Research On On-Line Detection System Of Slag Level In The Mold For Eleetroslag Casting Based On Machine Vision

In the casting process of electroslag,continuous on-line measurement of mold level is an important factor for guaranteeing the ingot production efficiency,improving the quality of electroslag remelting and upgratiing the production process.The current measurement system such as thermocouple method,isotope measurement method,eddy current method,electromagnetic method,gravimetric method,ultrasonic method,microwave method,image method,has some deficiencies:either narrow measurement range,or low measurement accuracy,or causing harm to humans,or the high use and maintenance costs.In order to overcome the shortcomings of existing systems,this paper researched on on-line detection system of slag level in the mold for eleetroslag casting based on machine vision and successfully conducted on-site applications.Firstly,it was established a non-contact level measurement system solutions based on machine vision and demonstrated the feasibility of using calibration method to meet the measurement accuracy;Secondly it was built an low-cost measurement system hardware composed of industrial cameras,lenses,filters,embedded computers,image acquisition chassis and focused on the design and realization of the image acquisition chassis and the selection of filters;Thirdly it was designed and implemented a measurement system software composed of image acquisition,calibration and calculation of liquid level,data storage system,and achieved a high level of real-time dynamic display and the level of real-time monitoring and introduced simply the operation of the software process;Finally,it was talked about the integration of the detection system hardware and software,about the layout of the system and operation of the detection process,and analyzed in detail the measurement resolution and error detection.The results show that the studied system meets the requirements of electroslag casting.with measurement range of up to 290mm,measurement accuracy of ±1.6mm,low cost of use and maintenance.