A method, system, and storage medium for obtaining the liquid level state on the surface of a crystallizer.

Abstract

This invention discloses a method, system, and storage medium for obtaining the liquid level state on the surface of a crystallizer. The method includes the following steps: a driving mechanism drives a steel plate to descend vertically, inserting the steel plate into the liquid level to be detected within the crystallizer, entering an effective detection state, and the steel plate maintains a constant height for at least a first preset time period within this effective detection state; the driving mechanism drives the steel plate to rise vertically to a first preset height, detaching the steel plate from the medium within the crystallizer while ensuring no obstruction between the measuring surface and the image sensor; the image sensor acquires and analyzes images of the steel plate measuring surface at the first preset height. This invention achieves automated, standardized, precise, and comprehensive detection of the liquid level state in the crystallizer, improving the reliability and reference value of liquid level state parameter acquisition, and providing solid data support for the refined control of continuous casting processes.

Description

Technical Field

[0001] This invention relates to the field of steel production technology, and in particular to a method, system, and storage medium for obtaining the liquid level state on the surface of a crystallizer. Background Technology

[0002] As a core piece of equipment in the continuous casting production process, the liquid level inside the crystallizer directly affects the surface forming quality of the continuously cast billet and is a key factor determining the smoothness of the entire continuous casting production process. For example, the thickness of the slag layer and the data on liquid level fluctuations are important bases for controlling core process parameters such as the steel inlet speed, the amount of protective slag added, and the continuous casting speed.

[0003] Currently, the industry commonly uses the wire contact measurement method to obtain relevant state parameters of the liquid surface in the crystallizer. The core of this method is to insert a metal wire into the mixture of molten steel and protective slag within the crystallizer. Utilizing the temperature differences between the different media—molten steel, protective slag, and air—a characteristic temperature imprint is formed on the surface of the metal wire. Subsequently, the thickness of the liquid-slag layer within the crystallizer is indirectly obtained by manually measuring the dimensions of this imprint. However, the metal wire is a linear measuring component, only capable of measuring a single point on the liquid surface of the crystallizer. Using single-point measurement data to characterize the thickness of the planar distributed liquid-slag layer within the entire crystallizer results in data bias and randomness, significantly reducing the accuracy and reliability of the measurement results. Furthermore, the entire measurement operation relies on manual labor, and the high temperatures, dust, and limited space around the crystallizer reduce the comfort of the workers. After the initial measurement, manual re-measurement is still required, making the process cumbersome. Summary of the Invention

[0004] The present invention aims to at least solve one of the technical problems existing in the prior art. To this end, the present invention proposes a method, system, and storage medium for obtaining the liquid level state on the surface of a crystallizer.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A method for obtaining the liquid level state on the surface of a crystallizer includes the following steps: S1, a driving mechanism drives a steel plate to descend vertically, so that the steel plate extends into the liquid surface to be detected inside the crystallizer and enters an effective detection state. The surface of the steel plate in the effective detection state completely covers the height area of ​​the liquid level to be detected inside the crystallizer, and the steel plate maintains a constant height for at least a first preset time period in the effective detection state; S2, the driving mechanism drives the steel plate to rise vertically to a first preset height, so that the steel plate is removed from the medium inside the crystallizer and the measuring surface is unobstructed from the image sensor; S3, the image sensor acquires and analyzes images of the measuring surface of the steel plate at the first preset height, and obtains the liquid level state on the surface of the crystallizer based on the imprint features formed on the surface of the steel plate due to temperature and medium differences. The liquid level state includes at least the liquid slag layer thickness data and / or liquid level fluctuation data on the surface of the crystallizer.

[0006] Further, step S3 specifically includes: S31, removing impurities attached to the surface of the steel plate; S32, the image sensor acquiring an image of the steel plate measuring surface at a first preset height; S33, analyzing the acquired image to obtain boundary marking lines between different layers of the liquid surface; S34, obtaining liquid slag layer thickness data and / or liquid surface fluctuation data based on the upper and lower boundary marking lines corresponding to the liquid slag layer, wherein the liquid slag layer thickness data includes at least one of the average thickness value of the liquid slag layer, the maximum thickness value of the liquid slag layer, and the minimum thickness value of the liquid slag layer.

[0007] Further, step S1 specifically includes: S11, the driving mechanism drives the steel plate to descend to a preset minimum position, and the liquid surface to be detected inserted into the crystallizer enters the effective detection state; S12, after the steel plate maintains a constant height and remains in the effective detection state for a first preset time, the driving mechanism drives the steel plate to rise vertically a first preset distance, and the steel plate remains in the effective detection state after rising; S13, step S12 is executed repeatedly, so that the steel plate completes multiple fixed-height dwell detections at different heights in the effective detection state within the crystallizer.

[0008] Further, step S11 specifically includes: after the driving mechanism drives the steel plate to continuously descend to the second preset height at the first preset speed, it switches to driving the steel plate to continue descending to the preset lowest position at the second preset speed, where the first preset speed is higher than the second preset speed.

[0009] Furthermore, step S11 also includes: after the steel plate stays at the preset lowest position for a second preset time, the driving mechanism drives the steel plate to rise a first preset distance.

[0010] Further, step S3 specifically includes: S31, removing impurities attached to the surface of the steel plate; S32, the image sensor acquiring an image of the steel plate measuring surface at a first preset height; S33, analyzing the acquired image to obtain boundary imprint lines between different layers of the liquid surface; S34, dividing the boundary imprint lines into multiple groups according to the first preset distance and the distribution of the boundary imprint lines; S35, obtaining liquid slag layer thickness data and / or liquid surface fluctuation data for different groups of boundary imprint lines based on the upper and lower boundary imprint lines corresponding to the liquid slag layer, wherein the liquid slag layer thickness data includes at least one of the following: average liquid slag layer thickness value, maximum liquid slag layer thickness value, and minimum liquid slag layer thickness value.

[0011] Furthermore, the step of analyzing the acquired images to obtain the boundary imprint lines between different layers of the liquid surface specifically includes: comparing the currently acquired steel plate measurement surface image with a blank reference image and performing pixel-by-pixel grayscale value calibration; filtering out the boundary imprint lines that are remnants of the previous imprint in the calibrated image, and retaining only the fresh boundary imprint lines formed in the current measurement.

[0012] Furthermore, the removal of impurities adhering to the surface of the steel plate specifically includes: removing impurities adhering to the surface of the steel plate by nitrogen purging combined with high-temperature resistant brushing.

[0013] This invention also provides a system for obtaining the liquid level state on the surface of a crystallizer, including a driving mechanism, a steel plate, and an image sensor. The driving mechanism is used to drive the steel plate to descend vertically, so that the steel plate extends into the liquid surface to be detected inside the crystallizer and enters an effective detection state. In the effective detection state, the surface of the steel plate completely covers the height area of ​​the liquid level to be detected inside the crystallizer, and the steel plate maintains a constant height for at least a first preset time period in the effective detection state. The driving mechanism is also used to drive the steel plate to rise vertically to a first preset height, so that the steel plate is removed from the medium inside the crystallizer and the measuring surface is unobstructed from the image sensor. The image sensor performs image acquisition and analysis on the measuring surface of the steel plate at the first preset height, and obtains the liquid level state on the surface of the crystallizer based on the imprint features formed on the surface of the steel plate due to temperature and medium differences. The liquid level state includes at least the liquid-slag layer thickness data and / or liquid level fluctuation data on the surface of the crystallizer.

[0014] The present invention also provides a storage medium storing a computer program, which, when executed by a processor, implements the method for obtaining the liquid level state on the surface of a crystallizer.

[0015] The present invention has the following beneficial effects: Using a planar steel plate instead of a linear metal wire as the measuring component, a drive mechanism moves the steel plate to an effective detection state that completely covers the area of ​​the liquid surface to be measured. It then completes a standardized first-preset height-holding period, ensuring full contact between the steel plate and the molten steel and protective slag media, forming a clear and complete planar feature imprint. This eliminates the limitations and randomness of single-point measurements, improving the accuracy of slag layer thickness measurement. Furthermore, it simultaneously acquires slag layer thickness data and liquid surface fluctuation data through the planar imprint feature, solving the problem of single measurement parameters in traditional methods and meeting the need for comprehensive liquid surface status data for refined control in continuous casting processes. Simultaneously, the drive mechanism automates the lifting and lowering of the steel plate, replacing the manual control required in the high-temperature and harsh environment surrounding the crystallizer. The manual measurement operation not only improves the work experience of the staff and eliminates human error, but also ensures a uniform contact time between the steel plate and the medium through standardized fixed-height dwell control, avoiding the problems of insufficient and unclear imprint formation in traditional manual operations, thus laying a reliable foundation for subsequent data acquisition. In addition, raising the steel plate to a first preset height with no obstruction before image acquisition ensures the clarity of the acquired images. Combined with the automated analysis of imprint features by the image sensor, the accuracy and efficiency of liquid level state data acquisition are further improved. This allows the measurement results to provide effective basis for the control of core continuous casting processes such as protective slag addition and continuous casting speed, helping to improve the smoothness of the continuous casting production process and the quality of the continuously cast billet. It effectively solves the technical defects of traditional metal wire contact measurement methods, such as single-point measurement limitations, single parameter acquisition, large manual operation errors and harsh working environments, and non-standard imprint formation. It realizes automated, standardized, accurate and comprehensive detection of the liquid level state of the crystallizer, improves the reliability and reference value of liquid level state parameter acquisition, and provides solid data support for the refined control of the continuous casting process.

[0016] In addition to the objectives, features, and advantages described above, the present invention has other objectives, features, and advantages. The invention will now be described in further detail with reference to the figures. Attached Figure Description

[0017] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 This is a schematic diagram of the overall process of one embodiment of the method of the present invention; Figure 2 This is a detailed flowchart of step S1 of one embodiment of the present invention; Figure 3 This is a detailed flowchart of step S3 of one embodiment of the present invention; Figure 4 This is a schematic diagram of the boundary marking lines obtained on the surface of the steel plate according to the present invention; Figure 5 This is a schematic diagram of the overall structure of the measuring device; Figure 6 This is a partial structural diagram of the measuring device; Figure 7 This is a partial structural diagram of one state during the operation of the measuring device; Figure 8 This is a structural schematic diagram of the first transmission component; Figure 9 This is a partial structural schematic diagram of another embodiment of the measuring device.

[0018] Legend: Frame 100, guide sleeve 110, transmission box 120; Steel plate 200, guide rod 210, limit nut 211, transmission bar 220; Driver component 300; Transmission mechanism 400, first transmission component 410, first gear 411, centering disc 412, shift pin 413, notch 414, second transmission component 420, second gear 421, shift disc 422, shift bar 423, strip-shaped opening groove 424, arc groove 425, third transmission component 430, fourth transmission component 440, intermediate gear 450, output gear 460, transmission rack 461; Crystallizer 500. Detailed Implementation

[0019] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0021] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0022] Furthermore, the use of terms such as "first" and "second" in this invention is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed by this invention.

[0023] Please refer to Figure 1 A preferred embodiment of the present invention provides a method for obtaining the liquid level state on the surface of a crystallizer, comprising steps S1, S2 and S3.

[0024] S1, the driving mechanism drives the steel plate to descend vertically, causing the steel plate to extend into the liquid surface to be detected within the crystallizer, entering an effective detection state. In the effective detection state, the surface of the steel plate completely covers the height area of ​​the liquid surface to be detected within the crystallizer, and the steel plate maintains a constant height for at least a first preset time period during this effective detection state. That is, the effective detection state occurs when the lower end of the steel plate extends into the medium within the crystallizer and its edge is lower than the height area of ​​the liquid surface to be detected within the crystallizer.

[0025] S2, the driving mechanism drives the steel plate to rise vertically to the first preset height, so that the steel plate is separated from the medium in the crystallizer and the measuring surface is unobstructed from the image sensor.

[0026] S3, the image sensor acquires and analyzes images of the steel plate measuring surface at the first preset height, and obtains the liquid surface state of the crystallizer based on the imprint characteristics formed on the steel plate surface due to temperature and medium differences. The liquid surface state includes at least the liquid slag layer thickness data and / or liquid surface fluctuation data of the liquid surface of the crystallizer.

[0027] This invention provides a method for obtaining the liquid level state on the surface of a crystallizer. A planar steel plate replaces the linear metal wire as the measuring component. A driving mechanism moves the steel plate to an effective detection state that completely covers the area of ​​the liquid level to be detected. By maintaining a fixed height for a first preset time, the steel plate ensures full contact with the molten steel and protective slag media, forming a clear and complete planar feature imprint. This eliminates the limitations and randomness of single-point measurements, improves the accuracy of liquid slag layer thickness measurement, and simultaneously acquires liquid slag layer thickness data and liquid level fluctuation data through the planar imprint feature. This solves the problem of single measurement parameters in traditional methods and meets the need for comprehensive liquid level state data for refined control in continuous casting processes. Furthermore, the driving mechanism automates the lifting and lowering of the steel plate, replacing the crystallizer itself. The manual measurement operation in the harsh high-temperature environment improved the working experience of the staff, eliminated human error, and ensured uniform contact time between the steel plate and the medium through standardized height control. This avoided the problems of insufficient and unclear imprint formation in traditional manual operations, laying a reliable foundation for subsequent data acquisition. Furthermore, raising the steel plate to a first preset height with no obstructions before image acquisition ensured image clarity. Combined with automated analysis of imprint features by image sensors, this further improved the accuracy and efficiency of liquid level data acquisition. The measurement results provide effective basis for controlling core continuous casting processes such as slag addition and casting speed, contributing to improved stability and billet quality in continuous casting production. This method effectively solves the technical shortcomings of traditional wire contact measurement methods, such as limited single-point measurement, single parameter acquisition, large manual operation errors in harsh working environments, and non-standard imprint formation. It achieves automated, standardized, accurate, and comprehensive detection of the liquid level state in the crystallizer, improving the reliability and reference value of liquid level parameters and providing solid data support for the refined control of the continuous casting process.

[0028] In some embodiments of the present invention, step S3 specifically includes steps S31, S32, S33 and S34.

[0029] S31, removes impurities adhering to the surface of the steel plate.

[0030] S32, The image sensor acquires an image of the steel plate measuring surface at the first preset height; S33, Analyze the acquired image to obtain the boundary imprint lines between different layers of the liquid surface; S34. Based on the upper and lower boundary markings corresponding to the liquid slag layer, obtain the liquid slag layer thickness data and / or liquid surface fluctuation data. The liquid slag layer thickness data includes at least one of the average liquid slag layer thickness value, the highest liquid slag layer thickness value, and the lowest liquid slag layer thickness value. This step is for an embodiment where only one measurement and data acquisition is performed on the steel plate.

[0031] The image acquisition and analysis steps were refined and optimized, further improving the accuracy and reference value of the measurement data. First, impurities adhering to the steel plate surface were removed, eliminating obstruction and interference from impurities in image acquisition and ensuring the clarity and integrity of the acquired images. Image analysis accurately extracted the boundary markings of different liquid layers, providing precise and clear reference for calculating the thickness of the liquid slag layer. Based on the boundary markings, the average, maximum, and minimum thickness values ​​of the liquid slag layer were calculated, achieving multi-dimensional quantitative analysis of the liquid slag layer thickness. Compared to a single thickness value, this provides a more comprehensive and realistic reflection of the actual state of the liquid slag layer within the crystallizer, offering more detailed and specific data support for continuous casting process control.

[0032] Reference Figure 2 In a specific embodiment of the present invention, step S1 specifically includes steps S11, S12 and S13.

[0033] S11, the drive mechanism drives the steel plate down to the preset lowest position, and the liquid surface to be detected by the steel plate entering the crystallizer enters the effective detection state.

[0034] S12, after the steel plate maintains its height and remains in an effective detection state for a first preset time, the drive mechanism drives the steel plate to rise vertically a first preset distance, and the steel plate remains in an effective detection state after rising. S13, repeat step S12 multiple times to ensure the steel plate completes multiple fixed-height dwell tests at different heights under effective detection conditions within the crystallizer. The number of times step S12 is repeated can be preset or adaptively set based on the detected liquid level height in the crystallizer to avoid empty testing of the steel plate.

[0035] By performing multiple fixed-height dwell measurements at different heights, the steel plate forms multiple sets of characteristic imprints at varying heights within the crystallizer's liquid surface. This allows for the acquisition of multi-dimensional, multi-set liquid surface state measurement data, avoiding the randomness of single measurements and further improving the comprehensiveness and reliability of the measurement results. Furthermore, all multiple measurements are completed within the effective detection state, eliminating the need for repeated raising and lowering of the steel plate. This improves measurement accuracy while maintaining operational efficiency, preventing excessive time consumption due to multiple measurements. The measured data sets can be integrated, such as averaging the parameters obtained from multiple measurements to improve data accuracy.

[0036] In a specific embodiment of the present invention, step S11 specifically includes: after the driving mechanism drives the steel plate to descend continuously at a first preset speed to a second preset height, it switches to driving the steel plate to continue descending at a second preset speed to a preset minimum position, where the first preset speed is higher than the second preset speed. The steel plate first descends to the second preset height at a faster first preset speed, realizing the rapid feeding of the measuring component, effectively shortening the overall time of the steel plate descent, and ensuring the efficiency requirements of continuous testing in continuous casting production; after approaching the liquid surface, it switches to a lower second preset speed to continue descending to the preset minimum position, reducing the impact force when the steel plate inserts into the liquid surface, avoiding disturbance of the liquid surface in the crystallizer caused by the high-speed insertion of the steel plate, effectively maintaining the stable state of the liquid surface to be tested, eliminating the distortion of the imprint caused by violent fluctuations in the liquid surface, ensuring the authenticity and accuracy of the imprint formation, providing a stable and reliable liquid surface state basis for subsequent image acquisition and data analysis, and further improving the accuracy of the overall measurement results. While ensuring the efficiency of the measurement operation, the adverse effects of liquid surface disturbance on the measurement results are avoided. It can be understood that the first preset speed and the second preset speed are the average speeds of the steel plate during the corresponding lifting and lowering phases.

[0037] Furthermore, step S11 also includes: after the steel plate stays at the preset lowest position for a second preset time, the driving mechanism drives the steel plate to rise a first preset distance. By setting a second preset time stay at the preset lowest position, high-temperature self-cleaning and imprint pretreatment of the steel plate surface are achieved, fundamentally reducing the interference of historical measurement imprints on subsequent multiple fixed-height stay tests, and improving the independence and accuracy of multiple measurement data. The steel plate stays in the high-temperature medium environment at the preset lowest position in the crystallizer for a second preset time, which can fully heat and eliminate the residual previous measurement imprints on the steel plate surface with the high temperature of the molten steel, realizing the restoration of the surface state of the steel plate measurement surface. This ensures that each subsequent fixed-height stay test can form fresh and clear feature imprints on the clean steel plate surface, avoiding boundary identification errors caused by the overlap and mixing of historical imprints and fresh imprints. At the same time, this high-temperature recovery method does not require additional cleaning components, and relies on the high-temperature environment of the crystallizer itself to complete the pretreatment, simplifying the measurement process and equipment structure. While improving measurement accuracy, it also takes into account the practicality of the method and the convenience of operation, ensuring the validity and comparability of each set of data in multiple fixed-height stay tests. Furthermore, after the steel plate is driven to rise a first preset distance after the second preset duration of dwell time, the multiple imprint acquisitions in step S12 are started again to reduce the interference caused by the second preset duration of dwell time to subsequent measurements. It is understandable that, in order to reduce measurement errors, the imprint obtained after the second preset duration of dwell time (i.e., the imprint at the highest position of the steel plate) can be disregarded during measurement to improve the accuracy of the measurement.

[0038] Reference Figure 3 In some embodiments of the present invention, step S3 specifically includes steps S31, S32, S33, S34 and S35.

[0039] S31, removes impurities adhering to the surface of the steel plate.

[0040] S32, the image sensor acquires an image of the steel plate measuring surface at a first preset height.

[0041] S33, analyze the acquired image to obtain the boundary imprint lines between different layers of the liquid surface.

[0042] S34, based on the first preset distance and the distribution of the boundary imprint lines, divide the boundary imprint lines into multiple groups.

[0043] S35. Based on the upper and lower boundary imprints corresponding to the liquid slag layer, obtain liquid slag layer thickness data and / or liquid surface fluctuation data for different sets of boundary imprints. The liquid slag layer thickness data shall include at least one of the following: average liquid slag layer thickness, maximum liquid slag layer thickness, and minimum liquid slag layer thickness.

[0044] The imprint lines are grouped according to the distribution of the boundary imprint lines based on a first preset distance. This allows for precise correspondence with the detection positions where the steel plate repeatedly stops at a fixed height, enabling independent analysis of multiple sets of detection data and obtaining the liquid slag layer thickness data corresponding to each group of imprints. For example, if the first preset distance is 15cm, the imprint lines are grouped according to this spacing. Figure 4 As shown, there are 6 sets of boundary marking lines, and different sets of boundary marking lines can be clearly divided according to a first preset distance.

[0045] It is understandable that liquid surface fluctuation data includes at least one of the following: liquid surface reference height value, maximum liquid surface fluctuation value, average liquid surface fluctuation amplitude, and range of liquid surface fluctuation amplitude. Typically, the length and width of the steel plate can be used as the two axes of a two-dimensional coordinate system, with the length as the horizontal axis and the width as the vertical axis. The thickness of the liquid slag layer at a given point can be obtained by taking points on the horizontal axis and measuring the distance between the upper and lower boundary lines of the liquid slag layer (the boundary line between the molten steel and the liquid slag layer, and the boundary line between the liquid slag layer and the sintered slag layer). By taking multiple points, the average thickness of the liquid slag layer can be obtained. Of course, when a sufficient number of points are taken, the largest thickness can be selected as the highest liquid slag layer thickness, and the smallest as the lowest. A point spacing can usually be set to take a series of points on the horizontal axis, and the average, highest, and lowest liquid slag layer thickness values ​​can be obtained from the liquid slag layer thickness data of this series of points. The reference height of the liquid surface can be obtained by taking multiple points along the boundary marking line between the molten steel and the slag layer, calculating the average height of the multiple points as the reference height of the liquid surface, and then obtaining the average amplitude of the liquid surface fluctuation based on the difference between the actual height of each point and the reference height of the liquid surface. The highest and lowest values ​​are selected from the actual heights of all points as the maximum and minimum values ​​of the liquid surface fluctuation, and the difference between the highest and lowest values ​​is taken as the range of the liquid surface fluctuation amplitude.

[0046] In some embodiments of the present invention, analyzing the acquired images to obtain boundary imprint lines between different layers of the liquid surface specifically includes: comparing the currently acquired image of the steel plate measurement surface with a blank reference image and performing pixel-by-pixel grayscale value calibration; filtering out boundary imprint lines that are remnants from the previous measurement in the calibrated image, and retaining only the fresh boundary imprint lines formed in the current measurement. It can be understood that by comparing the obtained boundary imprint lines with the previously obtained boundary imprint lines, it is possible to identify which imprint lines are remnants, and then filter out the remnant imprint lines.

[0047] Understandably, as a standard technical approach, image analysis involves preprocessing the image, including grayscale conversion, noise reduction, and edge enhancement of the acquired steel plate image. Gaussian filtering is used to eliminate image noise, and the Sobel operator is used to enhance the grayscale boundaries of the imprints, making the imprint boundaries clearer. An adaptive threshold segmentation algorithm is then used to divide the steel plate image into three imprint regions—a first imprint region, a second imprint region, and a third imprint region—by setting a grayscale threshold and automatically identifying the boundaries between them.

[0048] Understandably, residual marks are usually lighter in color and clearly distinguishable from fresh marks, which can be used as a basis for residual mark removal. First, the dynamic grayscale threshold of the detection image is calculated using the Otsu's method (OTSU) to distinguish between high-contrast fresh marks and low-contrast residual marks. Then, areas with grayscale values ​​below the dynamic threshold are marked as suspected residual areas, and a residual mask is generated. The residual mask areas are filled with background grayscale values, while fresh mark areas above the dynamic threshold are preserved, completing the digital removal of light-colored residual marks. Finally, local grayscale smoothing is performed on the processed image to eliminate pixel transition traces after mask processing, ensuring the overall continuity of the image.

[0049] Understandably, before the steel plate is used for the first time, an image of the brand-new steel plate without any markings is acquired to obtain a blank reference image. The grayscale value and pixel features of this image are stored in the image analysis system as a benchmark comparison template for subsequent removal of residual markings. The currently acquired steel plate measurement surface image is compared with the blank reference image, and pixel-by-pixel grayscale value calibration is performed. Specifically, the grayscale value of the steel plate measurement surface image acquired this time (denoted as the detection image) is calibrated pixel-by-pixel with the blank reference image. The grayscale difference between each pixel in the detection image and the corresponding pixel in the blank reference image is calculated, and this difference is normalized to make the background grayscale value of the detection image consistent with that of the blank reference image, thereby eliminating the residual background color difference (such as the grayscale deviation of light-colored oxide shadows) caused by the previous markings from the root.

[0050] The extraction process of the boundary imprint lines of the liquid surface layer was precisely processed, eliminating errors at the source of image analysis and further improving the reliability of the measurement data. Comparing the currently acquired image with a blank reference image and performing pixel-by-pixel grayscale calibration effectively eliminated interference from factors such as color differences on the steel plate surface, improving image consistency and analyzability. Filtering out residual imprints from the previous measurement in the calibrated image, retaining only the fresh boundary imprint lines formed in the current measurement, avoids boundary line identification errors caused by overlap between residual and fresh imprints, ensuring the accuracy of boundary imprint line extraction, fundamentally reducing errors in the image analysis process, and guaranteeing the accuracy of the final measurement data.

[0051] In a specific embodiment of the present invention, removing impurities adhering to the surface of the steel plate specifically includes: removing impurities adhering to the surface of the steel plate by nitrogen purging combined with high-temperature resistant brushing. By using nitrogen purging in conjunction with high-temperature resistant brushing, the nitrogen purging can quickly blow away light impurities such as slag and dust from the surface of the steel plate, while the high-temperature resistant brush can sweep away stubborn impurities adhering to the surface of the steel plate. The combination of the two achieves the removal of impurities from the surface of the steel plate, ensuring the clarity of image acquisition; at the same time, the brush material cannot damage the measurement surface of the steel plate, preventing damage to the fresh imprint formed in the current measurement and ensuring the integrity of the imprint features.

[0052] Of course, in some other embodiments, removing impurities attached to the surface of the steel plate can be achieved simply by purging with nitrogen, which can still effectively ensure the accuracy of subsequent image analysis.

[0053] The present invention also provides a system for obtaining the liquid level state on the surface of a crystallizer, including a driving mechanism, a steel plate, and an image sensor; the driving mechanism is used to drive the steel plate to descend vertically, so that the steel plate extends into the liquid level to be detected in the crystallizer and enters an effective detection state, wherein the surface of the steel plate in the effective detection state completely covers the liquid level height area to be detected in the crystallizer, and the steel plate maintains a constant height for at least a first preset time period in the effective detection state; the driving mechanism is also used to drive the steel plate to rise vertically to a first preset height, so that the steel plate is removed from the medium in the crystallizer and the measuring surface is kept unobstructed from the image sensor; the image sensor performs image acquisition and analysis on the measuring surface of the steel plate at the first preset height, and obtains the liquid level state on the surface of the crystallizer based on the imprint features formed on the surface of the steel plate due to temperature and medium differences, wherein the liquid level state includes at least the liquid-slag layer thickness data and / or liquid level fluctuation data on the surface of the crystallizer. It replaces the traditional manual measurement method, eliminating the need for staff to work in the high-temperature and harsh environment around the crystallizer, effectively improving the work experience of the staff; each component performs standardized actions according to the preset program, realizing the standardization of the measurement process, eliminating measurement errors caused by the subjectivity and randomness of manual operation, and improving the consistency and accuracy of measurement results; at the same time, the automated measurement process shortens the time of a single measurement, improves the overall efficiency of crystallizer liquid level detection, and can meet the continuous detection needs of steel continuous casting production.

[0054] The present invention also provides a storage medium storing a computer program, which, when executed by a processor, implements a method for obtaining the liquid level state on the surface of a crystallizer.

[0055] The following reference Figures 5 to 8 One embodiment of the measuring device for implementing this method will be described.

[0056] The measuring device includes a frame 100, a steel plate 200, a drive assembly 300, and a transmission mechanism 400. The frame 100 is equipped with a guide sleeve 110. The steel plate 200 can move up and down relative to the frame 100. The steel plate 200 is equipped with a guide rod 210 that cooperates with the guide sleeve 110. The guide sleeve 110 and the guide rod 210 cooperate to guide the up and down movement of the steel plate 200 relative to the frame 100. The drive assembly 300 is mounted on the frame 100. The transmission mechanism 400 is connected to the drive assembly 300 and the steel plate 200 to transmit power to the steel plate 200 and drive its up and down movement. This achieves automated drive for the up and down movement of the steel plate 200, replacing the manual measurement method in the prior art. It eliminates the need for operators to manually perform measurement actions in the high-temperature and harsh working environment around the crystallizer 500, effectively improving the operator's work experience. The upper end of the guide rod 210 is equipped with a threaded shaft, on which a limit nut 211 is threadedly connected. The position can be adjusted by turning the limit nut along the threaded shaft to precisely limit the descent limit of the steel plate 200, and also prevent the guide rod 210 from falling off the guide sleeve 110.

[0057] The transmission mechanism 400 includes a first transmission component 410, a second transmission component 420, a third transmission component 430, and a fourth transmission component 440. A transmission box 120 is provided on the frame 100, and the first and second transmission components 410 and 420 are rotatably mounted in the transmission box 120, providing some protection for the core transmission components. The third and fourth transmission components 430 and 440 are connected to the steel plate 200 to move synchronously with it. The first transmission component 410 is connected to the drive assembly 300 to obtain power. The first transmission component 410 and the second transmission component 420 are in a transmission cooperation, so that the continuously moving first transmission component 410 can drive the second transmission component 420 to move intermittently. The steel plate 200 has a measuring state and a continuously rising and falling state; the steel plate 200 in the measuring state is lower than the steel plate 200 in the continuously rising and falling state. When the steel plate 200 is in the continuously rising and falling state and has descended to its lowest position, the lowest point of the steel plate 200 is already immersed in the molten steel. During measurement, the first transmission component 410 disengages from the third transmission component 430, while the second transmission component 420 engages with the fourth transmission component 440 to drive the steel plate 200 up and down. This allows the continuously moving first transmission component 410 to drive the steel plate 200 in intermittent up-and-down motion. During continuous up-and-down motion, the second transmission component 420 disengages from the fourth transmission component 440, while the first transmission component 410 engages with the third transmission component 430 to drive the steel plate 200 in continuous up-and-down motion. In other words, the engagement of the first transmission component 410 with the third transmission component 430 and the engagement of the second transmission component 420 with the fourth transmission component 440 are alternated, thus achieving different operational characteristics at different stages. The system enables flexible switching between the measurement state and the continuous lifting state of the steel plate 200. In the measurement state, the steel plate 200 is in an effective detection state. The intermittent lifting and lowering of the steel plate 200 in the measurement state means that the measuring steel plate rises a certain distance and then stops for a period of time, which is enough to complete one imprint formation. Then it rises a certain distance again and stops for a period of time, thus forming multiple sets of imprints at different heights on the surface of the steel plate. This allows the measuring steel plate inserted into the liquid surface to complete multiple liquid surface contacts and form multiple sets of characteristic imprints, further enriching the measurement data, avoiding the randomness of a single measurement, and improving the comprehensiveness and accuracy of the measurement results.

[0058] A transmission bar 220 is provided at the upper middle part of the steel plate 200. The third transmission component 430 is a first rack provided on the transmission bar 220, and the fourth transmission component 440 is a second rack provided on the transmission bar 220. It can be understood that the transmission bar 220, the first rack, and the second rack are integral structural components. The first transmission component 410 includes a first gear 411 that meshes with the first rack, and the second transmission component 420 includes a second gear 421 that meshes with the second rack. It can be understood that the transmission between the gear and the rack can be direct meshing or indirect meshing through an intermediate transmission gear. In this embodiment, the second gear 421 and the second rack (fourth transmission component 440) are directly meshed, and the transmission between the first gear 411 and the first rack (third transmission component 430) is through an intermediate gear 450. The disengagement of the first gear 411 from the first rack (third transmission component 430) means that the intermediate gear 450 disengages from the first rack (third transmission component 430). A transmission bar 220 is set in the middle of the steel plate 200, and the third transmission component is set as the first rack and the fourth transmission component is set as the second rack. The first transmission component is set as the first gear 411 and the second transmission component is set as the second gear 421. The meshing transmission between the gear and the rack makes the power transmission smoother and more precise, and can accurately control the lifting stroke and speed of the measuring steel plate, ensuring that the displacement of each lifting is consistent during intermittent lifting and ensuring the consistency of multiple measurements.

[0059] Specifically, the first transmission component 410 includes a centering disk 412 coaxially fixed with the first gear 411. The outer periphery of the centering disk 412 is smaller than that of the first gear 411. A shift post 413 located on the outer periphery of the centering disk 412 is provided on the side of the first gear 411 facing the centering disk 412. The second transmission component 420 includes a dial 422 coaxially fixed with the second gear 421. A plurality of shift bars 423 are evenly arranged around the outer periphery of the dial 422. The shift bars 423 are provided with strip-shaped opening slots 424. The dial 422 has a centering disk between adjacent shift bars 423. The centering disc 412 has an arc groove 425 that fits its contour, and a notch 414 is provided on the peripheral wall of the centering disc 412. The first transmission member 410 has a mating state and an idle state. In the mating state, the lever 423 is inserted into the notch 414, and the lever 413 on the first transmission member 410 is inserted into the strip-shaped opening groove 424 and can drive the second transmission member 420 to rotate. At this time, the first transmission member 410 rotates, and because the lever 413 is inserted into the strip-shaped opening groove 424, it can drive the second transmission member 420 to rotate until the lever 413 disengages from the strip-shaped opening groove 424, and then enters the idle state, such as... Figure 7As shown, at this time, the shift post 413 is about to disengage from the strip-shaped opening slot 424, and the centering disk 412 and the arc groove 425 are centering and engaged, which is at the transition position between the two states. It can also be seen that at this time, it is also at the transition position between the measurement state and the continuous lifting state. At this time, the lowermost tooth of the second rack (fourth transmission component 440) is driven upward by the second gear 421 and is about to disengage from the transmission of the second gear 421; while the uppermost tooth of the first rack (third transmission component 430) has entered the range of motion of the first gear 411 and is about to be driven upward by the first gear 411. Of course, at this time, there is still a certain gap between the uppermost tooth of the first rack (third transmission component 430) and the outer tooth of the first gear 411 to provide a certain clearance margin, so that some clearance redundancy is left when the two states alternate, so as to avoid structural interference or jamming when the state is switched due to the design being too compact. In addition, from the moment the pusher 413 enters the strip-shaped opening groove 424 until it leaves the strip-shaped opening groove 424, although the rotational speed of the pusher 413 remains constant, the rotational speed of the driven second transmission component 420 is indeed constantly changing. The rotational speed of the driven second transmission component 420 gradually increases to its peak and then gradually decreases to zero, so that the speed of the measuring steel plate in the measurement state changes gradually during the rising process. This can effectively avoid the additional fluctuations in the liquid surface caused by the instantaneous high-speed start and stop of the steel plate, which would affect the measurement or damage the liquid surface state.

[0060] In the idling state, the centering disk 412 and the arc groove 425 are engaged in centering to achieve circumferential limiting of the second transmission component 420. At this time, since the shift pin 413 is disengaged from the strip-shaped opening groove 424, the rotation of the first transmission component 410 will not drive the rotation of the second transmission component 420. In addition, the centering disk 412 and the arc groove 425 further restrict the rotational freedom of the second transmission component 420. Only when the shift pin 413 re-enters the strip-shaped opening groove 424 can the second transmission component 420 be rotated again. By intermittently rotating the second transmission component 420, the steel plate 200 can be intermittently driven to rise and fall. Through the mechanical structure of centering disc 412, shift pin 413, notch 414, shift plate 422, shift bar 423, strip-shaped opening groove 424, and arc groove 425, the switching between two states—engaged and idle—is achieved. In the engaged state, the shift pin 413, embedded in the strip-shaped opening groove 424, can precisely drive the second transmission component to rotate, ensuring reliable power transmission. In the idle state, the centering engagement of centering disc 412 and arc groove 425 can reliably limit the circumferential movement of the second transmission component, preventing it from rotating due to its own weight or equipment vibration, ensuring accurate meshing position and no jamming or misalignment when engaging again. This purely mechanical engagement method eliminates the need for additional electrical control components, enabling the intermittent movement of the second transmission component 420 while the first transmission component 410 is continuously moving. This reduces the electrical control complexity and failure probability of the device, significantly improving the stability and reliability of the device's operation. Typically, the drive component 300 is a motor. The output shaft of the motor is connected to the first transmission component 410 through a reduction mechanism, which drives the first transmission component 410 to rotate, thereby controlling the lifting and lowering of the measuring steel plate.

[0061] Of course, in other embodiments of the present invention, other methods can also be used to achieve intermittent and continuous lifting and lowering of the measuring steel plate, for example... Figure 9 As shown, the drive assembly 300 is a motor, and the transmission mechanism 400 includes an output gear 460 and a transmission rack 461 disposed on the upper end of the measuring steel plate. The output shaft of the motor is connected to the output gear 460, and the output gear is connected to the transmission rack, which drives the measuring steel plate to rise and fall. The intermittent rising and falling of the measuring steel plate can be achieved by intermittently starting and stopping the motor, and the continuous rising and falling of the measuring steel plate can be achieved by continuous operation of the motor. The speed of the steel plate rising and falling is controlled by the speed of the motor.

[0062] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for obtaining the liquid level state on the surface of a crystallizer, characterized in that, Includes the following steps: S1, the driving mechanism drives the steel plate to descend vertically, so that the steel plate extends into the liquid surface to be detected in the crystallizer and enters the effective detection state. The surface of the steel plate in the effective detection state completely covers the height area of ​​the liquid surface to be detected in the crystallizer, and the steel plate maintains a constant height for at least a first preset time period in the effective detection state. S2, the driving mechanism drives the steel plate to rise vertically to the first preset height, so that the steel plate is separated from the medium in the crystallizer and the measurement surface and the image sensor are unobstructed; S3, the image sensor acquires and analyzes images of the steel plate measuring surface at a first preset height, and obtains the liquid surface state of the crystallizer based on the imprint characteristics formed on the steel plate surface due to temperature and medium differences. The liquid surface state includes at least the liquid slag layer thickness data and / or liquid surface fluctuation data of the liquid surface of the crystallizer.

2. The method for obtaining the liquid level state on the surface of a crystallizer according to claim 1, characterized in that, Step S3 specifically includes: S31, removes impurities adhering to the surface of the steel plate; S32, The image sensor acquires an image of the steel plate measuring surface at the first preset height; S33, Analyze the acquired image to obtain the boundary imprint lines between different layers of the liquid surface; S34. Based on the upper and lower boundary marking lines corresponding to the liquid slag layer, obtain the liquid slag layer thickness data and / or liquid surface fluctuation data. The liquid slag layer thickness data includes at least one of the average thickness value of the liquid slag layer, the maximum thickness value of the liquid slag layer, and the minimum thickness value of the liquid slag layer.

3. The method for obtaining the liquid level state on the surface of a crystallizer according to claim 1, characterized in that, Step S1 specifically includes: S11, the drive mechanism drives the steel plate down to the preset lowest position, and the liquid surface to be detected that extends into the crystallizer enters the effective detection state; S12, after the steel plate maintains its height and remains in an effective detection state for a first preset time, the drive mechanism drives the steel plate to rise vertically a first preset distance, and the steel plate remains in an effective detection state after rising. S13, repeat step S12 multiple times, so that the steel plate completes multiple fixed-height dwell tests at different heights under effective detection conditions in the crystallizer.

4. The method for obtaining the liquid level state on the surface of a crystallizer according to claim 3, characterized in that, Step S11 specifically includes: After the drive mechanism drives the steel plate to descend continuously at a first preset speed to a second preset height, it switches to driving the steel plate to continue descending at a second preset speed to a preset minimum position. The first preset speed is higher than the second preset speed.

5. The method for obtaining the liquid level state on the surface of a crystallizer according to claim 3, characterized in that, Step S11 further includes: after the steel plate stays at the preset lowest position for a second preset time, the driving mechanism drives the steel plate to rise a first preset distance.

6. The method for obtaining the liquid level state on the surface of a crystallizer according to claim 3, characterized in that, Step S3 specifically includes: S31, removes impurities adhering to the surface of the steel plate; S32, The image sensor acquires an image of the steel plate measuring surface at the first preset height; S33, Analyze the acquired image to obtain the boundary imprint lines between different layers of the liquid surface; S34, Based on the first preset distance and the distribution of the boundary imprint lines, divide the boundary imprint lines into multiple groups; S35. Based on the upper and lower boundary imprints corresponding to the liquid slag layer, obtain liquid slag layer thickness data and / or liquid surface fluctuation data for different sets of boundary imprints. The liquid slag layer thickness data includes at least one of the following: average liquid slag layer thickness value, maximum liquid slag layer thickness value, and minimum liquid slag layer thickness value.

7. The method for obtaining the liquid level state on the surface of a crystallizer according to claim 2 or 6, characterized in that, The process of analyzing the acquired images to obtain the boundary markings between different layers of the liquid surface specifically includes: The currently acquired image of the steel plate measurement surface is compared with the blank reference image, and pixel-by-pixel grayscale value calibration is performed. The filtered and calibrated image contains boundary imprint lines that are remnants of the previous imprint, while only retaining the fresh boundary imprint lines formed in the current measurement.

8. The method for obtaining the liquid level state on the surface of a crystallizer according to claim 6, characterized in that, The removal of impurities adhering to the surface of the steel plate specifically includes: removing impurities adhering to the surface of the steel plate by nitrogen purging combined with high-temperature resistant brushing.

9. A system for obtaining the liquid level state on the surface of a crystallizer, characterized in that, The system includes a drive mechanism, a steel plate, and an image sensor. The drive mechanism drives the steel plate vertically downward, allowing it to penetrate the liquid surface to be detected within the crystallizer and enter an effective detection state. In this effective detection state, the surface of the steel plate completely covers the height region of the liquid surface to be detected within the crystallizer, and the steel plate maintains a constant height for at least a first preset duration during this effective detection state. The drive mechanism also drives the steel plate vertically upward to a first preset height, allowing it to detach from the medium within the crystallizer and ensuring no obstruction between the measuring surface and the image sensor. The image sensor acquires and analyzes images of the measuring surface of the steel plate at the first preset height. Based on the imprint features formed on the steel plate surface due to temperature and medium differences, the system obtains the liquid surface state of the crystallizer. The liquid surface state includes at least the thickness data of the liquid-slag layer and / or liquid surface fluctuation data on the liquid surface of the crystallizer.

10. A storage medium storing a computer program, characterized in that, When the computer program is executed by a processor, it implements the method for obtaining the liquid level state on the surface of a crystallizer as described in any one of claims 1 to 8.

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