distance is then fed back to the control system in real time. In this embodiment, a PLC control system is preferably used. If there is a lateral deviation between the center of the front bolt hole 401 of the converter bearing seat and the center of the front bolt hole 501 of the converter base, lateral deviation correction is performed by differentially controlling the left and right hydraulic cylinders 14 and 15 to ensure lateral alignment. When the visual camera measures that the longitudinal distance y1 between the front bolt hole 401 of the converter bearing seat and the corresponding front bolt hole 501 of the converter base is equal to the braking distance s1 of the ladle car, the ladle car 2 is braked, thereby achieving precise alignment between the converter body and the converter base.

[0084] Furthermore, combined Figure 5 As shown, the specific process of judging and adjusting the lateral alignment of the bolt holes on the converter base and the corresponding bolt holes on the converter bearing seat includes:

[0085] Step 1: Scan the bolt hole 501 on the front side of the converter base using the visual camera 37 to obtain point cloud data;

[0086] Among them, the visual camera 37 must first be calibrated, and the correspondence between the points in the two-dimensional image and the points in the three-dimensional space is established through the calibration of the camera. Since the calibration is directly performed using existing technology, it will not be described in detail here.

[0087] Step 2: preprocessing the collected point cloud data, including mean filtering and image enhancement;

[0088] Furthermore, the mean filtering process preferably uses the mean_image() operator in Halcon, and the image enhancement preferably uses the emphasize(lmage:lmageEmphasize: MaskWidth, MaskHeight,Factor:) operator. In the embodiment of the present invention, MaskWidth is set to 7, MaskHeight is set to 7, and Factor is set to 1. The grayscale value (res) obtained by image enhancement calculation is as follows:

[0089] res =round((orig-mean) ×Factor)+ orig;

[0090] Where round is rounding, orig is the original grayscale value of the image, and mean is the grayscale value of the image after mean filtering.

[0091] Step 3: Using a circle-based template matching method to identify circles in the preprocessed image;

[0092] Since some unnecessary circles may be identified, but their area is relatively small, the select_shape() operator in Halcon can be used to filter by area, thereby filtering out the circles with smaller areas and obtaining the circles formed by the bolt holes, such as Figure 7 shown.

[0093] Step 4: Use the gen_area_center() operator to extract the center coordinates of the circle, and then mark the center coordinates of the bolt hole 501 on the front side of the converter base as the origin of the world coordinate system (0, 0);

[0094] Step 5: When the ladle car 2 advances to the point where the bolt hole on the converter bearing seat reaches the working range of the visual camera 37, the visual camera 37 photographs the bolt hole 401 on the front side of the converter bearing seat to obtain its point cloud data. Then, steps 2 to 4 are repeated to obtain the center coordinates (x3, y3) of the bolt hole 401 on the front side of the converter bearing seat. The lateral distance deviation between the bolt hole on the converter base and the corresponding bolt hole on the converter bearing seat is thus determined, and the data is fed back to the control system in real time.

[0095] like Figure 8 As shown, if there is a lateral deviation between the centers of the bolt holes 401 on the front side of the converter bearing seat and the bolt holes 501 on the front side of the converter base (the center distance deviation value does not meet the requirements), lateral correction is performed through differential control of the left-side pushing hydraulic cylinder 14 and the right-side pushing hydraulic cylinder 15, thereby effectively ensuring the lateral alignment between the bolt holes 401 on the front side of the converter bearing seat and the bolt holes 501 on the front side of the converter base.

[0096] Specifically, when the center distance deviation value between the front bolt hole 401 of the converter bearing seat and the front bolt hole 501 of the converter base does not meet the requirements, PID algorithm control is used for lateral correction, and the PID control output value u(t) = Kp×e(t) +Ki×∫(e(t)dt) + Kd×(de(t) / dt), where u(t) is the output of the controller, that is, the output correction amount; e(t) is the difference between the set value and the actual value, that is, the center distance deviation value (lateral spacing deviation value) between the front bolt hole 401 of the converter bearing seat and the front bolt hole of the converter base; kp is the proportional coefficient, which is 0.5; ki is the integral coefficient, which is 0.05; kd is the differential coefficient, which is 0. After each correction is completed, e(t) is calculated again according to the detection data of the visual camera and correction is performed again. Through continuous correction, the center of the bolt hole of the converter bearing seat and the bolt hole on the converter base are aligned in the horizontal direction.

[0097] To sum up, compared with the existing technology, the present invention can not only achieve precise positioning of the ladle car, but also achieve precise matching of the positioning bolt holes between the converter bearing seat and the converter base, which can effectively solve the current problems of high installation difficulty, low degree of automation and poor positioning accuracy in the installation process of steelmaking converters.

Claims

1. A converter installation and pushing system, characterized in that: include: A ladle car (2), the ladle car (2) being used to transport the converter (4) to the converter base (5) for installation; An intelligent pushing mechanism (1) is used to push a ladle car (2) to move along a steel rail (6), and comprises a pushing trolley (11). The left and right sides of the front portion of the frame of the pushing trolley (11) are connected to the ladle car (2) via a left pushing hydraulic cylinder (14) and a right pushing hydraulic cylinder (15), respectively. A clamping mechanism (13) is provided between the front and rear wheels on both sides of the frame of the pushing trolley (11). The steel rail (6) is clamped by the clamping mechanism (13), thereby fixing the intelligent pushing mechanism relative to the steel rail (6); and A position detection mechanism, the position detection mechanism comprising a first distance measuring sensor (31) and a second distance measuring sensor (32) arranged at intervals on one side of the ladle car body along the length direction of the ladle car (2), and a visual camera (37) mounted on the converter base (5); The first distance measuring sensor (31) and the second distance measuring sensor (32) are respectively installed at the positions of two trisection points on the left side of the ladle car, and are used to detect in real time whether the running track of the ladle car (2) has undergone lateral deviation or deflection during its movement, wherein the first distance measuring sensor (31) is close to the front of the ladle car, and the second distance measuring sensor (32) is close to the rear of the ladle car; the visual camera (37) is used to perform point cloud scanning on the bolt holes of the converter bearing seat on the ladle car (2) and the bolt holes on the converter base to obtain the alignment of the above-mentioned bolt holes; The intelligent pushing mechanism (1) and the position detection mechanism are both connected to a control system. Based on the feedback from the position detection mechanism, the control system performs differential speed control on the left-side pushing hydraulic cylinder (14) and the right-side pushing hydraulic cylinder (15) or controls the brakes of the ladle car (2), thereby achieving accurate positioning of the converter (4).

2. The converter installation and pushing system according to claim 1 is characterized in that: The left-side pushing hydraulic cylinder (14) is connected to the hydraulic pump (19) via a left-side three-position four-way electromagnetic reversing valve (141) and a left-side proportional flow valve (142); the right-side pushing hydraulic cylinder (15) is connected to the hydraulic pump (19) via a right-side three-position four-way electromagnetic reversing valve (151) and a right-side proportional flow valve (152).

3. The converter installation and pushing system according to claim 2 is characterized in that: The clamping mechanism (13) comprises a clamping hydraulic cylinder (131) and a hydraulic clamp, wherein the clamping hydraulic cylinder (131) is connected to the hydraulic pump (19) via a clamping hydraulic cylinder flow valve (132) and a clamping hydraulic cylinder reversing valve (133).

4. The converter installation and pushing system according to claim 3 is characterized in that: Pressure sensors (16) are provided on the oil inlet pipelines of the left-side pushing hydraulic cylinder (14), the right-side pushing hydraulic cylinder (15), and the clamping hydraulic cylinder (131).

5. The converter installation and pushing system according to any one of claims 1 to 4, characterized in that: The first distance measuring sensor (31) and the second distance measuring sensor (32) are both laser distance measuring sensors, and are both mounted on the ladle car body via a fixing bracket (34) and a magnetic adsorption member (35).

6. A method for installing and pushing a converter into position, characterized in that: The converter installation and pushing-in-place system according to any one of claims 1 to 5 is used, and the method comprises: During the process of transporting the converter (4) via the ladle car (2), the first distance measuring sensor (31) and the second distance measuring sensor (32) are used to detect the lateral distance between the two sensors and the outer side of the rail (6) in real time and feed back to the control system to determine whether the running track of the ladle car (2) has undergone lateral deviation or deflection; If the running track of the ladle car (2) has a lateral deviation or deflection, the control system controls the left-side pushing hydraulic cylinder (14) and the right-side pushing hydraulic cylinder (15) to perform differential speed control to achieve preliminary lateral deviation correction of the ladle car (2) and the converter; When the ladle car (2) advances to the point where the bolt holes on the converter bearing seat reach the working range of the visual camera (37), the visual camera (37) further photographs the bolt holes on the converter base and the converter bearing seat, and the alignment between the corresponding bolt holes on the converter base and the converter bearing seat is obtained through point cloud data processing and calculation, and is fed back to the control system in real time; If the center distance deviation value between the corresponding bolt holes on the converter base and the converter bearing seat does not meet the lateral alignment requirement when the converter is installed, the left-side pushing hydraulic cylinder (14) and the right-side pushing hydraulic cylinder (15) are further differentially controlled to achieve lateral alignment correction between the bolt holes on the converter bearing seat and the corresponding bolt holes on the converter base; When the longitudinal distance between the centers of the bolt holes on the converter bearing seat and the corresponding bolt holes on the converter base is equal to the braking distance of the ladle car, the ladle car (2) is controlled to brake, so that the bolt holes on the converter bearing seat are longitudinally aligned with the corresponding bolt holes on the converter base, thereby achieving accurate installation of the converter.

7. The method for installing and pushing a converter into position according to claim 6, characterized in that: When the ladle car (2) is used to transport the converter (4), the initial distance between the ladle car and the steel rail is first detected by the first distance measuring sensor (31), and the initial distance between the ladle car and the steel rail is detected by the second distance measuring sensor (32). During the movement of the ladle car, the lateral distances x1 and x2 between the first distance measuring sensor (31) and the second distance measuring sensor (32) and the steel rail are respectively detected in real time. By comparing the values ​​of x1 and x2 with the initial distances l1 and l2, the lateral offset or deflection of the ladle car's running track can be obtained.

8. The method for installing and pushing a converter into position according to claim 6, characterized in that: The point cloud data of the corresponding bolt holes on the converter base and the converter bearing seat are obtained based on the visual camera (37), so as to judge the alignment of the bolt holes on the converter base and the corresponding bolt holes on the converter bearing seat. The specific operation is as follows: S1. Before the ladle car transports the converter, the bolt hole (501) on the front side of the converter base is scanned using a visual camera (37) to obtain point cloud data thereof; S2. Preprocessing the collected point cloud data, wherein the preprocessing includes mean filtering and image enhancement; S3, using a circle-based template matching method to identify circles in the preprocessed image; S4. Use the gen_area_center() operator to extract the center coordinates of the circle, and then mark the center coordinates of the bolt hole (501) on the front side of the converter base as the origin (0, 0) of the world coordinates; S5. When the ladle car (2) advances to the point where the bolt hole on the converter bearing seat reaches the working range of the visual camera (37), the bolt hole (401) on the front side of the converter bearing seat is photographed by the visual camera (37) to obtain its point cloud data; Then, steps S2 to S4 are repeated to obtain the center coordinates (x3, y3) of the bolt hole (401) on the front side of the converter bearing seat, thereby obtaining the lateral distance deviation and longitudinal spacing between the bolt hole (401) on the front side of the converter bearing seat and the corresponding bolt hole (501) on the front side of the converter base.

9. The method for installing and pushing a converter into position according to any one of claims 6 to 8, characterized in that: The initial lateral deviation correction of the ladle car (2) and the lateral alignment correction process of the corresponding bolt holes on the converter bearing seat and the converter base are controlled by the PID algorithm.

10. The method for installing and pushing a converter into position according to claim 9, characterized in that: The PID control output value u(t) =Kp×e(t) + Ki×∫(e(t)dt) + Kd×(de(t) / dt), where u(t) is the output correction value; e(t) is the difference between the set value and the actual value of the center distance between the corresponding bolt holes on the converter bearing seat and the converter base; kp is the proportional coefficient, which is 0.5; ki is the integral coefficient, which is 0.05; and kd is the differential coefficient, which is 0.

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