LIGHT SOURCES FOR SIMULATING MOLTEN METAL LEAKAGE, METHODS FOR SIMULATING MOLTEN METAL LEAKAGE, METHODS FOR VERIFYING THE OPERATION OF MOLTEN METAL LEAK DETECTION EQUIPMENT, AND METHODS FOR SETTING UP MOLTEN METAL LEAK DETECTION EQUIPMENT.
Patent Information
- Authority / Receiving Office
- VN · VN
- Patent Type
- Applications
- Current Assignee / Owner
- JFE STEEL CORP
- Filing Date
- 2024-09-20
- Publication Date
- 2026-07-01
AI Technical Summary
Existing molten metal leak detection systems face challenges in adjusting and confirming their abnormal condition detection functions without actual occurrences, leading to potential missed detections and lengthy tuning processes due to infrequent events.
A light source capable of simulating molten metal leakage by adjusting its color space coordinates to match or differ from the molten metal's color space, allowing for easy simulation of leaks and verification of detection device operations.
Enables quick and accurate simulation of molten metal leaks, facilitating the tuning and confirmation of leak detection systems, ensuring timely and effective detection of leaks such as breakouts.
Smart Images
Figure VN1202603082_0
Abstract
Description
Light source for simulating molten metal leaks, molten metal leak simulation method, molten metal leak detection device operation confirmation method, and molten metal leak detection device setting method
[0001] The present invention relates to a light source for simulating a molten metal leak used to simulate a molten metal leak from a molten metal handling facility, a molten metal leak simulation method, a method for checking the operation of a molten metal leak detection device, and a method for setting a molten metal leak detection device.
[0002] In facilities that handle molten metal, accidents such as molten metal leaks that cause severe damage to the facility are inevitable. For this reason, when a molten metal leak occurs, it is necessary to detect it quickly and take measures to prevent the damage to the facility from spreading. A typical example of a facility that handles molten metal is a continuous casting machine that continuously casts molten metal. In continuous casting machines, a problem called a breakout inevitably occurs, in which the outer shell of the cast piece breaks and the molten metal inside sprays out.
[0003] Breakouts are abnormal phenomena that occur in areas where the outer skin of a slab is thin, and often occur within a range of 5 meters from directly below the device called the mold, which solidifies the outer skin of the slab. Breakouts have traditionally been detected by visual observation by an operator, or by placing a large number of sensors such as thermocouples and detecting breaks in the thermocouples due to molten metal splashing onto them.
[0004] As a technique for detecting breakouts, Patent Document 1 discloses a technique in which an image of a segment at the bottom of a mold is captured by a camera, the captured image is subjected to the abnormal condition determination logic of an image determination device to detect the occurrence of a breakout, and the supply of molten steel is automatically stopped. According to Patent Document 1, a breakout is detected by abnormal condition determination logic in which pixels whose RGB (the three primary colors of light) or HSV (hue, saturation, and brightness) thresholds all fall within a certain range are defined as a specific color, the number of pixels that exhibit the specific color is accumulated, and the occurrence of a breakout is detected when the instantaneous value of the accumulated value exceeds a predetermined threshold.
[0005] Japanese Patent Application Laid-Open No. 2001-269770
[0006] The device disclosed in Patent Document 1 has a problem in that the abnormal condition detection function of the abnormal condition detection device cannot be adjusted or its operation confirmed unless an abnormal condition such as a breakout occurs in the equipment in which the abnormal condition detection device is actually installed. In other words, after the abnormal condition detection device is installed in the target equipment, it is necessary to tune the judgment function using the results of capturing images of abnormal conditions that occur there, which results in a problem in that the first one or several abnormal conditions cannot be detected.
[0007] Furthermore, because abnormal conditions such as breakouts do not occur frequently, tuning the detection function of an abnormal condition detection device requires a significant amount of time. One possible solution to this problem is to tune the detection function using the abnormal condition detection results of similar equipment. However, because the imaging range of the camera differs depending on the equipment in question, and the surrounding environment, such as the layout of lighting within the factory, also differs, it is not possible to tune the detection function to detect abnormal conditions using the abnormal condition detection results of other similar equipment.
[0008] The present invention has been made in consideration of the problems of the prior art, and its object is to provide a light source for simulating a molten metal leak and a molten metal leak simulation method that can easily simulate a molten metal leak such as a breakout from molten metal handling equipment. Another object of the present invention is to provide a method for checking the operation of a molten metal leak detection device and a method for setting a molten metal leak detection device.
[0009] Means for solving the above problems are as follows: [1] A light source for simulating a molten metal leak used to simulate a molten metal leak from molten metal handling equipment, the light source for simulating a molten metal leak having a light-emitting unit that can adjust the color space coordinates of the light emitted. [2] The light source for simulating a molten metal leak according to [1], in which the color space coordinates of the light-emitting unit are adjusted to fall within the range of color space coordinates of pixels in image data generated by capturing an image of the molten metal. [3] A method for simulating a molten metal leak in molten metal handling equipment, the method comprising installing the light source for simulating a molten metal leak according to [2] in the equipment to simulate a molten metal leak from the equipment. [4] A method for confirming operation of a molten metal leak detection device that uses a light source for simulating a molten metal leak as described in [1], wherein the leak detection device has an imaging unit that images the molten metal handling equipment and generates image data, a data acquisition unit that acquires pixel count data of pixels that show a specific color included in a predetermined area of the image data, and a detection unit that detects a molten metal leak using the pixel count data, and the method comprises: an installation step of installing the leak simulating light source on the equipment, the color space coordinates of the light emitting unit being adjusted to be within the range of the color space coordinates of pixels in the image data generated by imaging the molten metal; an image data generation step of imaging the equipment including the leak simulating light source with the imaging unit and generating image data; a data acquisition step of acquiring pixel count data of pixels that show a specific color included in the predetermined area of the image data; and a confirmation step of confirming that the detection unit has detected a molten metal leak using the pixel count data.[5] A method for checking the operation of a molten metal leak detection device that uses a light source for simulating a molten metal leak as described in [1], wherein the leak detection device has an imaging unit that images the molten metal handling equipment and generates image data, a data acquisition unit that acquires pixel count data of pixels that show a specific color included in a predetermined area of the image data, and a detection unit that detects a molten metal leak using the pixel count data, and the method includes an installation step of installing the leak simulating light source on the equipment, the color space coordinates of the light emitting unit being adjusted to be outside the range of the color space coordinates of pixels in the image data generated by imaging the molten metal, an image data generation step of imaging the equipment including the leak simulating light source with the imaging unit and generating image data, a data acquisition step of acquiring pixel count data of pixels that show a specific color included in the predetermined area of the image data, and a confirmation step of using the pixel count data to confirm that the detection unit has not detected a leak of the molten metal. [6] A setting method for a molten metal leak detection device that uses a light source for simulating molten metal leaks as described in [2], wherein the leak detection device has an imaging unit that images the molten metal handling equipment and generates image data, a data acquisition unit that acquires pixel count data for pixels that show a specific color included in a predetermined area of the image data, and a detection unit that detects molten metal leaks using the pixel count data, and the setting method for a molten metal leak detection device has the following steps: an installation step of installing the light source for simulating leaks in the equipment; an image data generation step of using the imaging unit to image the equipment including the light source for simulating leaks and generate image data; and a setting step of setting the installation position of the imaging unit using the image data.[7] A setting method for a molten metal leak detection device that uses a light source for simulating a molten metal leak as described in [2], wherein the leak detection device has an imaging unit that images the molten metal handling equipment and generates image data, a data acquisition unit that acquires pixel count data for pixels that show a specific color included in a predetermined area of the image data, and a detection unit that detects a leak of molten metal using the pixel count data, and the setting method for a molten metal leak detection device has the following steps: an installation step of installing the light source for simulating a leak in the equipment; an image data generation step of using the imaging unit to image the equipment including the light source for simulating a leak and generate image data; and a setting step of setting a coordinate range in the color space of the specific color using coordinates in the color space of the pixel that shows the light source for simulating a leak in the image data. [8] A setting method for a molten metal leak detection device that uses a light source for simulating a molten metal leak as described in [2], wherein the leak detection device has an imaging unit that images the molten metal handling equipment and generates image data, a data acquisition unit that acquires pixel count data for pixels that show a specific color included in a predetermined area of the image data, and a detection unit that detects a molten metal leak using the pixel count data, and the setting method for a molten metal leak detection device has the following steps: an installation step of installing the light source for simulating a leak in the equipment; an image data generation step of using the imaging unit to image the equipment including the light source for simulating a leak and generate image data; a data acquisition step of acquiring pixel count data for pixels that show a specific color included in a predetermined area of the image data; and a setting step of using the pixel count data to set a threshold value used by the detection unit to detect a molten metal leak.
[0010] By using the light source for simulating a molten metal leak according to the present invention, it becomes possible to easily simulate a molten metal leak such as a breakout, and therefore, by using the light source for simulating a molten metal leak, it is possible to quickly and easily check the operation and tune the molten metal leak detection device.
[0011] Fig. 1 is a front view showing an example of a light source for simulating a molten metal leak according to this embodiment. Fig. 2 is a cross-sectional schematic diagram of a continuous metal casting machine using a molten metal leak detection device to detect a molten metal leak. Fig. 3 is a schematic diagram showing an example of the configuration of an image analysis device. Fig. 4 is a cross-sectional schematic diagram showing a state in which the molten metal leak detection device is being tuned.
[0012] The light source for simulating a molten metal leak according to this embodiment will be described below. The following embodiment shows a preferred example of the present invention, and the present invention is not limited to these embodiments in any way.
[0013] An embodiment will be described in which a light source for simulating a molten metal leak according to this embodiment is used to tune and check the operation of a molten metal leak detection device. FIG. 1 is a front view showing an example of a light source 10 for simulating a molten metal leak according to this embodiment. The light source 10 for simulating a molten metal leak has a housing 12 and a light-emitting unit 14. The housing 12 is a cylindrical member having a space therein capable of housing the light-emitting unit 14. The housing 12 is made of glass or resin that isotropically diffuses light emitted from the light-emitting unit 14. The size of the housing 12 is, for example, 30 mm in diameter and 50 mm in height.
[0014] The light-emitting unit 14 is a light-emitting body that can adjust the coordinates of the color space of the light it emits. In this embodiment, the color space is, for example, an RGB color space, and the coordinates of the color space of the emitted light are adjusted by independently adjusting the RGB values of the light-emitting body. The light-emitting unit 14 is composed of three LEDs that emit R, G, and B light, and the RGB values of the emitted light are independently adjusted by independently adjusting the light emitted from these LEDs with a dimmer.
[0015] The color space coordinates of the light emitted from the light-emitting unit 14 are adjusted to fall within the range of color space coordinates of pixels in image data generated by imaging the molten metal simulated by the light source 10 for simulating a molten metal leak. The component composition and temperature of the molten metal to be imaged are preferably similar to those of the molten metal detected by a molten metal leak detection device described below. The molten metal is preferably imaged in equipment that detects molten metal leaks with the molten metal leak detection device. For example, in a continuous metal casting machine described below, it is preferable to image the molten metal poured from a tundish into a mold. This makes it possible to simulate molten metal leaking from the equipment using the light emitted by the light source 10 for simulating a molten metal leak.
[0016] It is preferable that the color space coordinates of the light emitted from light-emitting unit 14 be adjusted so that the color space coordinates of pixels in image data generated by capturing an image of light-emitting unit 14 match the color space coordinates of pixels in image data generated by capturing an image of the molten metal. This makes it possible to more accurately simulate molten metal leaking from equipment using light emitted by light source 10 for simulating a molten metal leak.
[0017] The color space coordinates of the light emitted from the light-emitting unit 14 may be adjusted to be outside the range of color space coordinates of pixels in image data generated by capturing an image of the molten metal to be simulated by the light source 10 for simulating a molten metal leak. In this way, by adjusting the color space coordinates of the light emitted from the light-emitting unit 14 to be outside the range of color space coordinates of the molten metal, it becomes possible to simulate light emission different from that of molten metal leaking from equipment. In this way, the light source 10 for simulating a molten metal leak according to this embodiment has the light-emitting unit 14 that can adjust the color space coordinates of the emitted light, and therefore can simulate light emission from leaked molten metal with a single light source, as well as light emission in a color space different from that of molten metal.
[0018] The molten metal leak simulating light source 10 according to this embodiment is suitable for use in checking the operation and tuning of a molten metal leak detection device that detects molten metal leaks from molten metal handling equipment. The molten metal leak detection device detects molten metal leaks from the equipment by capturing images of the operating state of the equipment with a camera and analyzing the generated image data with an image analyzer.
[0019] Next, the molten metal leak detection device 50 will be described. Figure 2 is a cross-sectional schematic diagram of a continuous metal casting machine 20 that uses the molten metal leak detection device 50 to detect molten metal leaks. The continuous metal casting machine 20 shown in Figure 2 is an example of molten metal handling equipment. Other examples of molten metal handling equipment are transfer vessels and transfer ladles that transport molten metal, and molten metal leaks from these facilities may be detected by the molten metal leak detection device 50.
[0020] The continuous metal casting equipment 20 includes a mold 22, a tundish 24 installed above the mold 22, and a plurality of strand support rolls 26 arranged in a row below the mold 22. Although not shown, a ladle containing molten metal 28 is installed above the tundish 24, and the molten metal 28 is poured into the tundish 24 from the bottom of the ladle. A sliding shutter 29 and a submerged entry nozzle 30 are installed at the bottom of the tundish 24. The sliding shutter 29 slides, and when the sliding shutter 29 is released from its closure, the molten metal 28 is poured into the mold 22 through the submerged entry nozzle 30. The molten metal 28 solidifies as heat is removed from the inner surface of the mold 22, forming a solidified shell 32. This results in a strand 36 having the solidified shell 32 as its outer shell and an unsolidified layer 34 made of the molten metal 28 inside.
[0021] In the gaps between adjacent strand support rolls 26 in the casting direction, multiple secondary cooling zones 38, each equipped with spray nozzles (not shown), are installed along the casting direction from directly below the mold 22. The strand 36 is cooled as it is withdrawn by cooling water sprayed from the spray nozzles in the secondary cooling zones 38. While the strand 36 is transported by the strand support rolls 26 and passes through the multiple secondary cooling zones 38, the solidified shell 32 is appropriately cooled, solidification of the unsolidified layer 34 progresses, and solidification of the strand 36 is completed.
[0022] Downstream in the casting direction, a plurality of transport rolls 27 are installed for continuing to transport the slab 36. A slab cutter 40 is disposed above the transport rolls 27 for cutting the slab 36. After solidification is complete, the slab 36 is cut by the slab cutter 40, and slabs 36a of a predetermined length are continuously cast.
[0023] In such a continuous metal casting machine 20, a breakout may occur, in which the molten metal 28 leaks to the outside from the solidified shell 32 formed in the cast slab 36. The molten metal leak detection device 50 according to this embodiment is used to detect this leakage of the molten metal 28 to the outside.
[0024] The molten metal leak detection device 50 includes a camera 52 and an image analysis device 54. The camera 52 captures an image of the continuous metal casting machine 20, including the cast piece 36 below the mold 22, to generate image data, and transmits the generated image data to the image analysis device 54.
[0025] Image analysis device 54 acquires pixel count data, which is the number of pixels that exhibit a specific color, by counting the number of pixels that exhibit a specific color that are included in a predetermined area of the image data acquired from camera 52. Here, the specific color is a color that indicates molten metal 28 that is included in the predetermined area of the image data. Image analysis device 54 uses the pixel count data to detect whether molten metal 28 has leaked to the outside. Camera 52 is an example of an imaging unit, and camera 52 is, for example, a digital camera or video camera that has a CCD image sensor or a CMOS image sensor and is capable of generating color image data.
[0026] The molten metal leak detection device 50 may have two or more cameras 52 to capture images of the entire circumference below the mold 22. In this case, the image analysis device 54 acquires pixel count data obtained from each camera and detects leakage of the molten metal 28.
[0027] Next, the image analysis device 54 will be described. Fig. 3 is a schematic diagram showing an example configuration of the image analysis device 54. The image analysis device 54 is, for example, a general-purpose computer such as a workstation or a personal computer. The image analysis device 54 has a control unit 56, an input unit 58, an output unit 60, and a storage unit 62.
[0028] The control unit 56 is, for example, a CPU, and executes various programs stored in the storage unit 62 to cause the control unit 56 to function as a data acquisition unit 64 and a detection unit 66. The input unit 58 is, for example, a keyboard, a touch panel integrated with a display, or the like. The output unit 60 is, for example, an LCD, a CRT display, or a patrol lamp. The storage unit 62 is, for example, an information recording medium such as an updatable flash memory, a built-in hard disk or a memory card connected via a data communication terminal, or a read / write device for the information recording medium. The storage unit 62 stores programs and data used to acquire pixel count data indicating a specific color from image data received from the camera 52 and detect leakage of the molten metal 28 using the pixel count data.
[0029] Next, we will explain the processing executed by the data acquisition unit 64 and the detection unit 66. When the data acquisition unit 64 receives image data generated by the camera 52, it counts the number of pixels that exhibit a specific color included in a predetermined area of the image data and acquires pixel count data.
[0030] Specifically, when the data acquisition unit 64 receives the image data, it reads information indicating the predetermined area from the storage unit 62 and identifies the predetermined area. The predetermined area is set in order to eliminate disturbances that inevitably enter the imaging area depending on the installation position of the camera.
[0031] Furthermore, the data acquisition unit 64 converts the RGB values of each pixel into HSV values. This is because the range of the specific color is set as a range of HSV values. The range of the specific color may be set as a range of color space coordinates such as RGB values or HSV values. In this case, the data acquisition unit 64 converts the pixels so that they correspond to the color space in which the range of the specific color is set.
[0032] The data acquisition unit 64 reads information indicating the range of the specific color from the storage unit 62, compares the HSV values of all pixels included in the predetermined area with the information indicating the range, and counts the number of pixels that fall within the range of the specific color. In this way, the data acquisition unit 64 acquires pixel count data indicating the specific color.
[0033] The detection unit 66 executes a detection step and detects leakage of the molten metal 28 using the pixel count data acquired by the data acquisition unit 64. The detection unit 66 uses the pixel count data to determine whether the number of pixels showing a specific color is equal to or greater than a reference number. The detection unit 66 reads information indicating the reference number from the storage unit 62, and detects leakage of the molten metal 28 if the number of pixels showing a specific color is equal to or greater than the reference number. On the other hand, the detection unit 66 does not detect leakage of the molten metal 28 if the number of pixels showing a specific color is less than the reference number. The reference number is, for example, 1,000.
[0034] When the detection unit 66 detects a leak of the molten metal 28, it displays a message indicating that the molten metal 28 has leaked on the LCD or CRT display of the output unit 60, or turns on a patrol lamp, thereby alerting the surrounding area that the molten metal 28 has leaked.
[0035] In this way, the molten metal leak detection device 50 detects leaks of the molten metal 28 using pixel count data indicating the specific color. The position of the camera 52, the predetermined area used to detect leaks of the molten metal 28, the range of the specific color, and the reference number are determined by tuning performed when the molten metal leak detection device 50 is installed in the continuous metal casting machine 20. The molten metal leak detection device 50 is tuned using the molten metal leak simulating light source 10 according to this embodiment, in which the color space coordinates of the light-emitting portion 14 are adjusted to be within the range of the color space coordinates of the molten metal.
[0036] Figure 4 is a cross-sectional schematic diagram showing a state in which tuning of the molten metal leak detection device 50 is being performed. The area indicated by the dotted line in Figure 4 is a cross-sectional area of the continuous metal casting machine 20. As shown in Figure 4, when tuning the molten metal leak detection device 50, the light sources 10 for simulating molten metal leaks are installed at a position 70 close to the camera 52 and positions 72 and 74 far from the camera 52. This process is the installation step.
[0037] In a continuous metal casting machine 20, breakouts often occur within a range of 5 m from directly below the mold 22. For this reason, the light sources 10 for simulating molten metal leakage are installed at various positions within a range of up to 5 m below the mold 22. Images of the light sources 10 for simulating molten metal leakage installed at each position are captured by a camera 52, and image data is generated for each light source. This process is the image data generation step.
[0038] The predetermined area is set within a range that includes the position of the pixel representing the light source 10 for simulating a molten metal leak in each of the generated image data, but does not include any surrounding disturbances. This process is the setting step. Information indicating the predetermined area is input from the input unit 58 and stored in the storage unit 62.
[0039] The installation position of the camera 52 may be changed in consideration of the position of the light source 10 for simulating a leak of molten metal and surrounding disturbances. The installation position of the camera 52 after the change is set in consideration of the position of the light source 10 for simulating a leak of molten metal in the generated image data and surrounding disturbances. This process is also a setting step.
[0040] The range of the specific color is set so as to include the HSV values of the pixels of the light source 10 for simulating a molten metal leak in each of the generated image data. This process is also a setting step. Information indicating the range of the specific color is input from the input unit 58 and stored in the storage unit 62. This is the method for setting the specific color in the molten metal leak detection device 50. By setting the range of the specific color in this manner, it is possible to set the range of the specific color according to the surrounding environment, such as the arrangement of lighting in the factory. The range of the specific color is not limited to HSV values, but may also be set as a range of coordinates in the color space of RGB values. In this case, the range of the specific color is set to a range that includes the coordinates of the color space of the pixels of the light source 10 for simulating a molten metal leak in each of the generated image data.
[0041] The reference number is determined by having the data acquisition unit 64 count the number of pixels of a specific color contained in a predetermined area of the image data and acquiring pixel count data. This process is the data acquisition step. The reference number is set to a pixel number in the pixel count data that will detect a molten metal leak but will not detect the leak from molten metal splashes observed during normal operation. This process is the threshold setting step. Information indicating the reference number of pixels of a specific color is input from the input unit 58 and stored in the storage unit 62. This is the method for setting a threshold in the molten metal leak detection device. By determining the reference number as a threshold in this way, the reference number as a threshold can be set according to the surrounding environment, such as the arrangement of lighting in the factory.
[0042] It is preferable to perform the image data generating step by installing a molten metal leak simulating light source 10 whose RGB values are changed by about ±5% so that a molten metal leak can be detected even if the color of the molten metal changes slightly. Furthermore, if the influence of external disturbances such as sunlight from outside the factory, lighting inside the factory, or water vapor is expected, it is preferable to perform the image data generating step by changing the sunlight or lighting or adding water vapor, taking these external disturbances into consideration. The RGB values of the molten metal leak simulating light source 10 may be further adjusted to take these external disturbances into consideration.
[0043] Next, a method for confirming the operation of the molten metal leak detection device 50 will be described. The operation of the molten metal leak detection device 50 can be confirmed by using the light source 10 for simulating a molten metal leak according to this embodiment. To confirm the operation of the molten metal leak detection device 50, first, a light source 10 for simulating a molten metal leak, the color space coordinates of which for the light-emitting part 14 are adjusted to fall within the range of the color space coordinates of the molten metal, is installed at a predetermined position below the mold 22 in the continuous metal casting machine 20. This process is the installation step. If a position where the light source 10 for simulating a molten metal leak cannot be installed is occupied by a mirror, the light source 10 for simulating a molten metal leak may be installed at a position where the light reflected by the mirror is directed toward the camera 52.
[0044] The camera 52 captures an image of the continuous metal casting machine 20 including the molten metal leakage simulation light source 10 installed at a predetermined position, and generates image data. This process is the image data generation step.
[0045] The data acquisition unit 64 then counts the number of pixels of a specific color contained in a predetermined region of the image data and acquires pixel count data. This process is the data acquisition step. Using the pixel count data acquired in the data acquisition step, the detection unit 66 confirms that the number of pixels showing the specific color is equal to or greater than a reference number and that the detection unit 66 detects a leak of molten metal 28. This process is the confirmation step. The installation step, image data generation step, data acquisition step, and confirmation step are performed for various positions on the continuous metal casting machine 20. In this manner, the operation of the molten metal leak detection device 50 is confirmed. This operation confirmation is also preferably performed by varying the RGB values of the molten metal leak simulating light source 10 by approximately ±5%, changing the sunlight or lighting, or adding water vapor. The RGB values of the molten metal leak simulating light source 10 may be further adjusted to take these disturbances into account.
[0046] In the method for confirming the operation of the molten metal leak detection device 50, it is preferable to further use a molten metal leak simulating light source 10 in which the color space coordinates of the light-emitting unit 14 are adjusted to be outside the range of the color space coordinates of the molten metal, and to confirm that the light emitted does not detect a molten metal leak. In the past, the molten metal leak detection device 50 has malfunctioned by detecting a white flashlight used by an operator for equipment inspection. For this reason, a molten metal leak simulating light source 10 in which the color space coordinates of the light emitted from the light-emitting unit 14 are adjusted to coordinates that are not desired to be detected is used, and it is confirmed that the light emitted does not detect a molten metal leak. This makes it possible to confirm that the molten metal leak detection device 50 does not malfunction.
[0047] As described above, by using the light source 10 for simulating a molten metal leak according to this embodiment, it is possible to easily simulate a molten metal leak, such as a breakout, from molten metal handling equipment. Furthermore, by using the light source 10 for simulating a molten metal leak according to this embodiment, it is possible to quickly, easily, and safely check the operation and tune the molten metal leak detection device 50 that detects molten metal leaks. Furthermore, by tuning the molten metal leak detection device 50 using the light source 10 for simulating a molten metal leak, it becomes possible to detect a molten metal leak from the very first test.
[0048] The light source 10 for simulating a molten metal leak according to this embodiment can independently adjust the RGB values of the light-emitting unit 14, so it can simulate the light emitted from the molten metal in accordance with the component composition and temperature of the molten metal. In preparation for anticipated effects of external disturbances or changes in the color of the molten metal, it is also possible to adjust the RGB values by approximately ±5%.
[0049] Although the present embodiment has been described with reference to an example in which the light source 10 for simulating a molten metal leak is used to tune a molten metal leak detection device 50 that detects molten metal leaks based on the number of pixels of a specific color contained in a predetermined region of image data, the present invention is not limited to this example. For example, a camera may continuously capture images at predetermined time intervals to generate image data, and time-series data on the number of pixels of a specific color may be obtained from the image data. The time-series data may then be used to tune a molten metal leak detection device that detects molten metal leaks. In this case, the threshold for detecting molten metal leaks may be, for example, the duration over which the number of pixels of a specific color remains equal to or exceeds a reference number, or the integrated value of pixels within a predetermined time. The light source 10 for simulating a molten metal leak may be used to set this threshold.
[0050] REFERENCE SIGNS LIST 10 Light source for simulating molten metal leakage 12 Storage section 14 Light emitting section 20 Continuous metal casting machine 22 Mold 24 Tundish 26 Strand support roll 27 Transport roll 28 Molten metal 29 Sliding shutter 30 Submerged nozzle 32 Solidified shell 34 Unsolidified layer 36 Strand 36a Strand 38 Secondary cooling zone 40 Strand cutting machine 50 Molten metal leakage detection device 52 Camera 54 Image analysis device 56 Control section 58 Input section 60 Output section 62 Storage section 64 Data acquisition section 66 Detection section 70 Position 72 Position 74 Position
Claims
1. A light source for simulating a molten metal leak used to simulate a molten metal leak from a molten metal handling facility, the light source having a light-emitting part capable of adjusting the color space coordinates of the emitted light.
2. A light source for simulating a molten metal leak as described in claim 1, wherein the color space coordinates of the light-emitting part are adjusted to be within the range of color space coordinates of pixels in image data generated by imaging the molten metal.
3. A method for simulating a molten metal leak in a molten metal handling facility, comprising installing a light source for simulating a molten metal leak as described in claim 2 in the facility to simulate a molten metal leak from the facility.
4. A method for confirming operation of a molten metal leak detection device that uses a light source for simulating a molten metal leak as described in claim 1, wherein the leak detection device has an imaging unit that images the molten metal handling equipment to generate image data, a data acquisition unit that acquires pixel count data of pixels that exhibit a specific color included in a predetermined area of the image data, and a detection unit that detects a leak of molten metal using the pixel count data, the method comprising the steps of: installing the leak simulating light source in the equipment, the coordinates of the color space of the light emitting unit being adjusted to be within the range of the coordinates of the color space of pixels in the image data generated by imaging the molten metal; an image data generation step of imaging the equipment including the leak simulating light source with the imaging unit to generate image data; a data acquisition step of acquiring pixel count data of pixels that exhibit a specific color included in a predetermined area of the image data; and a confirmation step of confirming that the detection unit has detected a leak of the molten metal using the pixel count data.
5. A method for confirming operation of a molten metal leak detection device that uses a light source for simulating a molten metal leak as described in claim 1, wherein the leak detection device has an imaging unit that images the molten metal handling equipment to generate image data, a data acquisition unit that acquires pixel count data of pixels that exhibit a specific color included in a predetermined area of the image data, and a detection unit that detects a leak of molten metal using the pixel count data, the method comprising the steps of: installing the leak simulating light source in the equipment, the coordinates of the color space of the light emitting unit being adjusted to be outside the range of the coordinates of the color space of pixels in the image data generated by imaging the molten metal; an image data generation step of imaging the equipment including the leak simulating light source with the imaging unit to generate image data; a data acquisition step of acquiring pixel count data of pixels that exhibit a specific color included in a predetermined area of the image data; and a confirmation step of confirming that the detection unit has not detected a leak of the molten metal using the pixel count data.
6. A setting method for a molten metal leak detection device that uses a light source for simulating a molten metal leak as described in claim 2, wherein the leak detection device has an imaging unit that images the molten metal handling equipment and generates image data, a data acquisition unit that acquires pixel count data of pixels that exhibit a specific color included in a predetermined area of the image data, and a detection unit that detects the occurrence of a molten metal leak using the pixel count data, and the setting method for a molten metal leak detection device has the following steps: an installation step of installing the light source for simulating a leak in the equipment; an image data generation step of using the imaging unit to image the equipment including the light source for simulating a leak and generate image data; and a setting step of setting the installation position of the imaging unit using the image data.
7. A setting method for a molten metal leak detection device that uses a light source for simulating a molten metal leak as described in claim 2, wherein the leak detection device has an imaging unit that images the molten metal handling equipment and generates image data, a data acquisition unit that acquires pixel count data of pixels showing a specific color included in a predetermined area of the image data, and a detection unit that detects the occurrence of a molten metal leak using the pixel count data, and the setting method for a molten metal leak detection device has the following steps: an installation step of installing the light source for simulating a leak in the equipment; an image data generation step of imaging the equipment including the light source for simulating a leak with the imaging unit and generating image data; and a setting step of setting a coordinate range in the color space of the specific color using the coordinates in the color space of the pixel showing the light source for simulating a leak in the image data.
8. A setting method for a molten metal leak detection device using a light source for simulating a molten metal leak as described in claim 2, wherein the leak detection device has an imaging unit for imaging the molten metal handling equipment to generate image data, a data acquisition unit for acquiring pixel count data of pixels showing a specific color included in a predetermined area of the image data, and a detection unit for detecting a leak of molten metal using the pixel count data, and the setting method for a molten metal leak detection device comprises an installation step of installing the light source for simulating leaks in the equipment, an image data generation step of imaging the equipment including the light source for simulating leaks with the imaging unit to generate image data, a data acquisition step of acquiring pixel count data of pixels showing a specific color included in a predetermined area of the image data, and a setting step of setting a threshold value used by the detection unit to detect a leak of molten metal using the pixel count data.