Key Technologies Of Iron Ladle Automatic Thermal Inspection System

The iron ladle automatic thermal inspection system is a system that assists manual online measurement and offline analysis of the iron ladle health status through automatic detection techniques such as thickness measurement and temperature measurement.It provides a basis for thermal inspectors to decide whether the iron ladle should be offline repaired or rebuilt.The iron ladle automatic thermal inspection system includes iron ladle liner measuring unit,inro ladle shell temperature measuring unit and data analysis unit.The former measures the erosion of hot empty iron ladle lining with laser thickness gauge and takes pictures of hot empty iron ladle lining with high-resolution camera to find abnormalities such as excessive erosion of lining and brick drop;the middle one measures the temperature field of the whole ladle shell by infrared thermography to find abnormalities such as drilling iron or leaking through the cladding;the latter performs on-line diagnostic analysis and off-line statistical analysis based on the measured data.According to the requirements of thermal inspection technology,based on the on-site installed ladle lining thickness measurement and ladle shell temperature measurement hardware,several key technologies are studied in this paper,as follows:(1)Design and implementation of data acquisition and analysis software for thermal inspection.The software includes server program,client program and database.Based on My SQL,a series of database tables and views for collection and analysis are designed and implemented.Based on Net/C#,the software has 349 database tables/views.The client program has 6 main operations and display screens,such as temperature measurement/thickness measurement/temperature analysis/thickness analysis/positioning ball maintenance/data export.The server side has functions,such as temperature acquisition/thickness acquisition/temperature storage/thickness storage/historical information recording.The thermal inspector can realize one key automatic thickness measurement/full-automatic temperature measurement through the customer service program,and can retrieve and viewIVhistorical data at any time to analyze thickness or temperature trend.(2)The thermal inspection data acquisition and analysis software is used for data acquisition and analysis.In terms of thermal inspection data acquisition,the temperature acquisition module is used to automatically collect the shell temperature of each heavy package on site under each package age,and the joint thermal inspection workers use the data acquisition client to collect the lining erosion amount and photos of each empty package under each package age.At present,more than40000 groups of heavy package shell temperature data of 53 package numbers and more than 4500 groups of empty package lining erosion and photo data have been collected.In terms of thermal inspection analysis,the analysis software is used to carry out on-line diagnostic analysis and statistical analysis of erosion law on the measured data.In terms of on-line diagnosis and analysis,a major abnormality of brick falling off the peripheral wall was found by the thermal inspector in conjunction with the lining photos and erosion volume expansion map.In the aspect of statistical analysis of erosion law,the abnormal data elimination strategy and the calculation method of maximum value were studied,as well as the location distribution law of peripheral wall/bottom erosion value,and the erosion value and erosion rate in the erodible area.It is found that the erodible areas of the peripheral wall and the bottom of the ladle are 1m below the slag line and the large and small scour areas at the bottom of the ladle respectively.(3)Design and implementation of identification and working condition identification model.In order to replace manual triggering to realize full-automatic thickness measurement,the iron ladle identification and working condition intelligent on-line detection technology is studied,mainly including data collection,pretreatment,marking,model training and deployment related to ladle drop,ladle number and closure detection.The results show that the accuracy of 768 packet dropping and packet number detection can reach 99.5% and 95%respectively.This shows that the identification and industrial control intelligent online detection technology has the potential for automatic thickness measurement.