Online dismounting and washing anti-blocking system and method for secondary cooling area branch pipeline of continuous casting machine

Abstract

The invention discloses a continuous casting machine secondary cooling area branch pipeline on-line dismounting and washing anti-blocking system and method, the system comprises shunting switching units, the shunting switching units and secondary cooling branch pipelines are connected in a one-to-one correspondence grouping mode, and the shunting switching units are detachably connected with the secondary cooling branch pipelines through quick mounting structures; the system further comprises a blockage state monitoring unit, and flow, thickness and temperature data collected by the blockage state monitoring unit are transmitted to the central control unit. The blockage state monitoring unit comprises an electromagnetic flowmeter, an ultrasonic thickness gauge and an infrared thermometer; the measurement precision of the electromagnetic flowmeter is + / -1%, the precision of the ultrasonic thickness gauge is larger than or equal to 0.01 mm, and the infrared thermometer can monitor the surface temperature fluctuation of the casting blank and trigger an alarm.

Description

Technical Field

[0001] This invention belongs to the field of maintenance technology for continuous casting equipment in the metallurgical industry, specifically relating to an online disassembly and cleaning anti-clogging system and method for branch pipelines in the secondary cooling zone of a continuous casting machine. Background Technology

[0002] In existing technologies, the secondary cooling chamber of a continuous casting machine is the core area for billet solidification, and its spray cooling system consists of a main pipeline, multiple branch pipelines, and nozzles. Existing technologies generally employ two methods: filter cleaning and chemical circulation cleaning. Filter cleaning can only intercept large particles of impurities and cannot solve the problem of rust and sludge deposits on the inner walls of the branch pipelines. Chemical cleaning requires stopping the machine to inject chemicals, which poses a risk of pipeline corrosion and has limited effectiveness against hardened scale.

[0003] Traditional maintenance only checks the filters. When producing more than 15 heats, the flow rate in the secondary cooling chamber generally decreases. The narrow structure of the branch pipe with an inner diameter of 8-15mm is prone to the accumulation of complex dirt (rust + grease + calcium and magnesium salts), which cannot be removed by conventional methods. The nozzle failure rate caused by blockage is more than 15%, which leads to defects such as uneven cooling of the billet and surface cracks.

[0004] In view of the above factors, an online disassembly and cleaning anti-clogging system and method for the branch pipes in the secondary cooling zone of a continuous casting machine is provided to solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide an online disassembly and cleaning anti-clogging system and method for the branch pipes in the secondary cooling zone of a continuous casting machine, so as to solve the problems mentioned in the background art.

[0006] The objective of this invention is achieved through the following technical solution: an online disassembly and cleaning anti-clogging system for the branch pipes in the secondary cooling zone of a continuous casting machine, comprising a diversion and switching unit, wherein the diversion and switching unit is connected to the secondary cooling branch pipes in a one-to-one correspondence, and the diversion and switching unit is detachably connected to the secondary cooling branch pipes through a quick-installation structure;

[0007] It also includes a blockage status monitoring unit, which collects flow rate, thickness, and temperature data and transmits them to the central control unit;

[0008] Furthermore, the blockage status monitoring unit includes an electromagnetic flowmeter, an ultrasonic thickness gauge, and an infrared thermometer;

[0009] The electromagnetic flowmeter has a measurement accuracy of ±1%, the ultrasonic thickness gauge has an accuracy of ≥0.01mm, and the infrared thermometer can monitor surface temperature fluctuations of the billet and trigger an alarm.

[0010] Furthermore, the blockage monitoring unit includes three monitoring components: one is an electromagnetic flowmeter at the inlet of the branch pipe to monitor flow changes in real time; the second is an ultrasonic thickness gauge on the outer wall of the pipe to infer the degree of blockage by the thickness of scale; and the third is an infrared thermometer at the nozzle outlet to automatically alarm when the cooling effect decreases and the surface temperature of the billet rises by ≥10℃.

[0011] Furthermore, the central control unit adopts a PLC + touch screen control system, which is linked with the main control system of the continuous casting machine to automatically adjust the flow rate of the backup branch according to the billet casting speed.

[0012] Furthermore, the diversion switching unit includes a main pipeline and an electric valve installed on the main pipeline;

[0013] The main pipeline is also equipped with a backup branch, and the backup branch is equipped with an electric valve.

[0014] Furthermore, the quick-release structure adopts a composite sealing structure of double ferrules and O-rings.

[0015] A method for online disassembly, cleaning, and anti-clogging of branch pipelines in the secondary cooling zone of a continuous casting machine includes the following steps:

[0016] The central control unit analyzes and monitors data to determine the level of blockage and groups it into categories; it opens the backup branch and adjusts the flow rate, and closes the main line electric valve to complete the switch; it disassembles the blocked branch and uses a differentiated cleaning plan to remove the blockage according to the level of blockage; after airtightness testing, it resets the branch and switches back to the main line; it records the data and predicts the next blockage time.

[0017] A method for online disassembly and cleaning of branch pipes in the secondary cooling zone of a continuous casting machine to prevent blockage. In the above steps, for mild blockage with a flow rate decrease of 10-15%, high-pressure water flushing of 5-10MPa is used; for moderate blockage of 15-30%, soaking with "high-pressure water + 5% compound descaling agent" is used; and for severe blockage ≥30%, synergistic cleaning with "20MPa reverse high-pressure water + ultrasonic vibration" is used.

[0018] An application of an online disassembly and cleaning anti-clogging system for branch pipes in the secondary cooling zone of a continuous casting machine is described, which is used for the maintenance of the cooling system in the secondary cooling zone branch pipes of a continuous casting machine under continuous production conditions.

[0019] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0020] This invention utilizes the interruption gap for modular disassembly of branch pipelines. Through the diversion and switching unit, the cooling of the cast billet is not affected during the disassembly and cleaning process, completely eliminating downtime maintenance losses. Differentiated cleaning schemes are adopted for different blockage levels, with a composite blockage removal rate of ≥98%, avoiding contamination and secondary blockage by blockage materials, and extending the unobstructed cycle of branch pipelines from 30 days to 180 days.

[0021] This invention provides precise monitoring and proactive early warning. It employs a three-way monitoring component to achieve real-time perception of blockage status, with a prediction accuracy rate of ≥95%. This transforms passive maintenance into proactive prevention, reducing the defect rate of cast billets caused by blockage. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall connection of the present invention;

[0023] Figure 2 This is a schematic diagram of the main pipeline of the present invention;

[0024] Figure 3 This is an enlarged schematic diagram of the secondary cooling branch pipeline of the present invention;

[0025] Figure 4 This is a schematic diagram of the connection of the central control unit of the present invention;

[0026] Figure 5 This is a schematic diagram of the backup branch of the present invention. Detailed Implementation

[0027] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0028] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0029] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0030] like Figure 1-5As shown, an online disassembly and cleaning anti-clogging system for the branch pipes in the secondary cooling zone of a continuous casting machine includes a diversion and switching unit 1. The diversion and switching unit 1 is connected to the secondary cooling branch pipes 2 in a one-to-one correspondence. The diversion and switching unit 1 is detachably connected to the secondary cooling branch pipes 2 through a quick-connect structure 3.

[0031] It also includes a blockage status monitoring unit 4, which collects flow rate, thickness, and temperature data and transmits them to the central control unit 5.

[0032] A pipeline filter and a bypass pipeline are installed on the diversion and switching unit 1. An electric valve and a filter are installed on the bypass pipeline, and the two are connected in series. The pipeline filter is a structure disclosed in the prior art.

[0033] To facilitate real-time monitoring of pipeline information during operation via the blockage monitoring unit, the blockage monitoring unit includes three monitoring components: one is an electromagnetic flowmeter 6 at the branch pipe inlet, which monitors flow changes in real time; the second is an ultrasonic thickness gauge 7 on the outer wall of the pipeline, which infers the degree of blockage based on the scale thickness; and the third is an infrared thermometer 8 at the nozzle outlet, which automatically alarms when the cooling effect decreases, causing the surface temperature of the cast billet to rise by ≥10℃. The infrared thermometer 8 uses a TP2306 non-contact infrared temperature sensor, which is fixed to the nozzle pipeline position by a bracket.

[0034] Among them, the ultrasonic thickness gauge 7 is installed in a distributed manner on the outer wall of the branch pipe. The installation method can be fixed by clamp binding. The ultrasonic thickness gauge 7 adopts the TCH-100 series high-precision ultrasonic thickness gauge, and the electromagnetic flow meter can be a general pipeline flow meter.

[0035] The electromagnetic flowmeter 6 has a measurement accuracy of ±1%, the ultrasonic thickness gauge 7 has an accuracy of ≥0.01mm, and the infrared thermometer 8 can monitor the surface temperature fluctuation of the billet and trigger an alarm.

[0036] To facilitate the control of pipeline flow and real-time monitoring of the central control unit 5 during operation, a PLC + touch screen control system is adopted. The central control unit 5 is linked with the main control system of the continuous casting machine and automatically adjusts the flow of the backup branch according to the billet casting speed.

[0037] The diversion and switching unit 1 includes a main pipeline 9 and an electric valve 10 installed on the main pipeline 9;

[0038] The main pipeline 9 is also equipped with a backup branch pipeline 11, and an electric valve is installed on the backup branch pipeline 11.

[0039] The inlet of the backup branch 11 is before the electric valve 10 of the main pipeline. The backup branch 11 is connected to each secondary cooling branch, and each backup branch 11 is equipped with an electric valve. The central control unit 5 is electrically connected to the electric valve. The backup branch 11 is connected to the main pipeline and the secondary cooling branch through a quick-connect structure (not shown in the figure). Electric valves are installed before and after the secondary cooling branch.

[0040] To facilitate quick assembly and disassembly during use, the quick-assembly structure 3 adopts a double ferrule and O-ring composite sealing structure. The quick-assembly structure 3 is a structure disclosed in the prior art and will not be described in detail here.

[0041] A method for online disassembly, cleaning, and anti-clogging of branch pipelines in the secondary cooling zone of a continuous casting machine includes the following steps:

[0042] The central control unit analyzes and monitors data to determine the level of blockage and groups it into categories; it opens the backup branch and adjusts the flow rate, and closes the main line electric valve to complete the switch; it disassembles the blocked branch and uses a differentiated cleaning plan to remove the blockage according to the level of blockage; after airtightness testing, it resets the branch and switches back to the main line; it records the data and predicts the next blockage time.

[0043] A method for online disassembly and cleaning of branch pipes in the secondary cooling zone of a continuous casting machine to prevent blockage. In the above steps, for mild blockage with a flow rate decrease of 10-15%, high-pressure water flushing of 5-10MPa is used; for moderate blockage of 15-30%, soaking with "high-pressure water + 5% compound descaling agent" is used; and for severe blockage ≥30%, synergistic cleaning with "20MPa reverse high-pressure water + ultrasonic vibration" is used.

[0044] An application of an online disassembly and cleaning anti-clogging system for branch pipes in the secondary cooling zone of a continuous casting machine is described, which is used for the maintenance of the cooling system in the secondary cooling zone branch pipes of a continuous casting machine under continuous production conditions.

[0045] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0046] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. An online disassembly and cleaning anti-clogging system for branch pipelines in the secondary cooling zone of a continuous casting machine, characterized in that: It includes a diversion switching unit (1), which is connected to the secondary cooling branch pipe (2) in a one-to-one correspondence. The diversion switching unit (1) is detachably connected to the secondary cooling branch pipe (2) through a quick-installation structure (3). It also includes a blockage monitoring unit (4), which collects flow rate, thickness and temperature data and transmits them to the central control unit (5).

2. The online disassembly and cleaning anti-clogging system for branch pipelines in the secondary cooling zone of a continuous casting machine according to claim 1, characterized in that: The blockage monitoring unit includes three monitoring components: one is an electromagnetic flowmeter (6) at the inlet of the branch pipe, which monitors the flow rate change in real time; the second is an ultrasonic thickness gauge (7) on the outer wall of the pipe, which infers the degree of blockage by the thickness of the scale; and the third is an infrared thermometer (8) at the nozzle outlet, which automatically alarms when the cooling effect decreases and the surface temperature of the billet rises by ≥10℃.

3. The online disassembly and cleaning anti-clogging system for branch pipelines in the secondary cooling zone of a continuous casting machine according to claim 2, characterized in that: The electromagnetic flowmeter (6) has a measurement accuracy of ±1%, the ultrasonic thickness gauge (7) has an accuracy of ≥0.01mm, and the infrared thermometer (8) can monitor the surface temperature fluctuation of the billet and trigger an alarm.

4. The online disassembly and cleaning anti-clogging system for branch pipelines in the secondary cooling zone of a continuous casting machine according to claim 3, characterized in that: The central control unit (5) adopts a PLC + touch screen control system. The central control unit (5) is linked with the main control system of the continuous casting machine and automatically adjusts the flow rate of the backup branch according to the billet casting speed.

5. The online disassembly and cleaning anti-clogging system for branch pipelines in the secondary cooling zone of a continuous casting machine according to claim 4, characterized in that: The diversion switching unit (1) includes a main pipeline (9) and an electric valve (10) installed on the main pipeline (9); The main pipeline (9) is also equipped with a backup branch pipeline (11), and an electric valve is installed on the backup branch pipeline (11).

6. The online disassembly and cleaning anti-clogging system for branch pipelines in the secondary cooling zone of a continuous casting machine according to claim 5, characterized in that: The quick-release structure (3) adopts a double ferrule and O-ring composite sealing structure.

7. A method for online disassembly, cleaning, and anti-clogging of branch pipelines in the secondary cooling zone of a continuous casting machine according to claim 6, characterized in that: Includes the following steps: The central control unit analyzes and monitors data to determine the level of congestion and groups and marks it; it opens the backup branch and adjusts the flow rate, and closes the main electric valve to complete the switching. Disassemble the blocked branch pipe and remove the blockage using a differentiated cleaning plan based on the level of blockage; after airtightness testing, reconnect the branch pipe and switch back to the main line; record the data and predict the next blockage time.

8. A method for online disassembly, cleaning, and anti-clogging of branch pipelines in the secondary cooling zone of a continuous casting machine according to claim 7, characterized in that: In the above steps, for mild blockage with a flow rate decrease of 10-15%, use 5-10MPa high-pressure water flushing; for moderate blockage with a flow rate decrease of 15-30%, use "high-pressure water + 5% compound descaling agent soaking"; and for severe blockage with a flow rate decrease of ≥30%, use "20MPa reverse high-pressure water + ultrasonic vibration" for synergistic cleaning.

9. An application of the online disassembly and cleaning anti-clogging system for branch pipelines in the secondary cooling zone of a continuous casting machine according to claim 8, characterized in that: The online disassembly and cleaning anti-clogging system for the branch pipes in the secondary cooling zone of the continuous casting machine is applied to the maintenance of the cooling system in the secondary cooling zone of the continuous casting machine under continuous production conditions.

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