A device for monitoring the level of a casting trough

Abstract

This utility model discloses a molten metal casting trough level monitoring device, belonging to the field of metal casting safety monitoring technology. The device includes a liquid level sensing unit, a control unit, a first alarm unit, and a second alarm and execution unit. The liquid level sensing unit adopts a non-contact measurement method; the control unit presets two alarm thresholds, and its signal input terminal is connected to the liquid level sensing unit; the first alarm unit is connected to the first output terminal of the control unit, used to trigger an early warning when the liquid level reaches the first threshold; the second alarm and execution unit is connected to the second output terminal of the control unit, used to trigger a flow interruption alarm and control the flow path cut-off mechanism when the liquid level reaches a second, higher threshold. This utility model, through dual-level alarm and linkage control, achieves full-process protection from early warning to emergency flow interruption, effectively eliminating the risk of molten metal overflow and significantly improving production safety and automation levels.

Description

Technical Field

[0001] This utility model belongs to the field of safety monitoring technology for metal melting and casting processes, and specifically relates to a device for monitoring the level of a melting and casting trough. Background Technology

[0002] In the casting and smelting production of non-ferrous metals and steel, the stable control of the molten metal level directly determines the quality of the cast billet, production efficiency, and operational safety during the transfer and distribution of molten metal through the casting trough. Whether in continuous casting or semi-continuous casting processes, excessively high molten metal levels in the casting trough can easily lead to overflow accidents, causing high-temperature metal splashing and endangering equipment and operator safety; conversely, excessively low levels may result in insufficient material supply to the crystallizer, leading to defects in the cast billet and affecting product qualification rates. Therefore, real-time and accurate monitoring of the molten metal level in the casting trough, and timely triggering of intervention measures in case of abnormalities, is one of the core aspects of ensuring the stable operation of casting and smelting production. Traditional methods for monitoring the liquid level in casting baths primarily rely on manual observation or contact sensors. Manual observation depends on operator experience and suffers from issues such as response lag and strong subjectivity, making it unsuitable for the precise control requirements of modern continuous production. Contact sensors, on the other hand, are in direct contact with high-temperature molten metal, making them susceptible to metal corrosion, erosion, and sudden temperature changes. This results in short sensor lifespans, frequent maintenance, and signal drift under harsh conditions, compromising monitoring accuracy. As the casting industry moves towards larger scale and automation, the limitations of traditional monitoring methods are becoming increasingly apparent. Therefore, this utility model proposes a melting casting trough level monitoring device to at least partially solve the above problems. Utility Model Content

[0003] To address the aforementioned problems in the existing technology, this utility model provides a melting and casting trough level monitoring device, which solves the problems of delayed response, strong subjectivity, easy damage to contact sensors, and low monitoring accuracy in traditional melting and casting trough level monitoring.

[0004] The purpose of this utility model can be achieved through the following technical solution: a device for monitoring the level of a casting flow channel.

[0005] As a preferred technical solution of this utility model, it includes a liquid level sensing unit, a control unit, a first alarm unit, and a second alarm and execution unit; the liquid level sensing unit is used for non-contact measurement of molten metal level; the signal input terminal of the control unit is electrically connected to the output terminal of the liquid level sensing unit, and a first alarm threshold and a second alarm threshold are preset; the first alarm unit is electrically connected to the first output terminal of the control unit, and is used to trigger a warning-level alarm when the liquid level reaches the first alarm threshold; the second alarm and execution unit is electrically connected to the second output terminal of the control unit, and is used to trigger a flow interruption-level alarm and control the flow path cut-off mechanism to operate when the liquid level reaches the second alarm threshold; the liquid level sensing unit is provided with a protective cover with a cooling medium.

[0006] As a preferred technical solution of this utility model, the first alarm unit and the second alarm and execution unit are implemented by the same audible and visual alarm; the first output terminal of the control unit controls the audible and visual alarm to enter the intermittent alarm warning mode through the first relay, and the second output terminal of the control unit controls the audible and visual alarm to enter the continuous alarm interruption mode through the second relay and simultaneously activates the flow path cut-off mechanism.

[0007] As a preferred embodiment of this utility model, the second relay is a safety relay, and the hard-wired output signal of the safety relay is simultaneously sent to the emergency stop input terminal of the flow path cutting-off mechanism and the tilting furnace control system.

[0008] As a preferred embodiment of this utility model, the flow path cutting-off mechanism is an electric cutting-off valve or a pneumatic cutting-off valve.

[0009] As a preferred embodiment of this utility model, the liquid level sensing unit is a radar liquid level gauge or a laser liquid level gauge.

[0010] As a preferred embodiment of this utility model, it further includes a redundant sensing unit, which is a float-type liquid level sensor, a capacitive liquid level sensor, or a pressure liquid level sensor; the output terminal of the redundant sensing unit is connected to another signal input terminal of the control unit.

[0011] The beneficial effects of this invention are as follows: by adopting non-contact liquid level sensing and cooling protection technology, the influence of high temperature and harsh environment on measurement is overcome, significantly improving monitoring accuracy and sensor lifespan; by setting up dual-level alarm thresholds and hard-wired interlocking control of safety relays, a progressive safety response from early warning to emergency flow interruption is realized, effectively eliminating the risk of molten metal overflow; combined with redundant sensing design, the reliability of the system is further enhanced, and finally a highly reliable molten casting channel safety monitoring and interlocking protection system with fast response, stable operation, and low maintenance cost is constructed. Attached Figure Description

[0012] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0013] Figure 1 This is the system control flowchart of this utility model.

[0014] Figure 2 This is a structural block diagram of the present invention.

[0015] In the diagram: 100, level gauge; 200, shut-off valve. Detailed Implementation

[0016] To further illustrate the technical means and effects adopted by this utility model in order to achieve the intended utility model purpose, the following detailed description of the specific implementation methods, structure, features and effects of this utility model is provided in conjunction with the accompanying drawings and preferred embodiments.

[0017] Please see Figure 1 and Figure 2 This embodiment provides a melting and casting trough level monitoring device. The core idea of ​​this device is to achieve accurate and safe monitoring of the melting and casting trough level through non-contact measurement and dual-level alarm interlock control, so as to solve the problems of response lag, strong subjectivity, sensor damage and low monitoring accuracy of traditional monitoring methods mentioned in the background art. The device mainly includes a level sensing unit, a control unit, a first alarm unit and a second alarm and execution unit.

[0018] This utility model provides a molten casting flow level monitoring device, the overall design of which aims to construct a closed-loop safety protection system from real-time monitoring, graded early warning to emergency intervention. The components and their interrelationships are described in detail below.

[0019] The level sensing unit is responsible for acquiring the molten metal level data in the casting tank in real time and accurately. To overcome the harsh working conditions such as high temperature, corrosion, and metal surface fluctuations at the casting site, this embodiment preferably adopts a non-contact measurement method. The level sensing unit can be specifically implemented as a radar or laser level gauge 100.

[0020] Radar level gauge 100: It emits high-frequency radar pulses, which are reflected upon encountering the molten metal surface and received by a receiving antenna. By calculating the time difference between pulse transmission and reception, the distance from the sensor to the liquid surface can be accurately calculated, thus determining the liquid level. Radar waves have strong penetrating power and are not easily affected by environmental factors such as dust and steam, ensuring stable and reliable measurement.

[0021] Laser level gauge 100: This gauge emits a laser beam to the surface of molten metal and measures the round-trip distance of the beam using either the phase method or the time-of-flight method. The laser level gauge 100 offers advantages such as high measurement accuracy, concentrated beam, and fast response speed, making it particularly suitable for applications requiring high-precision control.

[0022] By employing a non-contact measurement method, direct contact between the sensor and high-temperature molten metal is fundamentally avoided, solving the problems of short lifespan, frequent maintenance, and signal drift caused by corrosion, wear, and adhesion in traditional contact sensors. To further ensure the long-term stable operation of the sensing unit in high-temperature radiation environments, this invention features a specially designed protective cover with a cooling medium. This cover completely encloses the liquid level sensing unit, and the cooling medium circulates inside, carrying away heat from the sensor's surroundings and keeping it within the allowable temperature range. This significantly extends the sensor's lifespan and improves measurement reliability.

[0023] The control unit is responsible for processing, analyzing, making decisions, and issuing commands. Its core function is to receive real-time liquid level signals from the liquid level sensing unit and compare them with internally preset alarm thresholds. In this embodiment, the control unit presets two key, progressive liquid level thresholds: a first alarm threshold and a second alarm threshold, wherein the second alarm threshold is higher than the first alarm threshold. Simultaneously, the control unit has at least two independent output terminals. The first output terminal is connected to the first alarm unit to trigger a pre-warning level alarm; the second output terminal is connected to the second alarm and execution unit to trigger a flow interruption level alarm and activate the execution mechanism.

[0024] The first alarm unit is electrically connected to the first output terminal of the control unit. When the control unit determines that the real-time liquid level has reached or exceeded the preset first alarm threshold, it will activate the first alarm unit through the first output terminal. The function of this unit is to trigger a warning-level alarm, the main purpose of which is to remind on-site operators to pay attention to abnormal liquid levels and take corresponding manual intervention measures, such as adjusting the tilting speed of the upstream tilting furnace or checking whether the downstream crystallizer is unobstructed.

[0025] The second alarm and execution unit is electrically connected to the second output terminal of the control unit. This is the system's last and most critical safety barrier. When the liquid level becomes uncontrolled and continues to rise, reaching or exceeding the preset second alarm threshold, the control unit will immediately activate this unit through the second output terminal. This unit has a dual function: Triggering a flow interruption alarm: Issues a more urgent and stronger alarm signal than the warning level, clearly indicating that the current state is dangerous.

[0026] Control the flow path cut-off mechanism: At the same time, the unit will send an execution signal to directly drive the flow path cut-off mechanism, forcibly cut off the source of molten metal, prevent the liquid level from continuing to rise from the source, and thus effectively prevent the overflow accident from occurring.

[0027] The alarm functions of the first and second alarm and execution units mentioned above can be implemented by the same audible and visual alarm. The operating modes are controlled by different output terminals and corresponding relays of the control unit to distinguish alarm levels. When the liquid level reaches the first threshold, the first relay drives the alarm into an intermittent warning mode, alerting operators with a slow-flashing warning light and a continuous siren. When the second threshold is reached, the second relay switches to a continuous flow interruption alarm mode, issuing an emergency warning with a high-frequency flashing warning light and a rapid, high-decibel siren. This design is both economical and efficient, allowing on-site personnel to intuitively assess the danger level. In high-risk casting environments, a safety relay is preferred for the second relay, whose forced-guided contact structure meets safety requirements, ensuring reliable disconnection of the safety circuit in case of a fault. More importantly, the safety relay outputs a hard-wired signal simultaneously to the flow path cutoff mechanism and the tilting furnace emergency stop input. The hard-wired connection bypasses the program and communication links, resulting in a fast and reliable response. This dual-cutoff mechanism blocks the molten metal supply from the source, significantly improving safety redundancy. The flow path shut-off mechanism is selected from electric or pneumatic shut-off valves 200 according to the site requirements. Both are quick to respond and reliable to switch, and the valve material is made of special high temperature and corrosion resistant materials, which are suitable for molten metal environments.

[0028] To enhance system availability and reliability, the device incorporates an optional redundant sensing unit. Its output connects to another signal input of the control unit, primarily serving as backup and cross-validation. When the primary sensing unit malfunctions, loses its signal, or exhibits an anomaly, the control unit can automatically or manually switch to the redundant sensing unit signal, ensuring uninterrupted monitoring. During normal operation, the control unit compares the readings of the primary and redundant units; if the difference exceeds a preset range, a maintenance alarm is issued to proactively identify and troubleshoot problems. To avoid common-cause failures, the redundant sensing unit is preferably a type with a different measurement principle than the primary sensor, such as a float-type, capacitive, or pressure-type liquid level sensor. For example, when smoke or dust affects radar and laser measurements, a float sensor based on the buoyancy principle can still operate normally, further enhancing the stability and reliability of the system monitoring through complementary principles.

[0029] The device's workflow is divided into five stages: During normal operation, the liquid level sensing unit continuously transmits the fluctuating molten metal level data within the safety zone to the control unit in real time, and neither the alarm nor the actuator activates; when the liquid level rises to the first alarm threshold due to excessive feeding or flow channel blockage, the control unit triggers the audible and visual alarm via the first relay to enter intermittent early warning mode, and the operator checks the equipment and adjusts the tilting furnace angle to intervene; after a certain period, the liquid level drops below the threshold, the alarm stops, and the system resumes normal monitoring; if the abnormality is not resolved and the liquid level rises to the second alarm threshold, the control unit drives the alarm to switch to continuous emergency alarm via the safety relay, and simultaneously outputs a hard-wired signal, one of which controls the flow path shut-off valve 200 to close, and the other triggers the tilting furnace to stop the molten metal supply; after the danger is eliminated, production can be resumed by manually resetting the safety system.

[0030] The above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to preferred embodiments, it is not intended to limit the present utility model. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present utility model. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present utility model without departing from the scope of the present utility model shall still fall within the scope of the present utility model.

Claims

1. A monitoring device for a casting launder position, characterized in that The system includes a liquid level sensing unit, a control unit, a first alarm unit, and a second alarm and execution unit. The liquid level sensing unit is used for non-contact measurement of molten metal level. The signal input terminal of the control unit is electrically connected to the output terminal of the liquid level sensing unit, and presets a first alarm threshold and a second alarm threshold. The first alarm unit is electrically connected to the first output terminal of the control unit and is used to trigger a warning-level alarm when the liquid level reaches the first alarm threshold. The second alarm and execution unit is electrically connected to the second output terminal of the control unit and is used to trigger a flow interruption-level alarm and control the flow path cut-off mechanism to operate when the liquid level reaches the second alarm threshold. The liquid level sensing unit is externally equipped with a protective cover with a cooling medium.

2. A mould monitoring device according to claim 1, wherein, The first alarm unit and the second alarm and execution unit are implemented by the same audible and visual alarm; the first output terminal of the control unit controls the audible and visual alarm to enter the intermittent alarm warning mode through the first relay, and the second output terminal of the control unit controls the audible and visual alarm to enter the continuous alarm interruption mode through the second relay and simultaneously activates the flow path cut-off mechanism.

3. The casting flow level monitoring device according to claim 2, characterized in that, The second relay is a safety relay, and the hard-wired output signal of the safety relay is simultaneously sent to the emergency stop input terminal of the flow path cutting-off mechanism and the tilting furnace control system.

4. A mold monitoring device as defined in claim 1, wherein The flow path cutting-off mechanism is an electric cutting-off valve or a pneumatic cutting-off valve.

5. A mold monitoring device as defined in claim 1, wherein The liquid level sensing unit is a radar liquid level gauge or a laser liquid level gauge.

6. The casting flow level monitoring device according to claim 1, characterized in that, It also includes a redundant sensing unit, which is a float-type liquid level sensor, a capacitive liquid level sensor, or a pressure liquid level sensor; the output of the redundant sensing unit is connected to another signal input of the control unit.

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