Thermocouple self-diagnosis device for bleed-out prediction of continuous casting crystallizer and use method

Abstract

The invention discloses a thermocouple self-diagnosis device for forecasting breakout of a continuous casting crystallizer and a using method. The thermocouple self-diagnosis device comprises a base. The first end of the movable cross beam is arranged on the base; the first servo driving mechanism is arranged on the movable cross beam, and the movable cross beam is driven by the first servo driving mechanism to move in the X-axis direction of the base; the second servo driving mechanism is arranged at the second end of the movable cross beam, and the second servo driving mechanism can move in the Y-axis direction of the movable cross beam; the lifting mechanism is arranged on the second servo driving mechanism, the lifting mechanism can move along with the second servo driving mechanism, and the lifting mechanism can ascend and descend in the Z-axis direction; and the servo rotating mechanism is arranged at the second end of the lifting mechanism, and a high-frequency heater is arranged on the servo rotating mechanism. According to the invention, each thermocouple can be detected orderly, and the problem of missing or repeated detection possibly occurring in a traditional detection mode is avoided.

Description

Technical Field

[0001] This invention relates to the field of continuous steel casting, and in particular to a thermocouple self-diagnostic device for predicting steel leakage in a continuous casting crystallizer and its usage method. Background Technology

[0002] In current continuous casting steel production technology, a leak prediction system is widely used to prevent molten steel from sticking and leaking during the pouring process in the crystallizer. To improve the accuracy and stability of the leak prediction system, while ensuring the stability of the data acquisition and analysis system, it is essential to ensure the correct installation position of each thermocouple installed within the copper plate of the crystallizer. Simultaneously, it is crucial to ensure the proper placement of each thermocouple lead cable in the aviation cable connector and the stability of the transmitted electrical signal. Any misalignment or poor pin contact can lead to false alarms or missed alarms in the leak prediction system. Therefore, higher requirements are placed on the installation and maintenance of thermocouples in the offline crystallizer leak prediction system, ensuring both installation accuracy and that each thermocouple meets the requirements of the production process.

[0003] Currently, in offline maintenance, after the thermocouples are installed, the first step is to measure the resistance of each thermocouple in the cable socket to confirm that no thermocouple cables were damaged during installation. The second step is to use an acetylene torch to heat each thermocouple within the copper plate to confirm its accurate installation position. With 3 rows and 6 columns on each of the inner and outer arc copper plates of a crystallizer, plus 3 rows and 1 column on each of the east and west sides, it requires two people to simultaneously check 42 thermocouples, which takes a considerable amount of time. This work demands a certain level of precision and patience from the operators; errors are easily made by maintenance personnel who lack a sense of responsibility.

[0004] In the prior art, patent application number CN202010349356.1 discloses a crystallizer leakage prediction method based on image processing, including: acquiring the temperature of a temperature measuring point arranged on the crystallizer to be tested; acquiring a first three-dimensional spatial coordinate about the position and temperature of the temperature measuring point based on the two-dimensional plane coordinates of the temperature and position of the temperature measuring point; forming a second three-dimensional spatial coordinate about the position and temperature rise rate of the temperature measuring point corresponding to the temperature of the temperature measuring point; slicing the temperature dimension and the temperature rise rate dimension parallel to the two-dimensional plane coordinates with a preset standard temperature and a preset standard temperature rise rate, respectively, to obtain a temperature section and a temperature rise rate section; and issuing a warning according to a preset warning rule based on the occurrence of the temperature section and the temperature rise rate section and the change of the temperature section parameters. This invention can solve the problems of current leakage prediction algorithms having limitations due to bottlenecks in leakage false alarm rate and false alarm rate.

[0005] However, the performance of image processing alarm algorithms largely depends on the quality of the input image. Low-resolution images, images with noise, or images with distortion can severely impact the accuracy of the algorithm. Furthermore, harsh working conditions within factories can prevent the algorithm from correctly identifying target objects or events, leading to false alarms or missed alarms.

[0006] Therefore, it is necessary to improve such a structure to overcome the above-mentioned defects. Summary of the Invention

[0007] The purpose of this invention is to provide a thermocouple self-diagnostic device and method for predicting steel leakage in continuous casting molds, which solves the problem that existing image processing-based methods for predicting steel leakage in molds cannot correctly identify target objects or events, thus leading to false alarms or missed alarms.

[0008] The above-mentioned technical objective of this invention has been achieved by the following technical solutions:

[0009] A thermocouple self-diagnostic device for predicting steel leakage in a continuous casting crystallizer includes,

[0010] The base provides support and installation space.

[0011] The movable crossbeam has its first end set on the base, and the movable crossbeam slides with the base. The second end of the movable crossbeam extends outward from the base.

[0012] The first servo drive mechanism is disposed on the first end of the moving crossbeam. The first servo drive mechanism is used to provide driving force and drive the moving crossbeam to move along the X-axis of the base.

[0013] The second servo drive mechanism is disposed on the second end of the moving crossbeam. The second servo drive mechanism is used to provide driving force and can move along the Y-axis of the moving crossbeam.

[0014] The lifting mechanism has its first end mounted on the second servo drive mechanism. The lifting mechanism can move synchronously with the second servo drive mechanism and can move up and down along the Z-axis.

[0015] The servo rotation mechanism is located on the second end of the lifting mechanism. A high-frequency heater is installed on the rotating end of the servo rotation mechanism, and the high-frequency heater is driven by the servo rotation mechanism to achieve 360-degree rotation.

[0016] A further provision of the present invention includes:

[0017] The control cabinet has its output terminals electrically connected to the first servo drive mechanism, the lifting mechanism, the rotating mechanism, and the second servo drive mechanism, respectively. Control commands are sent through the control cabinet to control the opening or closing of the control devices.

[0018] A further provision of the present invention includes:

[0019] The relay switching circuit includes multiple intermediate relays, each of which is connected to the output terminal of the PLC controller. The PLC controller controls the on / off state of the relays.

[0020] A further feature of the present invention is that the PLC controller is a Siemens 1200 controller.

[0021] A further configuration of the present invention is that the high-frequency heater is connected to an external frequency converter, and the heating power of the heater is adjusted by changing the output frequency through the frequency converter.

[0022] A further feature of the present invention is that a plurality of thermocouple detection cables are provided on the control cabinet, and the thermocouple detection cables are electrically connected to an external thermocouple socket.

[0023] A method for using a thermocouple self-diagnostic device for predicting steel leakage in a continuous casting crystallizer includes the following steps:

[0024] A1: Detection path setting: Set the position of the thermocouple as the detection point, set the outermost detection point closest to the diagnostic device at the top as the detection start point, connect each detection point counterclockwise from the initial detection point to form the detection path, complete the initial preparation, set the detection start point to N=1, and start the detection;

[0025] A2: For the first test, move the high-frequency heater to the test start point, start the resistance test, test point 1, and determine whether the resistance value of the thermocouple is normal. If the resistance value test result is abnormal, output an abnormal record. If the resistance value test result is normal, proceed to the next step.

[0026] A3: Secondary detection: The thermocouple that has completed the resistance detection is tested by a high-frequency heater. If the temperature detection result is abnormal, an abnormal record is output. If the temperature detection result is normal, proceed to the next step.

[0027] A4: Perform resistance and temperature tests on each thermocouple sequentially according to the set detection path, output and record the detection status of each thermocouple, and increment the detection count by one for each completed test.

[0028] A5: Determine the progress of the testing process based on the number of tests. Check if the number of tests N is equal to 42. If N < 42, continue testing, and the number of tests N = N + 1. If N = 42, the testing process is complete, the testing ends, and the testing records are generated into a test report for output.

[0029] The temperature detection in step A3 includes the following steps:

[0030] B1: First, record the temperature when not heated. Then, set the temperature to 70℃, 100℃, 130℃, and 160℃ respectively, and then read and record the temperature detected by the thermocouple.

[0031] In summary, the present invention has the following beneficial effects:

[0032] 1. This device can systematically test each thermocouple through a pre-set detection path, avoiding the problems of omission or repeated testing that may occur in traditional testing methods.

[0033] 2. Dual Verification: The device employs both resistance and temperature detection for verification, enabling more accurate assessment of the thermocouple's operational status. Resistance detection can initially screen out faulty thermocouples, while temperature detection further verifies their performance, thereby reducing false alarms and missed alarms.

[0034] 3. Automated operation: The entire testing process is completed automatically by the equipment, which improves the accuracy and consistency of the testing, reduces the difficulty of operation, and improves the testing efficiency.

[0035] 4. High efficiency and convenience: The PLC controller precisely controls the on / off state of the relays, enabling the individual testing of thermocouples, which greatly shortens the testing time and improves work efficiency. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the structure of the present invention.

[0037] Figure 2 This is a schematic diagram of the process flow of the present invention.

[0038] Figure 3 This is a schematic diagram of the relay switching circuit of the present invention.

[0039] Numbering: Crystallizer 1, Thermocouple 2, First Servo Drive Mechanism 7, Moving Beam 4, Lifting Mechanism 5, Servo Rotation Mechanism 6, Second Servo Drive Mechanism 3, Control Cabinet 8, Base 9, High-Frequency Heater 10. Detailed Implementation

[0040] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below with reference to the figures and specific embodiments.

[0041] like Figures 1 to 3 As shown, the present invention proposes a thermocouple self-diagnostic device for predicting steel leakage in a continuous casting crystallizer, which includes a base 9, the base 9 being used for providing support and installation space;

[0042] The movable crossbeam 4 has its first end mounted on the base 9, and the movable crossbeam 4 is slidably engaged with the base 9. The second end of the movable crossbeam 4 extends outward from the base 9.

[0043] The first servo drive mechanism 7 is disposed on the first end of the moving crossbeam 4. The first servo drive mechanism 7 is used to provide driving force and drive the moving crossbeam 4 to move along the X-axis of the base 9.

[0044] The second servo drive mechanism 3 is disposed on the second end of the moving crossbeam 4. The second servo drive mechanism 3 is used to provide driving force and can move along the Y-axis of the moving crossbeam 4.

[0045] The lifting mechanism 5 has its first end mounted on the second servo drive mechanism 3. The lifting mechanism 5 can move synchronously with the second servo drive mechanism 3 and can move up and down along the Z-axis.

[0046] Servo rotation mechanism 6 is set on the second end of lifting mechanism 5. A high-frequency heater 10 is set on the rotating end of servo rotation mechanism 6. The high-frequency heater 10 is connected to an external frequency converter. The frequency converter adjusts the heating power of the heater by changing the output frequency. Servo rotation mechanism 6 drives high-frequency heater 10 to achieve 360-degree rotation.

[0047] The control cabinet 8 has its output terminals electrically connected to the first servo drive mechanism 7, the lifting mechanism 5, the rotating mechanism, and the second servo drive mechanism 3, respectively. Control commands are sent through the control cabinet 8 to control the opening or closing of the device.

[0048] This device heats the copper plate of the crystallizer to a given temperature using a high-frequency heater. After the device is started, it detects the thermocouples in sequence according to a predetermined path. First, the resistance value of the thermocouples is detected, and then the temperature is detected.

[0049] The specific usage process is as follows: When in use, place this device near crystallizer 1, adjust the width of crystallizer 1 to the maximum, and connect the thermocouple detection cable of the control cabinet to the crystallizer thermocouple sockets BX1-BX4. Start the detection process, and move the high-frequency heater to the outermost thermocouple 2 at the top by operating the moving beam, lifting mechanism and lifting mechanism through the control cabinet. Detect the thermocouple signal. After the signal detection, first record the temperature when not heated, and then set 70℃, 100℃, 130℃ and 160℃ respectively, and read and record the temperature detected by the thermocouple. After the single-point detection is completed, detect each thermocouple according to the preset position and generate a detection report.

[0050] It also includes a relay switching circuit. In this embodiment, a total of 43 intermediate relays, KA1-KA43, are provided. Each relay is connected to the output terminal of the PLC controller. The PLC controller controls the on / off state of the relays. During the detection process, only one relay among KA1-KA42 is in the energized state. When the corresponding relay is energized, the contacts are connected to the two ends of the thermocouple being tested, thereby realizing the detection of the thermocouple. In this process, the intermediate relay KA43 is used to switch the energized state of the relay when measuring the resistance value and the thermocouple temperature. Through the relay switching circuit, the PLC controller can accurately control the on / off state of each relay, thereby realizing the detection of each thermocouple. Preferably, the PLC controller is a Siemens 1200 controller.

[0051] A method for using a thermocouple self-diagnostic device for predicting steel leakage in a continuous casting crystallizer includes the following steps:

[0052] A1: Detection path setting: Set the position of the thermocouple as the detection point, set the outermost detection point closest to the diagnostic device at the top as the detection start point, connect each detection point counterclockwise from the initial detection point to form the detection path, complete the initial preparation, set the detection start point to N=1, and start the detection;

[0053] A2: For the first test, move the high-frequency heater to the test start point, start the resistance test, test point 1, and determine whether the resistance value of the thermocouple is normal. If the resistance value test result is abnormal, output an abnormal record. If the resistance value test result is normal, proceed to the next step.

[0054] A3: Secondary detection: The thermocouple that has completed the resistance detection is tested by a high-frequency heater. If the temperature detection result is abnormal, an abnormal record is output. If the temperature detection result is normal, proceed to the next step.

[0055] A4: Perform resistance and temperature tests on each thermocouple sequentially according to the set detection path, output and record the detection status of each thermocouple, and increment the detection count by one for each completed test.

[0056] A5: Determine the progress of the testing process based on the number of tests. Check if the number of tests N is equal to 42. If N < 42, continue testing, and the number of tests N = N + 1. If N = 42, the testing process is complete, the testing ends, and the testing records are generated into a test report for output.

[0057] The temperature detection in step A3 includes the following steps: B1: First, record the temperature when not heated, then set the temperature to 70℃, 100℃, 130℃, and 160℃ respectively, and then read and record the temperature detected by the thermocouple.

[0058] Existing image processing-based methods for predicting crystallizer leakage are easily affected by environmental factors such as light, temperature, and humidity, leading to a decline in image quality and thus affecting the accuracy of the prediction. Furthermore, image processing methods rely on the camera's viewing angle and coverage, resulting in blind spots or overlapping areas, which can lead to missed or false alarms.

[0059] Thermocouple self-diagnostic devices directly monitor thermocouple performance through resistance and temperature detection. Compared to image processing-based prediction methods, their detection results are more direct and accurate. Image processing can be affected by various factors such as lighting, camera resolution, and image algorithms, while physical detection directly reflects the thermocouple's operating status. This device can detect thermocouple resistance and temperature in real time, and immediately output an anomaly record upon detection, helping to take timely measures to prevent molten steel leakage accidents.

[0060] Image processing methods typically only identify leaks after they have occurred through image analysis, lacking preventative capabilities. By setting a detection path and sequentially detecting each thermocouple, this device can comprehensively cover all key monitoring points within the crystallizer, forming a systematic detection system. In contrast, image processing methods may be limited by the camera's angle of view and coverage, making comprehensive monitoring difficult.

[0061] This self-diagnostic device, through a pre-defined detection path, can systematically and orderly test each thermocouple, greatly improving detection efficiency. Dual verification through resistance and temperature detection allows for more accurate assessment of the thermocouple's operating status, reducing false alarms and missed alarms. The entire testing process is automated, minimizing manual intervention and improving accuracy and consistency. Regular thermocouple testing can promptly identify potential problems, preventing accidents such as steel leakage and enhancing production safety.

[0062] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "left," and "right," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this invention is in use, or the orientation or positional relationship commonly understood by those skilled in the art. These terms are used only for the convenience of describing this invention and for 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. Furthermore, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance. In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, terms such as "set" and "connect" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances. In this document, the terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, which includes not only the elements listed but also other elements not expressly listed.

[0063] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A thermocouple self-diagnostic device for predicting steel leakage in a continuous casting crystallizer, characterized in that, include, The base provides support and installation space. The movable crossbeam has its first end set on the base, and the movable crossbeam slides with the base. The second end of the movable crossbeam extends outward from the base. The first servo drive mechanism is disposed on the first end of the moving crossbeam. The first servo drive mechanism is used to provide driving force and drive the moving crossbeam to move along the X-axis of the base. The second servo drive mechanism is disposed on the second end of the moving crossbeam. The second servo drive mechanism is used to provide driving force and can move along the Y-axis of the moving crossbeam. The lifting mechanism has its first end mounted on the second servo drive mechanism. The lifting mechanism can move synchronously with the second servo drive mechanism and can move up and down along the Z-axis. The servo rotation mechanism is located on the second end of the lifting mechanism. A high-frequency heater is installed on the rotating end of the servo rotation mechanism, and the high-frequency heater is driven by the servo rotation mechanism to achieve 360-degree rotation.

2. The thermocouple self-diagnostic device for predicting steel leakage in a continuous casting mold according to claim 1, characterized in that, It also includes, The control cabinet has its output terminals electrically connected to the first servo drive mechanism, the lifting mechanism, the rotating mechanism, and the second servo drive mechanism, respectively. Control commands are sent through the control cabinet to control the opening or closing of the control devices.

3. The thermocouple self-diagnostic device for predicting steel leakage in a continuous casting mold according to claim 1, characterized in that, It also includes, The relay switching circuit includes multiple intermediate relays, each of which is connected to the output terminal of the PLC controller. The PLC controller controls the on / off state of the relays.

4. The thermocouple self-diagnostic device for predicting steel leakage in a continuous casting mold according to claim 3, characterized in that, The PLC controller used is a Siemens 1200 controller.

5. The thermocouple self-diagnostic device for predicting steel leakage in a continuous casting mold according to claim 1, characterized in that, The high-frequency heater is connected to an external frequency converter, which adjusts the heating power of the heater by changing the output frequency.

6. The self-diagnostic device for predicting steel leakage in a continuous casting mold according to claim 2, characterized in that, The control cabinet is equipped with multiple thermocouple detection cables, which are electrically connected to external thermocouple sockets.

7. The method of using the thermocouple self-diagnostic device for predicting steel leakage in continuous casting molds according to any one of claims 1-6, characterized in that, Includes the following steps: A1: Detection path setting: Set the position of the thermocouple as the detection point, set the outermost detection point closest to the diagnostic device at the top as the detection start point, connect each detection point counterclockwise from the initial detection point to form the detection path, complete the initial preparation, set the detection start point to N=1, and start the detection; A2: For the first test, move the high-frequency heater to the test start point, start the resistance test, test point 1, and determine whether the resistance value of the thermocouple is normal. If the resistance value test result is abnormal, output an abnormal record. If the resistance value test result is normal, proceed to the next step. A3: Secondary detection: The thermocouple that has completed the resistance detection is tested by a high-frequency heater. If the temperature detection result is abnormal, an abnormal record is output. If the temperature detection result is normal, proceed to the next step. A4: Perform resistance and temperature tests on each thermocouple sequentially according to the set detection path, output and record the detection status of each thermocouple, and increment the detection count by one for each completed test. A5: Determine the progress of the testing process based on the number of tests. Check if the number of tests N is equal to 42. If N < 42, continue testing. The number of tests N = N + 1. If N=42, the detection process is complete, the detection ends, and the detection records are generated into a detection report for output.

8. The method of using the thermocouple self-diagnostic device for predicting steel leakage in continuous casting molds according to claim 7, characterized in that, The temperature detection in step A3 includes the following steps: B1: First, record the temperature when not heated. Then, set the temperature to 70℃, 100℃, 130℃, and 160℃ respectively, and then read and record the temperature detected by the thermocouple.

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