Automatic molten iron tank sampling device and method based on liquid level detection and hydraulic cover breaking

Abstract

The invention discloses a molten iron tank automatic sampling device and method based on liquid level detection and hydraulic cover breaking, and belongs to the technical field of molten iron sampling in the ferrous metallurgy industry. The infrared liquid level monitoring module, the hydraulic cover breaking device, the automatic sampling mechanical arm, the train installation positioning module and the real-time feedback system are electrically connected with the central control unit. Wherein the infrared liquid level monitoring module is used for detecting the liquid level height of molten iron in a molten iron tank and the crusting condition of a tank opening in a non-contact manner; the hydraulic cover breaking device is used for breaking a tank opening crusting layer; the automatic sampling mechanical arm is used for adjusting the sampling depth according to the liquid level height and completing sampling; the train mounting and positioning module is used for calibrating the alignment precision of the sampling device and the molten iron tank opening; and the real-time feedback system is used for outputting sampling related information. The device is suitable for'one-tank one-taking 'automatic sampling, component analysis pretreatment and sampling process management and control before a train transports the molten iron tank to enter a steelmaking workshop.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of molten iron sampling in the steel metallurgy industry, and particularly relates to a molten iron tank automatic sampling device and method based on liquid level detection and hydraulic cover breaking. BACKGROUND

[0002] In the whole process of steelmaking production, the chemical composition analysis of molten iron is a key link connecting molten iron transportation and smelting process, and the analysis result directly determines core process parameters such as the addition proportion of scrap steel, the dosage of slagging agent and the smelting time control. At present, the sampling operation of the train transportation molten iron tank still faces many technical problems, and the traditional method and the existing equipment all have obvious deficiencies. The traditional sampling relies on manual operation of handheld tools at close range, the temperature of the molten iron tank mouth is usually as high as 600-800℃, and the operator needs to complete the actions of alignment, sampling and recovery in a high-temperature environment, which has great labor intensity and has serious safety hazards such as molten iron splashing and burning. At the same time, the manual sampling of a single tank usually takes more than 5 minutes, which is difficult to meet the production needs of the train transportation molten iron tank “fast entry, fast sampling and fast turnover”, and is easy to cause congestion at the entrance of the workshop.

[0003] During long-distance transportation and standing of the molten iron, a thick and uneven crust layer is easily formed on the surface due to temperature drop, and the manual sampling cannot accurately judge the thickness of the crust and the real liquid level of the molten iron. If the sampling does not penetrate the crust, it will lead to sampling failure; if the sampling position is close to the tank wall or the edge of the crust, the sample is easy to be oxidized, causing the composition detection result to be distorted. In addition, the sampling habits of different operators are quite different, the sampling depth and sampling amount are not uniform, which further affects the consistency of the composition data.

[0004] After manual sampling, the sample needs to be sent to the laboratory for detection, and the detection result can reach the steelmaking control center after being recorded manually, paper transmission or system input. The whole process takes at least 20-30 minutes. At the same time, the train driver cannot know the sampling state in time, and if there is sampling failure or invalid sample, the train needs to be rescheduled to return to the sampling point, which causes the subsequent smelting process to be delayed due to waiting for data, affecting the production continuity. SUMMARY

[0005] In order to solve the problems of low efficiency, poor sampling effect and safety hazards of manual sampling in the prior art, the present application provides a molten iron tank automatic sampling device and method based on liquid level detection and hydraulic cover breaking, which is suitable for automatic sampling, composition analysis preprocessing and sampling process control of “one tank one sampling” before the train transportation molten iron tank enters the steelmaking workshop, and can provide accurate molten iron composition basic data support for the adjustment of scrap steel ratio and the optimization of smelting parameters in the steelmaking process.

[0006] The application is based on the technical scheme of a molten iron tank automatic sampling device and method based on liquid level detection and hydraulic cover breaking, which comprises the following: The molten iron tank automatic sampling device based on liquid level detection and hydraulic cover breaking comprises a central control unit, and an infrared liquid level monitoring module, a hydraulic cover breaking device, an automatic sampling mechanical arm, a train installation positioning module and a real-time feedback system electrically connected with the central control unit.

[0007] The further improvement of the above technical scheme of the application is that the infrared liquid level monitoring module is installed above the tank mouth of the molten iron tank, can identify the position and thickness of the crust in real time, and the detection data is transmitted to the central control unit in real time.

[0008] The further improvement of the above technical scheme of the application is that the hydraulic cover breaking device comprises a hydraulic drive rod and a cover breaking head made of alloy material, and the extension and retraction action of the hydraulic drive rod is controlled by the central control unit according to the crust detection result.

[0009] The further improvement of the above technical scheme of the application is that the automatic sampling mechanical arm is provided with a protective telescopic structure, and a sampler is installed at the tail end, and the protective telescopic structure can control the mechanical arm to stop descending and retract when an abnormal resistance is detected.

[0010] The further improvement of the above technical scheme of the application is that the train installation positioning module comprises a bracket fixed beside the train track, and a position adjusting assembly is arranged on the bracket, which can adapt to molten iron tank cars and molten iron tanks of different sizes.

[0011] The further improvement of the above technical scheme of the application is that the central control unit is a PLC or an industrial computer, and a "one tank same" logic control program is built-in, which can realize accurate control of single sampling of a single molten iron tank.

[0012] The further improvement of the above technical scheme of the application is that the real-time feedback system comprises a large-screen display monitor and a wireless communication module, the large-screen display monitor is used for displaying the sampling state, the liquid level and the crust condition, and the wireless communication module is used for sending the sampling signal to the train driver terminal.

[0013] The molten iron tank automatic sampling method based on liquid level detection and hydraulic cover breaking uses the above sampling device, which comprises the following steps, S1, positioning: after the train stops in the station, the sampling device is calibrated with the position of the ladle opening through the train-mounted positioning module to ensure vertical centering; S2, liquid level and crust detection: the infrared liquid level monitoring module scans the ladle opening to obtain the liquid level height of the molten iron and the ladle opening crust condition and transmit them to the central control unit; S3, cap breaking judgment and processing: the central control unit judges whether there is a crust according to the detection result, and if there is a crust, controls the hydraulic cap breaking device to start, and the cap breaking head extends and then retracts after breaking the crust layer; S4, automatic sampling: the central control unit sends instructions to the automatic sampling mechanical arm according to the liquid level height, and the mechanical arm adjusts the depth of descent to complete sampling and then retracts; S5, sampling feedback: after successful sampling, the central control unit outputs a "sampling complete" signal through the real-time feedback system; if an abnormality is detected, an alarm is triggered and sampling is paused.

[0014] The further improvement of the above technical scheme of the present application is that in step S2, the infrared liquid level monitoring module obtains the distance of the molten iron liquid level from the ladle opening and the crust thickness through non-contact distance measurement, and when the crust thickness is >10mm, it is determined that there is a crust that needs to be processed.

[0015] The further improvement of the above technical scheme of the present application is that in step S4, the descent depth of the automatic sampling mechanical arm is determined according to the liquid level height, so that the sampler extends to a position 200-400mm from the liquid level; during the descent process, if the protective telescopic structure detects an abnormal resistance, the mechanical arm automatically stops and retracts.

[0016] Due to the adoption of the above technical scheme, the technical progress achieved by the present application includes: The present application replaces manual close-range operation through full-process automatic control, and the operator only needs to monitor the equipment operation in the remote control room, thereby fundamentally eliminating safety risks such as high-temperature burns. At the same time, the single-ladle sampling time of the entire device is shortened, the sampling efficiency is improved, the rapid turnover demand of the train molten iron ladle is met, and the waiting time for dispatching at the workshop entrance is reduced.

[0017] The infrared liquid level monitoring module of the present application can accurately detect the liquid level height of the molten iron and the position and thickness of the crust, and the central control unit accurately controls the action stroke and pressure of the hydraulic cap breaking device according to the detection result, ensuring that the crust is completely broken. The automatic sampling mechanical arm self-adaptively adjusts the sampling depth according to the liquid level height, so that the sampler always extends into the core area of the molten iron, effectively avoiding crust interference and sampling position deviation, and improving the accuracy of the composition detection result.

[0018] The real-time feedback system of the present application realizes double-channel information transmission through large-screen display monitor and driver terminal, so that the steelmaking control center can obtain the sampling state in real time, and can quickly complete the scrap ratio adjustment combined with subsequent rapid test data.

[0019] The position adjusting assembly of the train-mounted positioning module of the present application can be adapted to trains with different wheelbase and tank opening diameter, and the protective telescopic structure of the automatic sampling mechanical arm and the abnormal processing module form double protection, so that when encountering conditions such as unbroken crust and low liquid level, the equipment automatically stops and alarms, avoiding damage to the mechanical arm or splashing of molten iron, and reducing the equipment failure rate. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 Fig. 1 is a structural schematic diagram of the molten iron tank automatic sampling device based on liquid level detection and hydraulic cover breaking of the present application; Figure 2 Fig. 2 is a flowchart of the molten iron tank automatic sampling method based on liquid level detection and hydraulic cover breaking of the present application.

[0021] In the drawings: 1, infrared liquid level monitoring module; 2, hydraulic cover breaking device; 3, automatic sampling mechanical arm; 4, positioning module; 5, molten iron tank. DETAILED DESCRIPTION

[0022] In order to make the purpose, technical scheme and advantages of the present application more clear and obvious, the present application will be further described in detail below in combination with specific embodiments. In the following description, the description of known structures and technologies is omitted to avoid unnecessary confusion of the concept of the present application.

[0023] Example 1 The present embodiment provides a molten iron tank automatic sampling device based on liquid level detection and hydraulic cover breaking, which comprises a central control unit, an infrared liquid level monitoring module 1, a hydraulic cover breaking device 2, an automatic sampling mechanical arm 3, a train-mounted positioning module 4 and a real-time feedback system, and each module realizes data interaction and instruction transmission through industrial Ethernet or wireless communication module.

[0024] The central control unit is equipped with a 10-inch touch screen operation interface, and is internally provided with a "one tank same" logic control program, a data storage module and an abnormal processing algorithm. The input interface of the PLC receives the signals of each detection module, and the output interface is connected with the actuator, so that full-automatic control of the sampling process can be realized; the touch screen can display the device running parameters and sampling state in real time, and supports manual setting of the liquid level safety height, crust thickness threshold, cover breaking pressure and other parameters.

[0025] The infrared liquid level monitoring module 1 is installed at a position 1.2 m above the mouth of the molten iron tank 5 through an adjustable angle support, the detection range of the sensor is 0.1-10 m, the ranging accuracy is ±2 mm, and the sampling frequency is 10 Hz. The infrared liquid level monitoring module 1 is connected with the central control unit through a cable, can collect the distance data from the surface of the tank mouth to the molten iron liquid level in real time, and obtain the crust thickness (the distance difference from the surface of the tank mouth to the molten iron liquid level) and the liquid level height through PLC calculation, and transmit to the control program for logical judgment.

[0026] The hydraulic cover breaking device 2 is composed of a hydraulic station, a hydraulic drive rod, a cover breaking head and a pressure sensor. The hydraulic station can provide adjustable pressure of 0-20 MPa for the molten iron tank based on liquid level detection and hydraulic cover breaking; the stroke of the hydraulic drive rod is adjustable in the range of 0-200 mm, and the telescopic speed is 0.05-0.2 m / s; the cover breaking head is forged from GH2132 high-temperature resistant alloy, the head is conical structure, the cone angle of the cover breaking head is 60°, and the surface is sprayed with wear-resistant coating and can withstand high temperature above 1000℃. The pressure sensor is installed at the end of the hydraulic drive rod, which can monitor the cover breaking pressure in real time and feed back to the PLC, so as to ensure that the cover breaking pressure is in the set range.

[0027] The automatic sampling mechanical arm 3 adopts a six-axis mechanical arm, a tension sensor is installed at the telescopic joint of the automatic sampling mechanical arm 3, and a protective telescopic structure is formed; the end of the automatic sampling mechanical arm 3 is connected with a high-temperature stainless steel sampling spoon through a quick-change joint, and can be replaced with a spiral sampling drill bit according to the sampling requirement. The automatic sampling mechanical arm 3 communicates with the central control unit through a PROFINET bus, receives motion instructions and feeds back position signals.

[0028] The train installation positioning module 4 includes H-shaped steel fixed supports on both sides of the track, a laser positioning sensor and an electric adjustment platform. The supports are fixed to the ground through expansion bolts at the bottom; the laser positioning sensor is installed on the inner side of the support, which can detect the center position of the tank mouth of the train tank car, and the detection accuracy is ±1 mm; the electric adjustment platform can drive the infrared liquid level monitoring module 1, the hydraulic cover breaking device 2 and the automatic sampling mechanical arm 3 to move along the horizontal direction, so as to realize accurate alignment with the tank mouth.

[0029] Real-time feedback system: composed of an industrial-grade large screen display monitor, a 5G communication module and a driver terminal. The large screen monitor is installed in the operation room and connected with the PLC through Ethernet, which can display the parameters such as liquid level height, crust thickness, mechanical arm position, cover breaking pressure, sampling state in real time, support historical data query and fault alarm prompt; the 5G communication module is integrated in the PLC, which can send information such as sampling success / failure, abnormal alarm to the train driver's vehicle-mounted display screen or special mobile phone PP, and support the driver to feed back the confirmation information through the terminal.

[0030] Example two The embodiment provides an automatic sampling method for molten iron tank based on liquid level detection and hydraulic cover breaking, and comprises the following steps. S1, train enters station and is positioned: the train transporting the molten iron tank 5 drives into the sampling area of the entrance of the steelmaking workshop along the special track, the driver stops after the ground guide line, sends a "request sampling" signal to the central control unit through the vehicle terminal, and uploads the tank car number and tank car model. After receiving the signal, the central control unit starts the laser positioning sensor of the train installation positioning module 4, the sensor scans the tank mouth, and obtains the horizontal deviation data of the center of the tank mouth and the sampling device. According to the preset parameters of the tank car, the PLC sends an adjustment instruction to the electric adjustment platform, the platform drives the sampling device to move along the horizontal direction until the laser positioning sensor detects that the deviation is less than or equal to 5mm, and feeds back a "positioning ready" signal to the PLC after the positioning is completed.

[0031] S2, liquid level and crust detection: after receiving the positioning ready signal, the central control unit starts the infrared liquid level monitoring module 1, the sensor continuously scans the tank mouth for 10 times, removes the maximum value and the minimum value, and then takes the average value, calculates the distance between the tank mouth surface and the molten iron liquid level, and obtains the molten iron liquid level and the crust thickness in combination with the installation height of the tank mouth from the sensor. The detection data is transmitted to the PLC in real time, the PLC determines whether there is a crust layer that needs to be treated, and records the liquid level data for subsequent sampling depth calculation.

[0032] S3, cover breaking judgment and processing: the central control unit sends a start instruction to the hydraulic cover breaking device 2 according to the crust detection result, the hydraulic station starts and adjusts the pressure, and the hydraulic drive rod extends at a speed of 0.1m / s. When the cover breaking head contacts the crust layer, the pressure sensor detects that the pressure rises, the PLC controls the hydraulic drive rod to keep the pressure stable and continuously extend until the crust is broken, at which time the pressure sensor detects that the pressure drops sharply, and then the hydraulic drive rod is controlled to retract to the initial position at a speed of 0.15m / s. After the cover breaking is completed, a "cover breaking ready" signal is fed back to the PLC. If the pressure continuously exceeds the preset upper limit value during the cover breaking process and no pressure drop is detected, the PLC determines that the cover breaking fails, immediately controls the hydraulic drive rod to retract, triggers an alarm, and sends an abnormal prompt to the driver terminal.

[0033] S4, automatic sampling execution: after receiving the cover breaking ready signal, the central control unit calculates the sampling depth according to the liquid level data. The PLC sends a motion instruction to the automatic sampling mechanical arm 3, the automatic sampling mechanical arm 3 drives the sampling spoon to extend into the molten iron liquid level, the sampling spoon completes the scooping after the sampling spoon completes the scooping, the automatic sampling mechanical arm 3 retracts to the initial position at a speed of 0.3m / s, and the sample is poured into the special conveying pipeline through the turnover mechanism. The sample is sent to the laboratory through the pipeline. During the descending process, if the tension sensor detects that the resistance exceeds 250N (preset threshold value), the PLC immediately controls the mechanical arm to stop descending and quickly retract, triggers an "abnormal resistance" alarm, and avoids equipment damage.

[0034] S5, sample feedback and abnormality processing: after the central control unit confirms that the mechanical arm is reset and the sample has been sent into the conveying pipeline, it is determined that the sampling is successful, a "sampling completed, sample conveying" signal is sent to the large screen display monitor, the large screen display monitor displays a green prompt information; at the same time, the 5G communication module sends a "sampling success, please drive away" text and voice prompt to the driver's vehicle terminal, and the driver can start the train to leave the sampling area after confirming through the terminal. If the liquid level is detected to be lower than the safety height, the cover breaking fails or the mechanical arm resistance is abnormal during sampling, the PLC immediately triggers the red alarm light to flash and the buzzer to alarm, the large screen monitor displays the specific abnormal reason, and sends a "sampling abnormal, please wait for processing" prompt to the driver's terminal, the system locks the sampling action, and after the fault is manually checked and reset, the sampling process can be restarted.

[0035] In the above embodiment, the present application provides a molten iron tank automatic sampling device and method based on liquid level detection and hydraulic cover breaking. The present application replaces manual close-range operation with full-process automatic control, so that the operator only needs to monitor the equipment operation in the remote control room, thereby fundamentally eliminating safety risks such as high-temperature burns. At the same time, the single-tank sampling time of the whole set of device is shortened, the sampling efficiency is improved, the rapid turnover demand of the train molten iron tank is matched, and the waiting time at the workshop entrance is reduced. The infrared liquid level monitoring module of the present application can accurately detect the molten iron liquid level height and the position and thickness of the crust, and the central control unit accurately controls the action stroke and pressure of the hydraulic cover breaking device according to the detection result, so as to ensure that the crust is completely broken. The automatic sampling mechanical arm adjusts the sampling depth according to the liquid level height, so that the sampler always extends into the core area of the molten iron, effectively avoids the interference of the crust and the deviation of the sampling position, and improves the accuracy of the composition detection result. The real-time feedback system of the present application realizes double-channel information transmission through the large screen display monitor and the driver's terminal, so that the steelmaking control center can obtain the sampling state in real time, and can quickly complete the scrap steel ratio adjustment combined with the subsequent rapid test data. The position adjusting assembly of the train installation positioning module of the present application can adapt to train tank cars and molten iron tanks with different wheelbase and different tank opening diameters. At the same time, the protective telescopic structure and the abnormality processing module of the automatic sampling mechanical arm form double protection, so that the equipment automatically stops and alarms when encountering unbroken crust, too low liquid level and the like, thereby avoiding mechanical arm damage or molten iron splashing, and reducing the equipment failure rate.

[0036] The above-described embodiments are merely preferred embodiments of the present application, and do not limit the concept and scope of the present application. Various modifications and improvements to the technical solutions of the present application made by those skilled in the art without departing from the design concept of the present application shall fall within the protection scope of the present application, and the technical content claimed by the present application has been fully recorded in the claims.

Claims

1. An automatic sampling device for molten iron ladles based on liquid level detection and hydraulic lid breaking, characterized in that: It includes a central control unit, and an infrared liquid level monitoring module (1), a hydraulic cap-breaking device (2), an automatic sampling robotic arm (3), a train installation and positioning module (4), and a real-time feedback system that are electrically connected to the central control unit; wherein, the infrared liquid level monitoring module (1) is used for non-contact detection of the liquid level height of the molten iron ladle (5) and the crust formation at the ladle opening; the hydraulic cap-breaking device (2) is used to break the crust layer at the ladle opening; the automatic sampling robotic arm (3) is used to adjust the sampling depth according to the liquid level height and complete the sampling; the train installation and positioning module (4) is used to calibrate the alignment accuracy between the sampling device and the ladle opening (5); and the real-time feedback system is used to output relevant sampling information.

2. The automatic sampling device for molten iron ladle based on liquid level detection and hydraulic lid breaking as described in claim 1, characterized in that: The infrared liquid level monitoring module (1) is installed above the mouth of the molten iron ladle (5) and can identify the position and thickness of the crust in real time, and the detection data is transmitted to the central control unit in real time.

3. The automatic sampling device for molten iron ladle based on liquid level detection and hydraulic cap breaking as described in claim 1, characterized in that: The hydraulic shell-breaking device (2) includes a hydraulic drive rod and a shell-breaking head made of alloy material. The extension and retraction of the hydraulic drive rod is controlled by the central control unit based on the shell detection results.

4. The automatic sampling device for molten iron ladle based on liquid level detection and hydraulic lid breaking as described in claim 1, characterized in that: The automatic sampling robotic arm (3) is equipped with a protective telescopic structure and a sampler is installed at the end. The protective telescopic structure can control the robotic arm to stop descending and retract when abnormal resistance is detected. The sampler is a sampling spoon or a sampling drill bit.

5. The automatic sampling device for molten iron ladle based on liquid level detection and hydraulic lid breaking as described in claim 1, characterized in that: The train installation positioning module (4) includes a bracket fixed to the side of the train track, and the bracket is equipped with a position adjustment component that can adapt to different sizes of train tank cars and molten iron ladles (5).

6. The automatic sampling device for molten iron ladle based on liquid level detection and hydraulic lid breaking according to claim 1, characterized in that: The central control unit is a PLC or industrial computer with a built-in "one ladle, one sample" logic control program, which can realize precise control of single sampling of a single section of molten iron ladle (5); the central control unit is also equipped with an abnormality handling module, which triggers an alarm and controls the system to suspend sampling when the liquid level is detected to be lower than the sampling safety height or the lid is broken.

7. The automatic sampling device for molten iron ladle based on liquid level detection and hydraulic lid breaking as described in claim 1, characterized in that: The real-time feedback system includes a large-screen display monitor and a wireless communication module. The large-screen display monitor is used to display the sampling status, liquid level, and crust formation, while the wireless communication module is used to send sampling signals to the train driver's terminal.

8. An automatic sampling method for molten iron ladles based on liquid level detection and hydraulic lid breaking, characterized in that: Using the sampling device according to any one of claims 1-7, the method includes the following steps. S1. Positioning and alignment: After the train enters the station and stops, the position of the sampling device and the mouth of the molten iron ladle (5) is calibrated by the positioning module (4) installed on the train to ensure vertical alignment; S2, Liquid level and crust detection: Infrared liquid level monitoring module (1) scans the ladle opening, obtains the molten iron liquid level height and the crust situation at the ladle opening and transmits it to the central control unit; S3, Determination and handling of shell breakage: The central control unit determines whether there is shelling based on the detection results. If there is shelling, it controls the hydraulic shell breakage device (2) to start, and the shell breakage head extends out to break the shelling layer and then retracts. S4. Automatic sampling: The central control unit sends a command to the automatic sampling robotic arm (3) according to the liquid level. The robotic arm adjusts the descent depth to complete the sampling and then retracts. S5. Sampling Feedback: After successful sampling, the central control unit outputs a "sampling completed" signal through the real-time feedback system; if an abnormality is detected, an alarm is triggered and sampling is paused.

9. The automatic sampling method for molten iron ladles based on liquid level detection and hydraulic lid breaking according to claim 8, characterized in that: In step S2, the infrared liquid level monitoring module (1) obtains the distance between the molten iron surface and the mouth of the tank and the thickness of the crust through non-contact ranging. When the crust thickness is greater than 10 mm, it is determined that there is a crust that needs to be treated.

10. The automatic sampling method for molten iron ladles based on liquid level detection and hydraulic lid breaking as described in claim 8, characterized in that: In step S4, the descent depth of the automatic sampling robotic arm (3) is determined according to the liquid level, so that the sampler extends to a distance of 200-400 mm from the liquid level; during the descent, if the protective telescopic structure detects abnormal resistance, the robotic arm will automatically stop and retract.

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