Slag Thickness Detection and Prediction in Continuous Casting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual measurement of slag thickness in continuous casting is labor-intensive, prone to errors, and not conducted in real-time, leading to inefficient and unreliable slag addition processes.
Innovation Solution
A method and system for real-time slag thickness detection and prediction using laser distance meters and electromagnetic liquid level meters to calculate and monitor slag thickness, constructing a three-dimensional dynamic model to predict slag addition locations and times based on melting speed, with feedback to a robot arm system for automated slag addition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement method is used to measure slag thickness, then the measurement can be performed with simple equipment, but the measurement is not conducted in real-time and has large measuring error
Solution Approach 1:
The patent replaces the manual mechanical measurement system with an automated optical measurement system using a laser distance meter. The laser distance meter non-contactively measures the distance to the slag layer, and through coordinate transformation and calculation, determines the slag thickness in real-time. This substitution eliminates manual intervention, achieves continuous real-time monitoring, and significantly improves measurement precision while reducing measurement time.
2Productivity
If manual measurement method is used to measure slag thickness, then the equipment required is simple, but the manual workload is large and measurement is not efficient
Solution Approach 1:
The system implements self-service automation where the laser distance meter automatically performs measurements, the control device automatically transforms coordinates and calculates slag thickness, and the system automatically predicts slag addition requirements. This eliminates manual measurement operations, reduces workload, and continuously provides accurate data for efficient slag addition control.
Solution Approach 2:
The system establishes a feedback loop where real-time slag thickness measurements are continuously monitored, compared against target values, and used to predict and control slag addition timing and quantity. This closed-loop feedback mechanism enables automated adjustment of slag addition operations, significantly improving addition efficiency and consistency.
3Reliability
If manual measurement method is used, then the system complexity is low, but the measurement is not conducted on-line and cannot direct slag addition efficiently
Solution Approach 1:
The control device serves multiple functions: it controls the laser distance meter for measurement, performs coordinate transformation based on measured data, calculates slag thickness, predicts slag addition timing and quantity, and provides feedback control. This multi-functional integration improves reliability by ensuring consistent data processing and control while managing system complexity through unified device architecture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and reliable real-time slag addition, reducing manual workload and measurement errors, ensuring consistent slag thickness and improved billet quality.
Implementation Method 1
acquiring a real-time distance L from a laser distance meter to a preset measurement point on the surface of the protective slag layer measured by the laser distance meter
Implementation Method 2
acquiring a real-time distance L from a laser distance meter to a preset measurement point on the surface of the protective slag layer measured by the laser distance meter
Implementation Method 3
acquiring a vertical distance D from a bottom of an electromagnetic liquid level meter to a molten steel surface measured by the electromagnetic liquid level meter
Data Source
AI summary
Provided are a method and a system for a slag thickness detection and a slag-adding prediction. The method includes: acquiring real-time measurement data and real-time auxiliary data of a slag point on a surface of a protective slag layer of a casting mold; calculating a real-time slag thickness value corresponding to the slag point by using the real-time measurement data and the real-time auxiliary data of the slag point; and predicting a location on the surface of the protective slag layer where a slag-adding is to be performed and a slag-adding time when the slag-adding is to be performed based on a change in the real-time slag thickness value corresponding to the slag point by taking a preset slag thickness value as a reference.