Breakout monitoring system of continuous casting machine

Abstract

The invention provides a bleed-out monitoring system of a continuous casting machine, and relates to the technical field of continuous casting machines, the bleed-out monitoring system of the continuous casting machine comprises a sensing pipeline, a monitoring unit and a control unit, the sensing pipeline is used for being erected in a secondary cooling chamber along the inner wall of the secondary cooling chamber of the continuous casting machine; an air inlet and an air outlet of the sensing pipeline extend out of the secondary cooling chamber in the radial direction of the secondary cooling chamber and are connected with the monitoring unit arranged on the outer wall of the secondary cooling chamber, and the control unit is in communication connection with the monitoring unit and used for judging whether steel breakout happens to the continuous casting machine or not according to the pressure change condition, collected by the monitoring unit, of the sensing pipeline. The bleed-out monitoring efficiency of the continuous casting machine can be improved.

Description

Technical Field

[0001] This invention relates to the field of continuous casting machine technology, and more specifically, to a continuous casting machine leakage monitoring system. Background Technology

[0002] Continuous casting machines are core equipment in the steel production process. Their main function is to continuously cast molten steel at high temperatures into various billets, such as square billets, round billets, and slabs. This significantly shortens the steel production process, reduces energy consumption and production costs, and is widely used in many steel-dependent industries, including construction, machinery, shipbuilding, and automobile manufacturing. The stability of their operation directly determines the production efficiency and product quality of steel companies. However, steel leakage, one of the most serious accidents in continuous casting production, not only causes the billets to be scrapped directly but can also damage core equipment such as crystallizers and roller conveyors, leading to fires, high-temperature molten steel splashing, and other safety accidents. This results in prolonged shutdowns for maintenance and repairs, causing huge economic losses to companies.

[0003] In related technologies, conventional steel leakage monitoring usually targets the crystallizer outlet of the continuous casting machine, but does not cover the secondary cooling chamber of the crystallizer. For steel leakage inside the secondary cooling chamber, manual inspection is usually required, which leads to a lag in the steel leakage monitoring response and affects the monitoring efficiency. Summary of the Invention

[0004] The problem addressed by this invention is how to improve the efficiency of steel leakage detection.

[0005] To address the above problems, this invention provides a leakage monitoring system for continuous casting machines.

[0006] In a first aspect, the present invention provides a leakage monitoring system for a continuous casting machine, comprising a sensing pipeline, a monitoring unit, and a control unit. The sensing pipeline is installed along the inner wall of the secondary cooling chamber of the continuous casting machine. The inlet and outlet of the sensing pipeline extend radially out of the secondary cooling chamber and are connected to the monitoring unit disposed on the outer wall of the secondary cooling chamber. The control unit is communicatively connected to the monitoring unit and is used to determine whether leakage has occurred in the continuous casting machine based on the pressure changes in the sensing pipeline collected by the monitoring unit.

[0007] Optionally, the monitoring unit includes a first pressure relay, a gas source control module, a first pipeline, a second pipeline, and a gas source ball valve. One end of the first pipeline is equipped with the first pressure relay, and the other end of the first pipeline is connected to the outlet of the sensing pipeline. The inlet of the sensing pipeline is connected to the outlet of the gas source control module. The inlet of the gas source control module is connected to one end of the second pipeline, and the other end of the second pipeline is connected to one end of the gas source ball valve. The other end of the gas source inlet ball valve is used to connect to a gas source.

[0008] Optionally, the control unit is communicatively connected to the first pressure relay; the step of determining whether the continuous casting machine has experienced steel leakage based on the pressure changes in the sensing pipeline collected by the monitoring unit includes: The steel leakage is determined based on the changes in the sensing pipeline pressure collected by the first pressure relay. The sensing pipeline pressure is the pressure collected by the first pressure relay based on a preset collection period.

[0009] Optionally, determining whether the steel leakage has occurred based on the changes in the sensing pipeline pressure collected by the first pressure relay includes: Based on the preset acquisition cycle, the current sensing pipeline pressure, and the previous sensing pipeline pressure, the corresponding pressure change rate is obtained through the preset pressure change rate relationship; If the pressure change rate is greater than or equal to the preset change rate threshold twice in a row, it is determined that the continuous casting machine has experienced steel leakage, and a steel leakage alarm is generated.

[0010] Optionally, the pressure change rate relationship satisfies: ; Where γ is the rate of change of pressure, P t For the pressure of the sensing pipeline currently described, P t-1 The pressure of the sensing pipeline mentioned above is T, which is the preset acquisition period.

[0011] Optionally, the gas source control module includes a second pressure relay, a pressure regulating valve, and a three-way valve. The first end of the three-way valve is connected to the air inlet of the sensing pipeline through the pressure regulating valve. The second end of the three-way valve is provided with the second pressure relay, and the third end of the three-way valve is connected to one end of the second pipeline.

[0012] Optionally, the control unit is communicatively connected to the second pressure relay and the pressure regulating valve, and the control unit is also used to adjust the pressure regulating valve according to the gas supply pressure collected by the second pressure relay.

[0013] Optionally, adjusting the pressure regulating valve based on the gas supply pressure collected by the second pressure relay includes: Obtain the current opening degree of the pressure regulating valve; The difference between the gas supply pressure and the preset gas supply pressure threshold is defined as the pressure deviation; Based on the current opening degree and the pressure deviation, the target opening degree is obtained through a preset adjustment relationship; The pressure regulating valve is controlled to adjust its opening to the target opening.

[0014] Optionally, the adjustment relationship satisfies: KV =K B +K P ×△P; Among them, K V Let K be the target opening. B K represents the current opening degree. P The preset opening adjustment coefficient is ΔP, which represents the pressure deviation.

[0015] Optionally, the system further includes a damping head, wherein a through hole matching the damping head is provided at the connection of the first, second and third ends of the tee, and the damping head is disposed in the through hole.

[0016] The beneficial effects of the continuous casting machine leakage monitoring system of the present invention are as follows: The layout of the sensing pipeline along the inner wall of the secondary cooling chamber enables comprehensive coverage of the key areas corresponding to the continuous casting billet's running path, effectively reducing monitoring blind spots and avoiding missed detections due to incomplete monitoring range, thus fundamentally improving the comprehensiveness and effectiveness of leakage risk detection; Furthermore, the design of the sensing pipeline's air inlet and outlet extending radially along the outer wall of the secondary cooling chamber and connecting to the monitoring unit avoids interference and damage to the monitoring unit caused by the harsh environment of high temperature, high humidity, and high dust in the secondary cooling chamber, ensuring the stable and continuous operation of the monitoring unit, reducing monitoring interruptions caused by equipment failure, and ensuring the sealing of gas transmission within the sensing pipeline, enabling the monitoring unit to accurately and in real-time collect pressure signals, reducing signal interference and data errors caused by environmental factors, and improving data acquisition efficiency and accuracy; Simultaneously, the control unit... The direct communication connection between the sensor and the monitoring unit enables rapid transmission and real-time analysis of pressure data. Combined with the built-in intelligent judgment algorithm, it can quickly respond to abnormal pressure changes without manual intervention, significantly shortening the time interval from signal capture to leakage detection. Compared with traditional monitoring methods, it significantly improves the response speed of leakage warning, allowing operators sufficient emergency response time and effectively preventing the escalation of leakage accidents. In addition, the separate layout of the sensing pipeline and the monitoring unit facilitates later installation, commissioning, maintenance and repair, reducing the impact of equipment downtime maintenance on production and ensuring the long-term stable operation efficiency of the monitoring system. This achieves high efficiency, accuracy and continuity of leakage monitoring in continuous casting production, reducing the labor intensity and risk of misjudgment of manual monitoring, and ensuring production continuity through timely warning and response, indirectly improving overall production efficiency. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of a continuous casting machine leakage monitoring system according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the monitoring unit according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the sensing pipeline and monitoring unit according to an embodiment of the present invention; Figure 4 This is a schematic diagram of the electrical principle of the sensing pipeline and monitoring unit according to an embodiment of the present invention.

[0018] Explanation of reference numerals in the attached figures: 1-Sensing pipeline; 2-Monitoring unit; 21-First pressure relay; 22-Gas source control module; 221-Second pressure relay; 222-Pressure regulating valve; 223-Tee; 224-Damping head; 23-First pipeline; 24-Second pipeline; 25-Gas source ball valve; 3-Crystallizer; 4-Second cooling chamber; 5-Gas source. Detailed Implementation

[0019] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Although some embodiments of the present invention are shown in the drawings, it should be understood that the present invention can be implemented in various forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the present invention. It should be understood that the accompanying drawings and embodiments of the present invention are for illustrative purposes only and are not intended to limit the scope of protection of the present invention.

[0020] It should be understood that the various steps described in the method embodiments of the present invention may be performed in different orders and / or in parallel. Furthermore, the method embodiments may include additional steps and / or omit the steps shown. The scope of the present invention is not limited in this respect.

[0021] The term "comprising" and its variations as used herein are open-ended, meaning "including but not limited to"; the term "based on" means "at least partially based on"; the term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one additional embodiment"; the term "some embodiments" means "at least some embodiments"; and the term "optionally" means "optional embodiments". Definitions of other terms will be given in the following description. It should be noted that the concepts of "first," "second," etc., mentioned in this invention are used only to distinguish different devices, modules, or units, and are not intended to limit the order of functions performed by these devices, modules, or units or their interdependencies.

[0022] It should be noted that the terms "a" and "a plurality of" used in this invention are illustrative rather than restrictive. Those skilled in the art should understand that, unless otherwise expressly indicated in the context, they should be understood as "one or more".

[0023] The names of the messages or information exchanged between the multiple devices in the embodiments of the present invention are for illustrative purposes only and are not intended to limit the scope of these messages or information.

[0024] In related technologies, conventional steel leakage monitoring techniques mostly focus on the outlet of the continuous casting machine's crystallizer, capturing initial steel leakage signals by deploying detection elements. However, they fail to include the secondary cooling chamber in the monitoring scope, creating a critical blind spot. As the core area for secondary cooling of the billet, the secondary cooling chamber is subjected to harsh environments of high temperature, strong heat radiation, and water vapor spray for extended periods, and its spatial structure is complex. Due to the lack of effective online monitoring methods, steel leakage in this area can only be judged by manual inspection. However, it is difficult for humans to monitor in real time, and inspections in high-temperature environments pose safety risks and response delays. Once leaked steel flows into the secondary cooling chamber without being intercepted at the front end, molten steel will spread rapidly, burning equipment such as roller conveyors and cooling pipes, and may also cause safety accidents such as molten steel splashing, forcing the production line to shut down for extended periods. This not only significantly reduces monitoring efficiency but also causes huge economic losses.

[0025] To address the problems existing in the aforementioned related technologies, embodiments of the present invention provide a steel leakage monitoring system for continuous casting machines.

[0026] like Figure 1 and Figure 3 As shown in the figure, an embodiment of the present invention provides a steel leakage monitoring system for a continuous casting machine, including a sensing pipeline 1, a monitoring unit 2, and a control unit. The sensing pipeline 1 is installed along the inner wall of the secondary cooling chamber 4 of the continuous casting machine. The air inlet and air outlet of the sensing pipeline 1 extend out of the secondary cooling chamber 4 in the radial direction and are connected to the monitoring unit 2, which is disposed on the outer wall of the secondary cooling chamber 4. The control unit is communicatively connected to the monitoring unit 2 and is used to determine whether steel leakage has occurred in the continuous casting machine based on the pressure change data of the sensing pipeline 1 collected by the monitoring unit 2.

[0027] Specifically, this system is designed to identify potential steel leakage risks in the continuous casting process in real time, ensuring production safety and equipment stability. The system consists of a sensing pipeline 1, a monitoring unit 2, and a control unit. Each component achieves rapid early warning of steel leakage through precise structural layout and signal interaction. The sensing pipeline 1, as the direct sensing carrier of the steel leakage signal, is made of high-temperature resistant, corrosion-resistant tubing with sufficient structural strength. The preferred material is high-temperature resistant copper tubing (alternatives include aluminum tubing with a wall thickness of 0.5 to 1 mm or stainless steel capillary tubes with a diameter of 2 to 6 mm). This ensures effective interception of high-temperature molten steel leaking from the outlet of the crystallizer 3 while avoiding contact with normal billets. The wiring must avoid moving parts such as the foot rollers. The sensing pipeline 1 is installed along the inner wall of the secondary cooling chamber 4 of the continuous casting machine (it can be arranged in a surrounding, segmented, or full-coverage manner depending on the cavity structure of the secondary cooling chamber 4). This ensures that the pipeline fully covers the key areas of the secondary cooling chamber 4 corresponding to the continuous casting billet's running path, such as capturing abnormalities caused by contact between high-temperature molten steel and the pipeline when steel leakage occurs at the outlet of the crystallizer 3. After the sensing pipeline 1 encircles the inner wall of the secondary cooling chamber 4, its air inlet and outlet converge on the same side. Both the inlet and outlet extend vertically out of the secondary cooling chamber 4 along its radial direction. These extended inlets and outlets are sealed to the corresponding inlets and outlets of the monitoring unit 2, which is fixed to the outer wall of the secondary cooling chamber 4. This prevents the influence of moisture and high temperatures within the secondary cooling chamber 4 on the monitoring unit 2 and ensures the airtightness of gas transmission within the pipeline, preventing a decrease in monitoring accuracy due to gas leakage. The monitoring unit 2 collects gas pressure parameters from the sensing pipeline 1 in real time. After preliminary processing of the collected analog or digital signals, it transmits them to the control unit via wired (e.g., industrial Ethernet, RS485 bus) or wireless (e.g., LoRa, 5G) communication. To ensure real-time monitoring, the sampling frequency of the monitoring unit 2 can be adjusted according to the continuous casting machine's operating speed and production process requirements. It also features an anti-interference design, effectively filtering out interference from vibrations, temperature fluctuations, and other factors in the secondary cooling chamber 4 environment. As the system's decision-making module, the control unit establishes stable two-way communication with the monitoring unit 2 through a preset communication protocol. After receiving the pressure data transmitted by the monitoring unit 2, it processes the data in real time and determines whether steel leakage has occurred in the continuous casting machine based on the processing results. Subsequently, it can issue a warning signal to the operator through an audible and visual alarm device. At the same time, it can output control commands to the main control system of the continuous casting machine (such as reducing the billet speed, cutting off the casting flow, and starting the emergency cooling system) according to preset logic, so as to realize the timely handling of steel leakage risk and fundamentally avoid equipment damage and production interruption caused by the expansion of steel leakage accidents.

[0028] In this embodiment, the layout of the sensing pipeline 1 along the inner wall of the secondary cooling chamber 4 enables comprehensive coverage of the key areas corresponding to the continuous casting billet's running path, effectively reducing monitoring blind spots and avoiding missed detections due to incomplete monitoring coverage. This fundamentally improves the comprehensiveness and effectiveness of steel leakage risk detection. Furthermore, the design of the sensing pipeline 1's inlet and outlet extending radially along the secondary cooling chamber 4 to the outer wall and connecting to the monitoring unit 2 avoids interference and damage to the monitoring unit 2 caused by the harsh environment of the secondary cooling chamber 4 (high temperature, high humidity, and high dust), ensuring the stable and continuous operation of the monitoring unit 2 and reducing monitoring interruptions due to equipment failure. It also ensures the airtightness of gas transmission within the sensing pipeline 1, enabling the monitoring unit 2 to accurately and in real-time acquire pressure signals, reducing signal interference and data errors caused by environmental factors, and improving data acquisition efficiency and accuracy. Simultaneously, the control unit and monitoring... The direct communication connection of Unit 2 enables rapid transmission and real-time analysis of pressure data. Combined with the built-in intelligent judgment algorithm, it can quickly respond to abnormal pressure changes without manual intervention, significantly shortening the time interval from signal capture to leakage detection. Compared with traditional monitoring methods, it significantly improves the response speed of leakage warning, allowing operators sufficient emergency response time and effectively preventing the escalation of leakage accidents. In addition, the separate layout of sensing pipeline 1 and monitoring unit 2 facilitates later installation, commissioning, maintenance and repair, reducing the impact of equipment downtime maintenance on production, ensuring the long-term stable operation efficiency of the monitoring system, and thus realizing the high efficiency, accuracy and continuity of leakage monitoring in continuous casting production. This not only reduces the labor intensity and risk of misjudgment of manual monitoring, but also ensures production continuity through timely warning and handling, indirectly improving overall production efficiency.

[0029] Optionally, such as Figure 2 and Figure 4 As shown, the monitoring unit 2 includes a first pressure relay 21, a gas source control module 22, a first pipeline 23, a second pipeline 24, and a gas source ball valve 25. The first pressure relay 21 is installed at one end of the first pipeline 23, and the other end of the first pipeline 23 is connected to the outlet of the sensing pipeline 1. The inlet of the sensing pipeline 1 is connected to the outlet of the gas source control module 22. The inlet of the gas source control module 22 is connected to one end of the second pipeline 24, and the other end of the second pipeline 24 is connected to one end of the gas source ball valve 25. The other end of the gas source 5 inlet ball valve is used to connect to the gas source 5.

[0030] In this optional embodiment, the first pipeline 23 serves as the connection carrier between the sensing pipeline 1 and the pressure monitoring element. It can be made of high-strength, corrosion-resistant pressure-resistant pipe material. A first pressure relay 21 is fixedly installed at one end of the first pipeline. This relay uses an industrial-grade pressure detection element with high response speed and high-precision measurement range. It can capture minute changes in gas pressure in the pipeline in real time and convert them into electrical signals for output, providing raw data support for the subsequent control unit's judgment. The other end of the first pipeline 23 is detachably sealed to the outlet of the sensing pipeline 1 through a sealing joint. A high-temperature resistant sealing gasket is used at the connection to effectively prevent pressure monitoring errors caused by gas leakage, while also facilitating later maintenance and pipeline replacement. The air inlet of sensing pipeline 1 is connected to the air outlet of gas source control module 22 through the same sealed connection method. As the core component for gas source parameter adjustment, gas source control module 22 integrates pressure regulator, flow control valve and pressure stabilizing component. Its core function is to perform pressure calibration, flow stabilization and impurity filtration of the gas input from gas source 5, so as to ensure that the gas pressure entering sensing pipeline 1 is always maintained within the preset stable range, avoiding false monitoring problems caused by gas source pressure fluctuations. At the same time, the pressure and flow parameters of the gas in the pipeline can be flexibly adjusted according to the production process requirements of continuous casting machine. The air inlet of the air source control module 22 is sealed to one end of the second pipeline 24, which also uses pressure-resistant and sealed tubing. Its other end is fixedly connected to one end of the air source ball valve 25 via a threaded or quick-connect fitting. The air source ball valve 25 is a manually or electrically controlled valve with reliable sealing performance. Its other end has a standard air source 5 interface for quick connection to an external compressed air source or inert gas source. The air source ball valve 25 enables rapid start-up and shutdown control of the entire air circuit system, facilitating the disconnection of the air source 5 during system maintenance and repair. It also has overcurrent protection to prevent damage to pipelines and components from abnormally high air source pressure. All pipeline and component connections in the entire monitoring unit 2 employ a double-sealing design to ensure the airtightness of the air circuit system and prevent gas leakage from affecting pressure monitoring accuracy. Furthermore, all components are industrial-grade devices adapted to the high temperature and humidity environment of the outer wall of the secondary cooling chamber 4, ensuring long-term stable operation of the monitoring unit 2 under harsh conditions.

[0031] Optionally, such as Figure 1 and Figure 2 As shown, the control unit is communicatively connected to the first pressure relay 21; the step of determining whether the continuous casting machine has experienced steel leakage based on the pressure change data of the sensing pipeline 1 collected by the monitoring unit 2 includes: The steel leakage is determined based on the changes in the sensing pipeline pressure collected by the first pressure relay 21. The sensing pipeline pressure is the pressure collected by the first pressure relay 21 based on a preset collection period.

[0032] In this optional embodiment, the control unit and the first pressure relay 21 establish a bidirectional data connection using a stable and reliable industrial-grade communication method. Specifically, signal transmission can be achieved through wired or wireless communication. The communication process follows a preset standardized communication protocol to ensure the real-time, accuracy, and anti-interference of pressure data transmission. At the same time, the control unit can send parameter configuration commands (such as acquisition cycle, pressure measurement range, signal output mode, etc.) to the first pressure relay 21 through this communication link to achieve flexible control of the pressure monitoring process. Correspondingly, the control unit determines whether a leak has occurred in the continuous casting machine based on the pressure changes in the sensing pipeline collected by the monitoring unit 2. The core of this process relies on the first pressure relay 21 to collect and transmit pressure data, and uses preset logical judgment rules to accurately identify the risk of leaks. The sensing pipeline pressure specifically refers to the real-time gas pressure value in the sensing pipeline 1 continuously collected by the first pressure relay 21 according to a preset collection cycle (this cycle can be flexibly adjusted according to production conditions such as the continuous casting machine's billet pulling speed and the temperature distribution in the secondary cooling chamber 4, for example, set to 50ms to 500ms, ensuring that rapid pressure changes during leaks are captured while avoiding processing delays caused by data redundancy). The first pressure relay 21 transmits the collected pressure analog signal (such as a 4 to 20mA flow signal) or digital signal (such as binary data) to the sensor. The pressure data is transmitted to the control unit in real time through the aforementioned communication link. After receiving the pressure data, the control unit first performs preprocessing such as filtering and noise reduction to remove invalid data caused by environmental vibration, electromagnetic interference, and other factors. Then, it performs multi-dimensional analysis of pressure changes through a built-in judgment algorithm, including comparing the deviation between the real-time pressure value and the preset benchmark pressure value, calculating the pressure change rate (slope) per unit time, and monitoring whether there are sudden changes or continuous abnormal fluctuations in pressure. When the pressure data meets the preset leakage judgment conditions (such as a sudden drop in pressure exceeding a set threshold, or an absolute value of the pressure change rate exceeding a critical value and lasting for a certain period of time), the control unit determines that the continuous casting machine may be leaking steel, thereby triggering subsequent early warning and emergency control procedures. The entire judgment process does not require manual intervention, realizing the automation and rapid identification of leakage risk.

[0033] Optionally, determining whether the steel leakage has occurred based on the changes in the sensing pipeline pressure collected by the first pressure relay 21 includes: Based on the preset acquisition cycle, the current sensing pipeline pressure, and the previous sensing pipeline pressure, the corresponding pressure change rate is obtained through the preset pressure change rate relationship; If the pressure change rate is greater than or equal to the preset change rate threshold twice in a row, it is determined that the continuous casting machine has experienced steel leakage, and a steel leakage alarm is generated.

[0034] Optionally, the pressure change rate relationship satisfies: ; Where γ is the rate of change of pressure, P t For the pressure of the sensing pipeline currently described, P t-1 The pressure of the sensing pipeline mentioned above is T, which is the preset acquisition period.

[0035] In this optional embodiment, after receiving the sensing pipeline pressure data continuously collected by the first pressure relay 21 according to the preset collection cycle, the control unit first extracts the current sensing pipeline pressure value corresponding to the current collection cycle and the previous sensing pipeline pressure value corresponding to the previous collection cycle. These two continuous pressure data are then substituted into the preset pressure change rate relationship along with the preset collection cycle to calculate the corresponding pressure change rate data in real time. The core of this method is to accurately quantify the rate of change of sensing pipeline pressure per unit time by using the ratio of the pressure difference between two adjacent cycles to the collection time interval, thus intuitively reflecting the dynamic change trend of gas pressure in the pipeline. The preset rate of change threshold is a critical value determined through a large number of experiments and process optimizations, based on factors such as the working parameters of the second cooling chamber 4 of the continuous casting machine, the material characteristics of the sensing pipeline 1, and the pressure change law caused by the contact between high-temperature molten steel and the pipeline during steel leakage. (For example, by combining steel leakage simulation experiments at different billet speeds and casting temperatures, the minimum critical value of the pressure change rate when steel leakage occurs is determined, while a certain safety margin is reserved to avoid misjudgment.) Its value can be flexibly adjusted according to the actual production scenario to ensure that it can accurately capture the real pressure change caused by steel leakage, while filtering out false pressure changes caused by interference factors such as vibration and instantaneous fluctuations of the air source 5. After obtaining the calculated pressure change rate each time, the control unit compares it with a preset change rate threshold in real time. If two consecutive calculated pressure change rates are both greater than or equal to the preset change rate threshold, it determines that a steel leakage has occurred in the continuous casting machine. This "two consecutive" judgment logic is designed to further improve the accuracy and anti-interference capability of steel leakage judgment, effectively eliminating the risk of misjudgment caused by single instantaneous interference (such as airflow fluctuations in the secondary cooling chamber 4, instantaneous sensor errors), and ensuring that an alarm is triggered only when the pressure exhibits a continuous and sudden steel leakage characteristic. At this time, the control unit immediately generates a standardized steel leakage alarm signal. This alarm signal can simultaneously trigger local audible and visual alarm devices (such as buzzers and warning lights) to issue an immediate reminder to on-site operators. At the same time, it transmits alarm information (including key parameters such as steel leakage judgment time, pressure change rate data, and acquisition cycle) to the continuous casting machine main control system and production monitoring center through the communication link. It can also output emergency control commands according to preset linkage logic, providing a reliable basis for subsequent rapid handling of steel leakage accidents and reduction of losses.

[0036] Optionally, such as Figure 2 and Figure 4As shown, the gas source control module 22 includes a second pressure relay 221, a pressure regulating valve 222, and a three-way valve 223. The first end of the three-way valve 223 is connected to the air inlet of the sensing pipeline 1 through the pressure regulating valve 222. The second end of the three-way valve 223 is provided with the second pressure relay 221. The third end of the three-way valve 223 is connected to one end of the second pipeline 24.

[0037] In this optional embodiment, the three-way valve 223, as the core component for gas flow diversion and connection, is made of pressure-resistant and corrosion-resistant metal material (such as stainless steel). It has three independent interface ends and an internal conductive design to ensure smooth gas flow. Its first end is fixedly connected to the inlet end of the pressure regulating valve 222 (which may be equipped with a pressure gauge for detecting the pressure inside the valve) through a sealing joint. The outlet end of the pressure regulating valve 222 is detachably sealed to the air inlet of the sensing pipeline 1. The pressure regulating valve 222 is an industrial-grade regulating valve with high-precision pressure regulation capability. Its core function is to accurately regulate and stabilize the pressure of the incoming gas source 5 according to the operating conditions of the continuous casting machine and the pressure requirements of the sensing pipeline 1, ensuring that the gas pressure output to the sensing pipeline 1 is always maintained within the preset optimal monitoring range. It also has a certain flow control capability to avoid affecting the pressure monitoring sensitivity due to excessively fast or slow gas flow rate. Furthermore, the internally integrated filter component can filter impurities and moisture in the gas source 5 to prevent clogging of the sensing pipeline 1 or damage to the pressure monitoring element. The second end of the tee 223 is fixedly installed with a second pressure relay 221 via a threaded connection or quick-connect fitting. This relay uses an industrial-grade pressure detection element that is compatible with the first pressure relay 21 and has the function of communicating with the control unit. Its core function is to collect the intake pressure data at the tee 223 in real time, that is, to monitor the air source pressure before the pressure regulating valve 222, forming a dual monitoring and feedback of the intake pressure. When the intake pressure is abnormally high or low, the second pressure relay 221 can transmit the pressure abnormality signal to the control unit in a timely manner, so that the control unit can issue an early warning or adjust the working state of the pressure regulating valve 222 in conjunction with the control unit to ensure the pressure stability of the air circuit system. The third end of the tee 223 is sealed to one end of the second pipeline 24 through a sealing joint, forming a complete air intake channel from the air source 5 to the tee 223, then to the pressure regulating valve 222 and the sensing pipeline 1. This connection method not only ensures the airtightness of the air circuit, but also facilitates the disassembly, maintenance and replacement of the various components of the air source control module 22 in the later stage. The entire air source control module 22 realizes the three major functions of pressure regulation of the air source 5, air intake pressure monitoring and stable air supply to the sensing pipeline 1 through the diversion design of the tee 223, providing a reliable air source 5 guarantee for the pressure monitoring accuracy and stability of the steel leakage monitoring system.

[0038] Optionally, such as Figure 2 and Figure 4As shown, the control unit is communicatively connected to the second pressure relay 221 and the pressure regulating valve 222. The control unit is also used to adjust the pressure regulating valve 222 according to the air supply pressure collected by the second pressure relay 221.

[0039] In this optional embodiment, the control unit serves as the core control hub of the entire steel leakage monitoring system. It establishes bidirectional data interaction connections with the second pressure relay 221 and the pressure regulating valve 222 through a stable and reliable industrial-grade communication link. The communication method can be selected as wired or wireless communication according to the on-site working conditions, and follows a standardized communication protocol to ensure the real-time performance, accuracy, and anti-interference of data transmission. It can receive the pressure data transmitted by the second pressure relay 221 in real time and issue precise adjustment control commands to the pressure regulating valve 222 to achieve closed-loop control of the gas supply pressure. The second pressure relay 221 collects the air supply pressure data at the three-way valve 223 in real time (i.e., the air source pressure before entering the pressure regulating valve 222), and transmits the collected pressure analog or digital signal to the control unit according to the preset collection frequency. This pressure data serves as the core feedback basis for air supply pressure regulation, and directly reflects the stability of the air source 5 input. After receiving the air supply pressure data, the control unit first compares it with the preset target air supply pressure range (determined through experimental calibration based on the monitoring sensitivity requirements of the sensing pipeline 1, the operating parameters of the second cooling chamber 4 of the continuous casting machine, and the characteristics of sudden changes in leakage pressure, for example, 0.3MPa to 0.6MPa) in real time, and analyzes the deviation value and deviation trend between the actual air supply pressure and the target pressure. When the actual gas supply pressure is detected to be higher than the target pressure upper limit, the control unit immediately sends a control command to the pressure regulating valve 222 to reduce the opening. By adjusting the valve core opening, the gas flow is reduced, thereby lowering the gas supply pressure to the target range. When the actual gas supply pressure is lower than the target pressure lower limit, the control unit sends a control command to increase the opening, increasing the gas flow to compensate for the pressure. If the gas supply pressure fluctuates, the control unit can also use a PID (proportional-integral-derivative) control algorithm to finely control the pressure regulating valve 222, correcting the valve opening in real time to ensure that the gas supply pressure remains stable within the preset range. This dynamic adjustment mechanism based on feedback from the second pressure relay 221 can effectively offset the impact of gas source pressure fluctuations and pipeline resistance changes on gas supply stability, ensuring that the gas pressure in the sensing pipeline 1 is in the optimal monitoring state. It avoids distortion of the pressure signal collected by the first pressure relay 21 due to abnormal gas supply pressure, thereby improving the accuracy and reliability of steel leakage detection, and extending the service life of components such as the pressure regulating valve 222 and the sensing pipeline 1.

[0040] Optionally, such as Figure 2 and Figure 4As shown, adjusting the pressure regulating valve 222 according to the gas supply pressure collected by the second pressure relay 221 includes: Obtain the current opening degree of the pressure regulating valve 222; The difference between the gas supply pressure and the preset gas supply pressure threshold is defined as the pressure deviation; Based on the current opening degree and the pressure deviation, the target opening degree is obtained through a preset adjustment relationship; The pressure regulating valve 222 is controlled to adjust the opening to the target opening.

[0041] Optionally, the adjustment relationship satisfies: K V =K B +K P ×△P; Among them, K V Let K be the target opening. B K represents the current opening degree. P The preset opening adjustment coefficient is ΔP, which represents the pressure deviation.

[0042] In this optional embodiment, during the gas supply pressure regulation process, the control unit first establishes communication with the position sensor or opening feedback module integrated with the pressure regulating valve 222 to obtain the actual opening data of the valve in real time (the opening value is expressed as a percentage or millimeter-level stroke, accurately reflecting the current position of the valve core and ensuring the accuracy of the regulation reference); then, the control unit compares the real-time gas supply pressure collected by the second pressure relay 221 with the preset gas supply pressure threshold (this threshold is the target pressure value calibrated based on the optimal monitoring pressure range of sensing pipeline 1, the characteristics of gas source 5, and the operating conditions of the secondary cooling chamber 4, including an upper limit threshold and a lower limit threshold, forming an allowable pressure fluctuation range) and defines the difference between the real-time gas supply pressure and the preset gas supply pressure threshold as the pressure deviation (if the real-time pressure is higher than the threshold, it is a positive deviation; if it is lower than the threshold, it is a negative deviation; the deviation value directly reflects the degree to which the gas supply pressure deviates from the target value); next, the control unit calls the preset regulation relationship (this regulation relationship is constructed based on PID control algorithm, linear regulation model, or nonlinear regulation formula fitted by a large amount of experimental data, fully considering the magnitude of the pressure deviation, Factors such as the current valve opening status, valve response speed, and gas source pressure inertia are considered to ensure the smoothness and accuracy of the adjustment process. The acquired current opening data and calculated pressure deviation are substituted into the adjustment relationship, and an algorithm is used to calculate the target opening adapted to the current operating conditions. For example, when the pressure deviation is positive and the current opening is large, the target opening will decrease proportionally; if the pressure deviation is negative and the current opening is small, the target opening will increase proportionally. Simultaneously, a maximum step size limit for opening adjustment is set to avoid sudden changes in valve opening causing drastic fluctuations in gas supply pressure. Finally... The control unit sends a target opening control command to the pressure regulating valve 222 via a communication link, driving the valve's actuator (electric actuator or pneumatic actuator) to precisely adjust the valve opening to the target opening position. At the same time, it receives the valve opening feedback signal in real time to verify whether the adjustment is in place. If there is a deviation, a secondary fine adjustment is performed, forming a closed-loop regulation process of "opening acquisition - deviation calculation - target setting - execution adjustment - feedback verification". This ensures that the gas supply pressure is quickly stabilized within the preset threshold range, providing a reliable guarantee for the pressure monitoring accuracy of the steel leakage monitoring system.

[0043] Optionally, such as Figure 2 and Figure 4 As shown, the system also includes a damping head 224. A through hole matching the damping head 224 is provided at the connection of the first end, the second end and the third end of the tee 223. The damping head 224 is disposed in the through hole.

[0044] In this optional embodiment, a damping head 224 is added to further optimize the airflow stability of the gas source control module 22 and reduce the impact of pressure fluctuations on monitoring accuracy. At the junction of the first end (connected to the pressure regulating valve 222), the second end (installed with the second pressure relay 221), and the third end (connected to the ball valve 25 of the air source 5) of the three-way valve 223, a through hole is pre-machined to match the outer dimensions and installation accuracy of the damping head 224. The through hole is opened along the axis of the core channel for airflow convergence and diversion inside the three-way valve 223. The diameter of the hole is interference-fitted or precision clearance-fitted with the outer diameter of the damping head 224 to ensure sealing and structural stability after installation. The damping head 224 is made of a material (such as engineering plastic, stainless steel, or ceramic) that is resistant to gaseous media corrosion and has a certain structural strength. Its shape is cylindrical or conical, and it has honeycomb, microporous, or spiral damping channels inside. The overall structure is compact and does not affect the normal airflow of each port of the three-way valve 223. The damping head 224 is fixed in the through hole by an embedded installation method. After installation, its two ends smoothly transition with the airflow channels inside the three-way valve 223 to avoid forming airflow dead angles or sudden changes in local resistance. The core function of the damping head 224 is to buffer, stabilize, and reduce noise in the airflow passing through the three-way valve 223. When the gas from the gas source 5 enters through the third end of the three-way valve 223, it must flow through the internal damping channel of the damping head 224 before being diverted to the first end (towards the pressure regulating valve 222) and the second end (towards the second pressure relay 221). This channel structure throttles and rectifyes the airflow, effectively reducing airflow impacts and pressure pulsations caused by instantaneous fluctuations in the gas source 5, valve actions, or pipeline vibrations. This makes the airflow velocity and pressure changes more stable, preventing false fluctuations in the gas supply pressure data collected by the second pressure relay 221 due to instantaneous airflow impacts. It also reduces the inertial impact of the airflow during the adjustment process of the pressure regulating valve 222, improving the stability and accuracy of pressure regulation. Furthermore, the tight fit between the damping head 224 and the through-hole ensures the overall airtightness of the gas path, preventing gas leakage, and facilitates later disassembly and maintenance. This further enhances the operational stability of the gas source control module 22 and provides additional structural protection for the pressure monitoring accuracy of the entire steel leakage monitoring system.

[0045] While the present invention has been disclosed above, its scope of protection is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention, and all such changes and modifications will fall within the scope of protection of the present invention.

Claims

1. A leak detection system for a continuous casting machine, characterized in that, The system includes a sensing pipeline (1), a monitoring unit (2), and a control unit. The sensing pipeline (1) is installed along the inner wall of the secondary cooling chamber (4) of the continuous casting machine. The air inlet and outlet of the sensing pipeline (1) extend out of the secondary cooling chamber (4) in the radial direction and are connected to the monitoring unit (2) located on the outer wall of the secondary cooling chamber (4). The control unit is communicatively connected to the monitoring unit (2) and is used to determine whether the continuous casting machine has experienced steel leakage based on the pressure change in the sensing pipeline (1) collected by the monitoring unit (2).

2. The continuous casting machine leakage monitoring system according to claim 1, characterized in that, The monitoring unit (2) includes a first pressure relay (21), a gas source control module (22), a first pipeline (23), a second pipeline (24), and a gas source ball valve (25). One end of the first pipeline (23) is provided with the first pressure relay (21), and the other end of the first pipeline (23) is connected to the outlet of the sensing pipeline (1). The inlet of the sensing pipeline (1) is connected to the outlet of the gas source control module (22). The inlet of the gas source control module (22) is connected to one end of the second pipeline (24), and the other end of the second pipeline (24) is connected to one end of the gas source ball valve (25). The other end of the gas source (5) inlet ball valve is used to connect to the gas source (5).

3. The continuous casting machine leakage monitoring system according to claim 2, characterized in that, The control unit is communicatively connected to the first pressure relay (21); the step of determining whether the continuous casting machine has experienced steel leakage based on the pressure change of the sensing pipeline (1) collected by the monitoring unit (2) includes: The steel leakage is determined based on the change in the sensing pipeline pressure collected by the first pressure relay (21). The sensing pipeline pressure is the pressure collected by the first pressure relay (21) based on a preset collection period.

4. The continuous casting machine leakage monitoring system according to claim 3, characterized in that, The step of determining whether the steel leakage has occurred based on the changes in the sensing pipeline pressure collected by the first pressure relay (21) includes: Based on the preset acquisition cycle, the current sensing pipeline pressure, and the previous sensing pipeline pressure, the corresponding pressure change rate is obtained through the preset pressure change rate relationship; If the pressure change rate is greater than or equal to the preset change rate threshold twice in a row, it is determined that the continuous casting machine has experienced steel leakage, and a steel leakage alarm is generated.

5. The continuous casting machine leakage monitoring system according to claim 4, characterized in that, The pressure change rate relationship satisfies: ； Where γ is the rate of change of pressure, P t For the pressure of the sensing pipeline currently described, P t-1 The pressure of the sensing pipeline mentioned above is T, which is the preset acquisition period.

6. The continuous casting machine leakage monitoring system according to claim 2, characterized in that, The gas source control module (22) includes a second pressure relay (221), a pressure regulating valve (222), and a three-way valve (223). The first end of the three-way valve (223) is connected to the air inlet of the sensing pipeline (1) through the pressure regulating valve (222). The second end of the three-way valve (223) is provided with the second pressure relay (221), and the third end of the three-way valve (223) is connected to one end of the second pipeline (24).

7. The continuous casting machine leakage monitoring system according to claim 6, characterized in that, The control unit is communicatively connected to the second pressure relay (221) and the pressure regulating valve (222). The control unit is also used to adjust the pressure regulating valve (222) according to the gas supply pressure collected by the second pressure relay (221).

8. The continuous casting machine leakage monitoring system according to claim 7, characterized in that, The adjustment of the pressure regulating valve (222) based on the gas supply pressure collected by the second pressure relay (221) includes: Obtain the current opening degree of the pressure regulating valve (222); The difference between the gas supply pressure and the preset gas supply pressure threshold is defined as the pressure deviation; Based on the current opening degree and the pressure deviation, the target opening degree is obtained through a preset adjustment relationship; The pressure regulating valve (222) is controlled to adjust the opening to the target opening.

9. The continuous casting machine leakage monitoring system according to claim 8, characterized in that, The adjustment relationship satisfies: K V =K B +K P ×△P; Among them, K V Let K be the target opening. B K represents the current opening degree. P The preset opening adjustment coefficient is ΔP, which represents the pressure deviation.

10. The continuous casting machine leakage monitoring system according to claim 6, characterized in that, It also includes a damping head (224), and a through hole matching the damping head (224) is provided at the connection of the first end, the second end and the third end of the tee (223), and the damping head (224) is disposed in the through hole.

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