Slag Volume Evaluation Using Density-Thickness Correlation
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Solution Overview
Problem
Current methods for evaluating slag volume on molten metal surfaces are inaccurate and time-consuming, particularly in partial slag scraping operations, as they fail to account for slag thickness and require complex processes, leading to difficulties in determining the remaining slag amount in containers.
Innovation Solution
A method that calculates the volume of slag by capturing images of the molten metal surface and using an approximation curve to correlate slag thickness with density, allowing for precise evaluation of slag volume before and after scraping, and calculating the residual ratio of slag in the container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the slag area method is used to obtain slag scraping rate, then the measurement process is simple, but the measurement precision deteriorates because slag collapse causes slag area and slag scraping rate to become uncorrelated
Solution Approach 1:
The patent transitions from two-dimensional area measurement to three-dimensional volume measurement by incorporating slag thickness information. The volume is calculated by integrating thickness values across the slag area, which provides accurate measurement even when slag collapses and changes shape, resolving the uncorrelation problem between area and scraping rate.
Solution Approach 2:
The patent changes the measurement parameter from area to volume by introducing thickness as an additional dimension. This parameter change allows accurate tracking of slag quantity regardless of shape changes or collapse, maintaining correlation between measurement and actual scraping rate.
2Measurement precision
If the luminance histogram method is used to discriminate slag and molten metal, then the discrimination accuracy is improved, but the device complexity increases due to multiple processes required
Solution Approach 1:
The patent extracts only the necessary information (slag thickness and volume) directly from the captured image using the approximation curve, rather than performing multiple sequential processes including luminance histogram analysis, stage determination, threshold value calculation, and binarization. This extraction approach maintains accuracy while reducing complexity.
Solution Approach 2:
The patent uses an approximation curve (a simplified mathematical model) to represent the complex relationship between image density and slag thickness, allowing direct calculation of volume without reproducing the multiple intermediate steps of the luminance histogram method.
3Measurement precision
If the luminance histogram method is used to calculate slag amount, then the discrimination between slag and molten metal is improved, but the productivity deteriorates due to many processes required
Solution Approach 1:
The patent pre-establishes the approximation curve that directly relates image density to slag thickness before actual measurement. This preliminary preparation allows rapid volume calculation during operation by simply applying the pre-defined curve to the captured image, eliminating the need for multiple sequential processes and significantly improving productivity.
4Loss of substance
If partial slag scraping is performed to reduce molten metal loss, then the loss of substance is reduced, but the reliability deteriorates because remaining slag may harmfully affect the post-process
Solution Approach 1:
The patent implements continuous monitoring of slag volume during the scraping process using image capture and volume calculation. This feedback mechanism allows real-time adjustment of scraping operations to achieve the optimal balance between retaining enough slag to minimize metal loss and removing sufficient slag to prevent post-process contamination, thereby improving both metal yield and process reliability.
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
This approach enables more accurate and prompt evaluation of slag volume, optimizing the slag scraping process and ensuring minimal residual slag, thus enhancing the yield and reducing losses during molten metal processing.
Implementation Method 1
a captured image of a molten metal surface in the container is obtained by a capturing process using an image capturing device
Data Source
AI summary
A slag volume evaluation method for a molten metal surface includes calculating an approximation curve indicating a correspondence between a thickness of slag and a density parameter in advance by measuring thicknesses of a plurality of pieces of the slag which float on a surface of a molten metal in a container and differ from each other in thickness, and calculating a value of the density parameter which is correlated to a density in a pixel region corresponding to the plurality of pieces of the slag in a captured image of a molten metal surface in the container; and calculating a volume of the slag by calculating and integrating the thickness of the slag for each of pixels constituting the captured image obtained by capturing an image of the molten metal surface which is an evaluation target, according to a value of the density parameter of each of the pixels and the approximation curve.