CN117358892B - Deformation monitoring and early warning method and system for crystallizer copper pipe - Google Patents
Deformation monitoring and early warning method and system for crystallizer copper pipe Download PDFInfo
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- 238000012544 monitoring process Methods 0.000 title claims abstract description 202
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 title claims abstract description 114
- 229910052802 copper Inorganic materials 0.000 title claims abstract description 114
- 239000010949 copper Substances 0.000 title claims abstract description 114
- 238000000034 method Methods 0.000 title claims abstract description 41
- 238000004458 analytical method Methods 0.000 claims abstract description 42
- 238000013507 mapping Methods 0.000 claims abstract description 26
- 238000012806 monitoring device Methods 0.000 claims abstract description 10
- 230000035882 stress Effects 0.000 claims description 55
- 238000012545 processing Methods 0.000 claims description 31
- 238000001514 detection method Methods 0.000 claims description 27
- 238000002425 crystallisation Methods 0.000 claims description 19
- 230000008025 crystallization Effects 0.000 claims description 19
- 230000035605 chemotaxis Effects 0.000 claims description 16
- 238000006243 chemical reaction Methods 0.000 claims description 11
- 230000009466 transformation Effects 0.000 claims description 8
- 238000004364 calculation method Methods 0.000 claims description 6
- 230000003399 chemotactic effect Effects 0.000 claims description 5
- 238000012216 screening Methods 0.000 claims description 5
- 230000032683 aging Effects 0.000 claims description 3
- 230000011218 segmentation Effects 0.000 claims description 3
- 238000007689 inspection Methods 0.000 claims 1
- 230000000694 effects Effects 0.000 abstract description 5
- 229910000831 Steel Inorganic materials 0.000 description 20
- 239000010959 steel Substances 0.000 description 20
- 230000008859 change Effects 0.000 description 13
- 238000009826 distribution Methods 0.000 description 9
- 230000008569 process Effects 0.000 description 8
- 238000011156 evaluation Methods 0.000 description 6
- 239000000463 material Substances 0.000 description 6
- 239000011159 matrix material Substances 0.000 description 5
- 238000005070 sampling Methods 0.000 description 5
- 238000005452 bending Methods 0.000 description 3
- 238000009749 continuous casting Methods 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 239000013078 crystal Substances 0.000 description 2
- 238000003066 decision tree Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 230000002427 irreversible effect Effects 0.000 description 2
- 238000012417 linear regression Methods 0.000 description 2
- 238000003723 Smelting Methods 0.000 description 1
- 230000002159 abnormal effect Effects 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000018109 developmental process Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000005284 excitation Effects 0.000 description 1
- 238000010801 machine learning Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 230000000877 morphologic effect Effects 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 238000012549 training Methods 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/16—Controlling or regulating processes or operations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D46/00—Controlling, supervising, not restricted to casting covered by a single main group, e.g. for safety reasons
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Abstract
The invention discloses a deformation monitoring and early warning method and system for a crystallizer copper pipe, belonging to the field of intelligent monitoring, wherein the method comprises the following steps: determining deformation monitoring points positioned on the copper pipe of the crystallizer; combining a sensing monitoring device to monitor the temperature and stress of deformation monitoring points and building a situation trend curve; performing deformation analysis on deformation monitoring points in a continuous heat exchange environment, and determining single-point deformation data; detecting the local geometric state of the copper pipe of the crystallizer, and determining section geometric data; configuring a diversified deformation reference table, wherein the diversified deformation reference table comprises a mapping index sequence under a multi-level deformation standard; and traversing the diversified deformation reference table, matching the single-point deformation data with the section geometric data, determining the whole deformation grade and generating deformation early warning information. The technical problems that in the prior art, the deformation monitoring precision of the copper tube of the crystallizer is low and deformation trend prediction cannot be performed are solved, and the technical effects of accurately monitoring and early warning the deformation of the copper tube of the crystallizer are achieved.
Description
Technical Field
The invention relates to the field of intelligent monitoring, in particular to a deformation monitoring and early warning method and system for a crystallizer copper pipe.
Background
The continuous casting machine is used as an important device for smelting steel, and the crystallizer is used as a key component for continuous solidification, so that the quality of molten steel is directly affected. In the prior art, the crystallizer is mostly made of steel pipes, but under the action of high temperature and large load, the steel pipes of the crystallizer are easy to deform, so that quality problems such as product surface cracks and inclusions are caused, and the stable operation of the continuous casting machine is seriously influenced. Aiming at the deformation problem of the crystallizer steel pipe, the existing monitoring means have the technical difficulties that the monitoring precision is not high, the deformation trend prediction cannot be carried out, and the like.
Disclosure of Invention
The application aims to solve the technical problems that in the prior art, the deformation monitoring precision of the copper tube of the crystallizer is low and deformation trend prediction cannot be performed.
In view of the above problems, the present application provides a deformation monitoring and early warning method and system for a copper tube of a crystallizer.
In a first aspect of the disclosure, a deformation monitoring and early warning method for a copper tube of a crystallizer is provided, the method comprising: determining deformation monitoring points positioned on the crystallizer copper pipe, wherein the sections of the deformation monitoring points at equidistant positions are randomly distributed; the temperature monitoring and the stress monitoring of the deformation monitoring points are carried out by combining the sensing monitoring device, the same coordinate system conversion of monitoring data is carried out, and a situation chemotactic curve is built; the deformation analysis module is combined to perform deformation analysis on deformation monitoring points in a continuous heat exchange environment, and single-point deformation data are determined, wherein a situation trend deformation curve is embedded in the deformation analysis module, and the single-point deformation data comprise a crystallization softening coefficient and a plastic deformation coefficient; based on a copper pipe geometric detection module, detecting the local geometric state of the crystallizer copper pipe, and determining section geometric data, wherein the copper pipe geometric detection module comprises a straight section processing branch and a curved section processing branch; configuring a diversified deformation reference table, wherein the diversified deformation reference table comprises a mapping index sequence under a multi-level deformation standard; and traversing the diversified deformation reference table, matching the single-point deformation data with the section geometric data, determining the whole deformation grade and generating deformation early warning information.
In another aspect of the present disclosure, a deformation monitoring and early warning system for a copper tube of a crystallizer is provided, the system comprising: the deformation monitoring point determining module is used for determining deformation monitoring points positioned on the crystallizer copper pipe, and the deformation monitoring points are randomly distributed on the cross section at equidistant positions; the deformation monitoring point monitoring module is used for carrying out temperature monitoring and stress monitoring of the deformation monitoring points by combining the sensing monitoring device, carrying out the same coordinate system conversion of monitoring data and constructing a situation trend curve; the single-point deformation data module is used for carrying out deformation analysis on deformation monitoring points in a continuous heat exchange environment in combination with the deformation analysis module to determine single-point deformation data, wherein a situation trend deformation curve is embedded in the deformation analysis module, and the single-point deformation data comprises a crystallization softening coefficient and a plastic deformation coefficient; the geometric state detection module is used for detecting the local geometric state of the copper pipe of the crystallizer based on the copper pipe geometric detection module and determining section geometric data, and the copper pipe geometric detection module comprises a straight section processing branch and a curved section processing branch; the deformation reference table configuration module is used for configuring a diversified deformation reference table, wherein the diversified deformation reference table comprises a mapping index sequence under a multi-level deformation standard; the deformation early warning information module is used for traversing the diversified deformation reference table, matching the single-point deformation data with the section geometric data, determining the whole deformation grade and generating deformation early warning information.
One or more technical solutions provided in the present application have at least the following technical effects or advantages:
due to the fact that deformation monitoring points located on the crystallizer steel tube are determined, deformation information of each position of the steel tube is comprehensively and accurately captured; the temperature monitoring and the stress monitoring of deformation monitoring points are carried out by combining a sensing monitoring device, a deformation situation curve is established, and the deformation trend prediction of the crystallizer steel pipe under the thermodynamic load is realized; the deformation analysis module is combined to perform deformation analysis on deformation monitoring points in a continuous heat exchange environment, single-point deformation data combining a temperature field and a stress field are determined, and deformation evaluation parameterization and accuracy are achieved; based on the steel pipe geometric detection module, the local geometric state detection is carried out on the crystallizer steel pipe so as to distinguish the difference of the deformation rules of the straight section and the curved section, so that the deformation analysis is more targeted; a diversified deformation reference table is configured, detection standards are set for different deformation degrees, and deformation early warning systems are enabled to be comprehensive; the technical scheme of matching monitoring data and standards, determining deformation grade and generating early warning information to realize accurate monitoring and early warning of the deformation process of the crystallizer steel pipe solves the technical problems that the deformation monitoring precision of the crystallizer copper pipe in the prior art is low and deformation trend prediction cannot be performed, and achieves the technical effect of realizing accurate monitoring and early warning of the deformation of the crystallizer copper pipe.
The foregoing description is only an overview of the technical solutions of the present application, and may be implemented according to the content of the specification in order to make the technical means of the present application more clearly understood, and in order to make the above-mentioned and other objects, features and advantages of the present application more clearly understood, the following detailed description of the present application will be given.
Drawings
Fig. 1 is a schematic flow chart of a deformation monitoring and early warning method for a copper tube of a crystallizer according to an embodiment of the present application;
fig. 2 is a schematic flow chart of a situation trend curve generated in a deformation monitoring and early warning method for a copper tube of a crystallizer according to an embodiment of the present application;
fig. 3 is a schematic structural diagram of a deformation monitoring and early warning system for a copper tube of a crystallizer according to an embodiment of the present application.
Reference numerals illustrate: the system comprises a deformation monitoring point determining module 11, a deformation monitoring point monitoring module 12, a single-point deformation data module 13, a geometric state detecting module 14, a deformation reference table configuration module 15 and a deformation early warning information module 16.
Detailed Description
The technical scheme provided by the application has the following overall thought:
the embodiment of the application provides a deformation monitoring and early warning method and system for a crystallizer copper pipe. Firstly, multipoint deformation monitoring points are arranged on a crystallizer steel pipe so as to comprehensively and accurately capture deformation information of different positions. Then, real-time deformation situation prediction is established through monitoring of temperature and stress sensors, and judgment of deformation trend is achieved. Meanwhile, a deformation analysis module is arranged, deformation calculation analysis is carried out on each monitoring point by combining temperature field and stress field parameters, and accurate single-point deformation data are obtained. In addition, the steel pipe geometric shape detection module is utilized to distinguish the straight section and the curved section of the steel pipe, so that the deformation analysis pertinence is stronger. To systematically perform deformation determination, a diversified deformation reference table is constructed. And finally, determining the overall deformation grade of the crystallizer steel pipe through the data obtained by matching monitoring and the diversified deformation reference table, and generating deformation early-warning information according to the early-warning rule. The method realizes the accurate monitoring and scientific early warning of the deformation process of the crystallizer steel tube, effectively solves the technical problem that the accurate deformation monitoring and trend prediction cannot be carried out in the prior art, and achieves the technical effect of improving the running stability of the continuous casting machine.
Having described the basic principles of the present application, various non-limiting embodiments of the present application will now be described in detail with reference to the accompanying drawings.
Example 1
As shown in fig. 1, an embodiment of the present application provides a deformation monitoring and early warning method for a copper tube of a crystallizer, where the method includes:
determining deformation monitoring points positioned on the crystallizer copper pipe, wherein the sections of the deformation monitoring points at equidistant positions are randomly distributed;
in the embodiment of the application, the deformation monitoring point is a specific position point for detecting the deformation of the crystallizer copper pipe. In order to comprehensively monitor the deformation condition of the copper pipe, a plurality of deformation monitoring points are arranged on the section of the copper pipe. The position of the deformation monitoring point is determined by combining equidistant distribution and random distribution.
First, the positions of a plurality of preliminary deformation monitoring points are determined on the section of the copper pipe at fixed intervals, for example, one deformation monitoring point is determined every 10 cm. Then, on each section, a certain number of points are randomly selected as final deformation monitoring points within a range containing the preliminary deformation monitoring points. The mode of the equidistant distribution and the random distribution is integrated, so that the deformation monitoring points are approximately and uniformly distributed, the randomness of deformation monitoring is increased, the monitoring precision of the deformation condition of the copper pipe is improved, and a foundation is provided for subsequent deformation monitoring and analysis.
The temperature monitoring and the stress monitoring of the deformation monitoring points are carried out by combining a sensing monitoring device, the same coordinate system conversion of monitoring data is carried out, and a situation chemotactic curve is built;
further, the method specifically comprises the following steps:
based on a temperature sensor, performing field temperature monitoring on the deformation monitoring points of the crystallizer copper pipe to obtain a temperature field;
based on a stress sensor, monitoring field stress of the deformation monitoring points of the crystallizer copper pipe, and obtaining a stress field;
and coaxially converting the temperature field and the stress field to generate a situation chemotaxis curve, wherein the situation chemotaxis curve has aging updating property.
Further, as shown in fig. 2, this step further includes:
setting up a transformation coordinate system by taking time, deformation monitoring points, field temperature and field stress as coordinate axes;
determining a first coordinate set by taking time, deformation monitoring points and field temperature as coordinate dimensions;
determining a second coordinate set by taking time, deformation monitoring and field stress as coordinate dimensions, wherein the first coordinate set and the second coordinate set have a mapping relation;
and aiming at the first coordinate set and the second coordinate set, distributing the first coordinate set and the second coordinate set in the transformation coordinate system to serve as the situation chemotaxis curve.
In a preferred embodiment, the temperature sensor and the stress sensor are installed at predetermined deformation monitoring point positions to constitute a sensing monitoring device. When the crystallizer copper pipe runs, the temperature sensor monitors the temperature of each deformation monitoring point in real time, and the stress sensor monitors the stress of each deformation monitoring point in real time. Then, a temperature sensor detects a temperature value t of a space coordinate point (x, y, z) of each deformation monitoring point of the crystallizer copper pipe in a covering field to obtain a temperature field (x, y, z, t); the stress sensor detects the stress value f of each spatial coordinate point (x, y, z) of each deformation monitoring point of the crystallizer copper pipe in the covering field, and obtains the stress field (x, y, z, f). The temperature field represents the temperature distribution state of the crystallizer copper pipe in the three-dimensional space of the area near the deformation monitoring point; the stress field represents the stress distribution state of the crystallizer copper pipe in the three-dimensional space of the area near the deformation monitoring point.
Then, four coordinate axes of the transformation coordinate system are respectively determined as time, deformation monitoring points, field temperature and field stress. Wherein, the time axis represents the trend of the data of the temperature field and the stress field along with time; the deformation monitoring point axis represents the distribution of the temperature field and the stress field on each monitoring point; the field temperature axis and the field stress axis represent data measures of temperature and stress fields. And then, a four-dimensional conversion coordinate system integrating information reflecting the temperature field and the stress field is built according to the determined coordinate axes, so that a foundation is laid for subsequent coordinate conversion. Then, in constructing a transformed coordinate system, a time, a deformation monitoring point, and a field temperature are selected as coordinate axes, as coordinate dimensions of a first coordinate set representing a three-dimensional coordinate set of temperature field data, each coordinate point representing a temperature field value at the deformation monitoring point at the time. Meanwhile, in the constructed transformation coordinate system, time, deformation monitoring points and field stress are selected as coordinate axes and serve as coordinate dimensions of a second coordinate set, wherein the second coordinate set represents a three-dimensional coordinate set of stress field data, and each coordinate point represents a stress field value at the deformation monitoring point at the time. The first coordinate set and the second coordinate set have a mapping relation, and each deformation monitoring point at each time point has a temperature field value and a stress field value.
Thereafter, in the transformed coordinate system, all coordinate points of the first coordinate set representing the temperature field and the second coordinate set representing the stress field are distributed in a four-dimensional space of the transformed coordinate system. I.e. each coordinate point occupies a four-dimensional position in the transformed coordinate system. And then, the distribution of the discrete coordinate points in a four-dimensional space is connected into a smooth curve, the smooth curve reflecting the distribution of the coordinate sets is a situation trend curve representing the change trend of the temperature field and the stress field of the copper tube of the crystallizer, and a foundation is established for analyzing the deformation process of the copper tube of the crystallizer.
Different types of monitoring data are integrated in the same coordinate system through the same coordinate system conversion of the monitoring data, a situation trend curve which comprehensively reflects the deformation situation change of the copper pipe is generated based on the integrated monitoring data, the change condition of a temperature field, a stress field and a potential deformation trend of the copper pipe of the crystallizer under the heat load condition is reflected, and support is provided for subsequent deformation prediction and early warning.
Combining a deformation analysis module to perform deformation analysis on the deformation monitoring points in a continuous heat exchange environment, and determining single-point deformation data, wherein the deformation analysis module is embedded with the situation chemotactic curve, and the single-point deformation data comprises a crystallization softening coefficient and a plastic deformation coefficient;
further, the embodiment of the application further includes:
wherein, under different heat exchange environments, the crystallization softening index threshold value is different from the plastic deformation index threshold value;
configuring a plurality of monitoring time intervals, the plurality of monitoring time intervals corresponding to different heat exchange environments;
collecting environment variables of the continuous heat exchange environment, and adjusting the monitoring time interval if the environment variables are out of limit;
along with the adjustment of the monitoring time interval, the axial coordinate spacing of the situation chemotaxis curve is synchronously adjusted.
In a preferred embodiment, the deformation analysis module is a module for analyzing the deformation of the copper tube of the crystallizer, and the module has a situation trend curve embedded therein and reflects the thermal load situation of the copper tube. In the deformation analysis process of the deformation monitoring points under the continuous heat exchange environment, different heat exchange environments correspond to different crystallization softening thresholds and plastic deformation thresholds. Wherein, the crystallization softening index threshold value is a critical value for judging the crystallization softening degree of the material; the plastic deformation index threshold is a critical value for judging plastic deformation of the material. For example, in a high temperature environment, the copper tube material is more prone to loose crystal structure and change in atomic distance, so that the corresponding crystallization softening threshold is lowered, and meanwhile, the yield strength of the material is lowered due to high temperature, so that the corresponding plastic deformation threshold is lowered, and only small stress is needed to possibly cause irreversible plastic deformation. In contrast, in a low temperature environment, greater thermal excitation and stress are required to crystallize, soften and plastically deform the copper tube. Therefore, according to different heat exchange environment conditions, different crystallization softening thresholds and plastic deformation thresholds are set so as to realize accurate judgment of the deformation process of the copper pipe of the crystallizer.
Then, according to the operation period of the crystallizer and the heat exchange condition, a plurality of typical heat exchange environment stages are divided, and each heat exchange environment stage corresponds to a matched monitoring time interval. In the high-temperature environment stage, a shorter monitoring time interval is set to capture rapid deformation; in a low temperature environment, a longer monitoring time interval is set. Different monitoring time intervals correspond to respective heat exchange environments, so that configuration of a plurality of monitoring time intervals is realized, targeted monitoring of deformation characteristics of the crystallizer copper pipe in different operation stages is realized, and deformation analysis is more accurate and effective.
Then, during the operation of the crystallizer, environmental variables affecting heat exchange, including inlet and outlet temperatures, system pressure, medium flow, etc., are continuously collected. And analyzing the change trend and the numerical value of the environment variable, and judging whether the change trend and the numerical value exceed a preset limit range. If the environment changes significantly, such as temperature, pressure increases or decreases suddenly, the monitoring interval is adjusted accordingly. For example, when the environment changes drastically, the monitoring interval is shortened; when stable, the interval is extended. Thereby enabling the deformation analysis to adapt to changes in the heat exchange environment by adjustment of the monitoring interval.
The time axis of the situation trend curve represents the trend of the thermal load change along with time, the coordinate interval on the time axis is set according to the monitoring time interval of deformation analysis, and the interval size, namely the difference value of the time scales of the two coordinate points, represents one monitoring interval period. When the monitoring time interval is adjusted according to the heat exchange environment, the coordinate interval of the situation curve time axis is also synchronously adjusted. As the monitoring interval is shortened, the time axis coordinate spacing is decreased, and vice versa. Therefore, the sampling analysis of the situation chemotaxis curve is synchronously adapted to the environmental change, the real-time synchronization of deformation analysis and the heat exchange environment is realized, and the monitoring precision of the deformation process of the crystallizer copper pipe is improved.
Then, based on the data of the embedded situation deformation curve, comparing and calculating with a corresponding crystallization softening threshold value and a corresponding plastic deformation threshold value by utilizing a deformation analysis module to obtain a crystallization softening coefficient of each deformation monitoring point, wherein the crystallization softening coefficient represents the loosening degree of a crystal structure of the material under the heat load; and meanwhile, calculating the plastic deformation coefficient of each deformation monitoring point to represent the irreversible deformation degree of the material. The crystallization softening coefficient and the plastic deformation coefficient of each deformation monitoring point are used as single-point deformation data to reflect the local specific deformation condition of the crystallizer copper pipe, so that the dynamic analysis of the deformation characteristics of the copper pipe under the complex heat exchange condition is realized, the single-point deformation data is obtained, and the foundation is laid for the subsequent deformation evaluation.
Further, determining single point deformation data, the embodiment of the application further includes:
calling a copper pipe work record, and building a trend prediction tree, wherein the trend prediction tree comprises a multi-level decision layer;
based on the operation time limit of the crystallizer copper pipe, combining the single-point deformation data, performing matching decision on the trend prediction tree, and obtaining a deformation prediction result, wherein the deformation prediction result comprises a single-point deformation moment point and deformation degree;
and determining whether to execute operation early warning or not based on the deformation prediction result.
In a preferred embodiment, after single point deformation data reflecting the local deformation condition of the copper tube is determined, first, operation data of the crystallizer copper tube for a period of time is collected to form a copper tube working record, and various operation parameters such as information of heat exchange environment conditions, temperature change, stress change and the like are contained in the record. Secondly, a multi-layer decision tree model is built on the collected record data by utilizing a machine learning algorithm, each node in the decision tree represents a judgment rule and a decision result, and a multi-level decision layer structure is formed by combining different judgment rules, so that a trend prediction tree is obtained. For example, the first layer is divided according to the heat exchange environment condition, the second layer is divided according to the temperature change, and the like, each layer of decision is comprehensively judged based on different parameters to form a new decision node, and finally a tree-shaped trend prediction model structure is formed to conduct prediction analysis on the deformation trend of the copper pipe.
Then, in the trend predicting tree model, the operation time limit of the copper pipe (the current operation period of the crystallizer copper pipe is the remaining time) is input, and meanwhile, the obtained single-point deformation data of each deformation monitoring point is input. And matching the time limit data and the deformation data of the copper pipe of the crystallizer on the multi-level decision nodes of the prediction tree. And predicting the development trend of each point deformation in future time through decision analysis of the trend prediction tree, and obtaining a deformation prediction result. The deformation prediction result comprises deformation moment points and deformation degrees of each deformation monitoring point in the future, wherein the deformation moment points represent when deformation is expected to occur; the degree of deformation represents the expected magnitude of deformation.
And then analyzing deformation prediction results, checking whether deformation time of each monitoring point is within the current operation time limit of the copper pipe, and judging whether the predicted deformation degree exceeds a preset safety threshold. If the deformation moment of one or more points is within the current working period and the deformation predicted value exceeds the standard, confirming that the working early warning is executed, automatically generating working early warning information, and prompting in a visual and audio mode. The early warning information marks which positions will have problems, and the specific content of the problems. And then, the operation early warning information is transmitted to operators to prompt to take corresponding treatment measures so as to realize intelligent early warning of potential problems and improve the stable operation level of the crystallizer copper pipe.
Detecting the local geometric state of the crystallizer copper pipe based on a copper pipe geometric detection module, and determining section geometric data, wherein the copper pipe geometric detection module comprises a straight section processing branch and a curved section processing branch;
further, the embodiment of the application further includes:
performing section segmentation on the crystallizer copper pipe to determine a straight section and a curve section;
based on the straight section processing branch, screening and linearly fitting the deformation monitoring points aiming at the straight section to determine a linear coefficient;
based on the curved section processing branch, performing curve fitting and Gaussian curvature calculation on the curved section to determine a curvature coefficient;
the segment geometry data is determined based on the linear coefficients and the curvature coefficients.
Further, screening and linear fitting are performed on deformation monitoring points aiming at the straight line section, and the method comprises the following steps:
carrying out symmetry judgment on the curve section and mapping the symmetry section;
based on the mapping symmetrical sections, extracting a first symmetrical section, and calculating and obtaining curvature coefficients by combining the curved section processing branches;
the second symmetric segment is mapped based on the curvature coefficient.
In a preferred embodiment, the copper tube geometry detection module is a functional module for detecting the local geometry of the copper tube of the crystallizer. The module comprises a straight section processing branch and a curved section processing branch, wherein the straight section processing branch is used for specially processing a straight section of the copper pipe; the curve section processing branch is specially used for processing the curve section of the copper pipe.
Firstly, extracting the axial line central line data of a crystallizer copper pipe according to a three-dimensional CAD model of the crystallizer copper pipe, and dividing the copper pipe into a plurality of sections along the axial direction of the central line by adopting an equidistant dividing method. Secondly, analyzing the axial vector change of each section, and judging the section as a straight line section if the vector is kept unchanged; if the axial vector changes, the section of the copper tube is bent in a space shape, the section of the copper tube belongs to a curve section, the judgment is repeated, all sections are classified according to straight lines or curve types, and the complete division of the straight line section and the curve section in the copper tube is obtained.
Then, removing abnormal points from the deformation monitoring points of the determined straight line section, and screening and selecting part of representative deformation monitoring points by using a uniformly distributed sampling method; and extracting space coordinate values of the selected deformation monitoring points, inputting coordinate data of the points into a linear regression model, and training the linear regression model to obtain an equation of the best fit straight line. In the equation, the parameter before the linear term is a linear fitting coefficient, which indicates the inclination degree of the straight line. If the linear coefficient approaches 0, the linear section tends to be horizontal; if the linear coefficient increases, this means that the degree of inclination of the straight line section increases. Linear coefficients reflecting the geometry of the straight line segments are then determined from the linear fit.
Then, the central axis of the curve section is detected, a plurality of corresponding points are selected on both sides of the central axis, and the curvature radius and the rotation angle of the pairs of points are calculated. Comparing the difference of the parameters of the corresponding points at the two sides, and judging that the curve section is symmetrical if the difference is within a set error range; otherwise, the asymmetry is determined. For the symmetrical sections, a curve on the side of the central axis is determined as a first symmetrical section. And then, generating a second symmetrical section through central axis mapping based on the data of the first symmetrical section, so that the first symmetrical section and the second symmetrical section obtained through mapping are symmetrical about the central axis, and judging and mapping correspondence of the symmetrical sections are completed. And then, extracting a first symmetrical section from the symmetrical sections, introducing an established curve section processing branch module, inputting curve data of the first symmetrical section into a curve section processing branch, performing curve fitting and Gaussian curvature calculation, and outputting curvature coefficients of the curve of the first symmetrical section to represent the integral bending characteristics of the first symmetrical section. And then, because the first symmetrical section and the second symmetrical section are symmetrical, the curvature coefficient of the second symmetrical section is the same as that of the first symmetrical section, and the curvature coefficient of the first symmetrical section can be directly mapped to the second symmetrical section, so that the geometric detection efficiency of the curve section is improved. For an asymmetric section, firstly, carrying out high-density sampling on the whole curve section to obtain multi-point coordinate data, and calculating a Gaussian curvature value of the curve at each sampling point to represent the bending degree of the space curve at the point. Then, the arithmetic mean value of the gaussian curvatures of all the sampling points is counted, and the mean curvature is taken as the curvature coefficient of the whole curve section to reflect the whole bending characteristics of the asymmetric curve section.
Then, the linear coefficients of all the straight line sections are combined into one-dimensional matrix, and the curvature coefficients of all the curve sections are combined into one-dimensional matrix. And transversely splicing the two matrixes to form a comprehensive parameter matrix, wherein the comprehensive parameter matrix comprises linear coefficients and curvature coefficients of all sections, and the matrix is section geometric data representing the overall geometric state of the copper pipe of the crystallizer and reflects the spatial morphological characteristics of the copper pipe at each position.
Configuring a diversified deformation reference table, wherein the diversified deformation reference table comprises a mapping index sequence under a multi-level deformation standard;
in an embodiment of the present application, the multi-level deformation reference table is a reference standard including a plurality of sets of deformation evaluation parameters, and the multi-level deformation reference table includes a mapping index sequence under a multi-level deformation standard, where the mapping index sequence is a series of changed index values determined according to different deformation standards.
Firstly, collecting different deformation evaluation standards in the industry, including enterprise standards, production standards and the like; these criteria are compared and the levels of the criteria are categorized with varying degrees of stringency. And secondly, extracting parameter indexes of deformation judgment, such as a stress threshold value, a deformation limit value and the like, at each standard level. Again, a set of mapping values for each index is determined based on the severity of the criterion, representing a change from light to light. And repeating the process to obtain the mapping index sequence under each level standard. Then, integrating all the level standards and the corresponding index sequences into a table, wherein the rows represent standard levels and the columns represent mapping index sequences. The table is a reference table for the composition of the diversified deformations.
And traversing the multi-element deformation reference table, matching the single-point deformation data with the section geometric data, determining the whole deformation grade and generating deformation early warning information.
In the embodiment of the present application, first, all deformation evaluation criteria in the diversified deformation reference table are extracted, including a plurality of severity levels. And simultaneously, the obtained single-point deformation data and section geometric data are taken out. In the first level standard, the data is matched with various threshold requirements, whether the data meets the first level standard is judged, and if the data does not meet the first level standard, the data is relaxed to the second level. And (3) circularly matching step by step until the lowest conforming standard grade is found, wherein the grade is the current integral deformation grade of the crystallizer steel pipe. And then comparing the deformation grade with the warning grade, and if the deformation grade is lower than the warning grade, generating deformation early warning information comprising deformation positions and overrun items. And then, the deformation early warning information is sent to the monitoring personnel to take corresponding treatment measures. And through multistage deformation standard matching judgment, the accurate monitoring and early warning of the deformation of the copper pipe of the crystallizer are realized.
In summary, the deformation monitoring and early warning method for the copper tube of the crystallizer provided by the embodiment of the application has the following technical effects:
deformation monitoring points located on the crystallizer copper pipe are determined, and the sections of the deformation monitoring points at equidistant positions are randomly distributed so as to comprehensively and accurately capture deformation information of each position of the steel pipe. And the temperature monitoring and the stress monitoring of the deformation monitoring points are carried out by combining the sensing monitoring device, the same coordinate system conversion of monitoring data is carried out, a situation trend curve is built, and the deformation trend prediction of the crystallizer steel pipe under the thermodynamic load is realized. And combining a deformation analysis module to perform deformation analysis on deformation monitoring points in a continuous heat exchange environment, and determining single-point deformation data, wherein a situation trend deformation curve is embedded in the deformation analysis module, and the single-point deformation data comprises a crystallization softening coefficient and a plastic deformation coefficient, so that deformation evaluation parameterization and accuracy are realized. Based on the copper pipe geometric detection module, the partial geometric state detection is carried out on the crystallizer copper pipe, the section geometric data is determined, the copper pipe geometric detection module comprises a straight section processing branch and a curved section processing branch, the difference of the deformation rule of the straight section and the curved section is distinguished, and the deformation analysis is more targeted. And configuring a diversified deformation reference table, wherein the diversified deformation reference table comprises a mapping index sequence under a multi-level deformation standard, so that detection standards are set for different deformation degrees, and the deformation early warning system is more comprehensive. And traversing the diversified deformation reference table, matching the single-point deformation data with the section geometric data, determining the overall deformation grade and generating deformation early warning information, and realizing accurate monitoring and early warning of the deformation process of the crystallizer steel tube.
Example two
Based on the same inventive concept as the deformation monitoring and early warning method for the copper tube of the crystallizer in the foregoing embodiment, as shown in fig. 3, an embodiment of the present application provides a deformation monitoring and early warning system for the copper tube of the crystallizer, where the system includes:
the deformation monitoring point determining module 11 is used for determining deformation monitoring points positioned on the crystallizer copper pipe, and the sections of the deformation monitoring points at equidistant positions are randomly distributed;
the deformation monitoring point monitoring module 12 is used for carrying out temperature monitoring and stress monitoring of the deformation monitoring points by combining a sensing monitoring device, carrying out the same coordinate system conversion of monitoring data and constructing a situation trend curve;
the single-point deformation data module 13 is used for carrying out deformation analysis on the deformation monitoring points in a continuous heat exchange environment in combination with a deformation analysis module to determine single-point deformation data, wherein the deformation analysis module is embedded with the situation trend deformation curve, and the single-point deformation data comprises a crystallization softening coefficient and a plastic deformation coefficient;
the geometric state detection module 14 is used for detecting the local geometric state of the copper pipe of the crystallizer based on the copper pipe geometric detection module, and determining section geometric data, wherein the copper pipe geometric detection module comprises a straight section processing branch and a curved section processing branch;
the deformation reference table configuration module 15 is configured to configure a diversified deformation reference table, where the diversified deformation reference table includes a mapping index sequence under a multi-level deformation standard;
and the deformation early-warning information module 16 is used for traversing the multi-element deformation reference table, matching the single-point deformation data with the section geometric data, determining the whole deformation grade and generating deformation early-warning information.
Further, the deformation monitoring point monitoring module 12 includes the following steps:
based on a temperature sensor, performing field temperature monitoring on the deformation monitoring points of the crystallizer copper pipe to obtain a temperature field;
based on a stress sensor, monitoring field stress of the deformation monitoring points of the crystallizer copper pipe, and obtaining a stress field;
and coaxially converting the temperature field and the stress field to generate a situation chemotaxis curve, wherein the situation chemotaxis curve has aging updating property.
Further, the deformation monitoring point monitoring module 12 further includes the following steps:
setting up a transformation coordinate system by taking time, deformation monitoring points, field temperature and field stress as coordinate axes;
determining a first coordinate set by taking time, deformation monitoring points and field temperature as coordinate dimensions;
determining a second coordinate set by taking time, deformation monitoring and field stress as coordinate dimensions, wherein the first coordinate set and the second coordinate set have a mapping relation;
and aiming at the first coordinate set and the second coordinate set, distributing the first coordinate set and the second coordinate set in the transformation coordinate system to serve as the situation chemotaxis curve.
Further, the single point deformation data module 13 includes the following steps:
wherein, under different heat exchange environments, the crystallization softening index threshold value is different from the plastic deformation index threshold value;
configuring a plurality of monitoring time intervals, the plurality of monitoring time intervals corresponding to different heat exchange environments;
collecting environment variables of the continuous heat exchange environment, and adjusting the monitoring time interval if the environment variables are out of limit;
along with the adjustment of the monitoring time interval, the axial coordinate spacing of the situation chemotaxis curve is synchronously adjusted.
Further, the single point deformation data module 13 further includes the following execution steps:
calling a copper pipe work record, and building a trend prediction tree, wherein the trend prediction tree comprises a multi-level decision layer;
based on the operation time limit of the crystallizer copper pipe, combining the single-point deformation data, performing matching decision on the trend prediction tree, and obtaining a deformation prediction result, wherein the deformation prediction result comprises a single-point deformation moment point and deformation degree;
and determining whether to execute operation early warning or not based on the deformation prediction result.
Further, the geometry detection module 14 comprises the following execution steps:
performing section segmentation on the crystallizer copper pipe to determine a straight section and a curve section;
based on the straight section processing branch, screening and linearly fitting the deformation monitoring points aiming at the straight section to determine a linear coefficient;
based on the curved section processing branch, performing curve fitting and Gaussian curvature calculation on the curved section to determine a curvature coefficient;
the segment geometry data is determined based on the linear coefficients and the curvature coefficients.
Further, the geometry detection module 14 further comprises the following execution steps:
carrying out symmetry judgment on the curve section and mapping the symmetry section;
based on the mapping symmetrical sections, extracting a first symmetrical section, and calculating and obtaining curvature coefficients by combining the curved section processing branches;
the second symmetric segment is mapped based on the curvature coefficient.
Any of the steps of the methods described above may be stored as computer instructions or programs in a non-limiting computer memory and may be called by a non-limiting computer processor to identify any of the methods to implement embodiments of the present application, without unnecessary limitations.
Further, the first or second element may not only represent a sequential relationship, but may also represent a particular concept, and/or may be selected individually or in whole among a plurality of elements. It will be apparent to those skilled in the art that various modifications and variations can be made in the present application without departing from the scope of the application. Thus, if such modifications and variations of the present application fall within the scope of the present application and the equivalents thereof, the present application is intended to cover such modifications and variations.
Claims (4)
1. The deformation monitoring and early warning method for the copper pipe of the crystallizer is characterized by comprising the following steps of:
determining deformation monitoring points positioned on the crystallizer copper pipe, wherein the sections of the deformation monitoring points at equidistant positions are randomly distributed;
the temperature monitoring and the stress monitoring of the deformation monitoring points are carried out by combining a sensing monitoring device, the same coordinate system conversion of monitoring data is carried out, and a situation chemotactic curve is built;
combining a deformation analysis module to perform deformation analysis on the deformation monitoring points in a continuous heat exchange environment, and determining single-point deformation data, wherein the deformation analysis module is embedded with the situation chemotactic curve, and the single-point deformation data comprises a crystallization softening coefficient and a plastic deformation coefficient;
detecting the local geometric state of the crystallizer copper pipe based on a copper pipe geometric detection module, and determining section geometric data, wherein the copper pipe geometric detection module comprises a straight section processing branch and a curved section processing branch;
configuring a diversified deformation reference table, wherein the diversified deformation reference table comprises a mapping index sequence under a multi-level deformation standard;
traversing the multi-element deformation reference table, matching the single-point deformation data with the section geometric data, determining the whole deformation grade and generating deformation early warning information;
the method for constructing the situation chemotaxis curve comprises the following steps:
based on a temperature sensor, performing field temperature monitoring on the deformation monitoring points of the crystallizer copper pipe to obtain a temperature field;
based on a stress sensor, monitoring field stress of the deformation monitoring points of the crystallizer copper pipe, and obtaining a stress field;
coaxially converting the temperature field and the stress field to generate a situation chemotaxis curve, wherein the situation chemotaxis curve has aging updating property;
wherein, the temperature field and the stress field are subjected to coaxial conversion to generate a situation chemotaxis curve, and the method comprises the following steps:
setting up a transformation coordinate system by taking time, deformation monitoring points, field temperature and field stress as coordinate axes;
determining a first coordinate set by taking time, deformation monitoring points and field temperature as coordinate dimensions;
determining a second coordinate set by taking time, deformation monitoring and field stress as coordinate dimensions, wherein the first coordinate set and the second coordinate set have a mapping relation;
distributing the first coordinate set and the second coordinate set in the transformation coordinate system to serve as the situation chemotaxis curve;
the deformation analysis is carried out on the deformation monitoring points in a continuous heat exchange environment, and the method comprises the following steps:
wherein, under different heat exchange environments, the crystallization softening index threshold value is different from the plastic deformation index threshold value;
configuring a plurality of monitoring time intervals, the plurality of monitoring time intervals corresponding to different heat exchange environments;
collecting environment variables of the continuous heat exchange environment, and adjusting the monitoring time interval if the environment variables are out of limit;
along with the adjustment of the monitoring time interval, the axial coordinate spacing of the situation chemotaxis curve is synchronously adjusted;
wherein after the single point deformation data is determined, the method comprises the following steps:
calling a copper pipe work record, and building a trend prediction tree, wherein the trend prediction tree comprises a multi-level decision layer;
based on the operation time limit of the crystallizer copper pipe, combining the single-point deformation data, performing matching decision on the trend prediction tree, and obtaining a deformation prediction result, wherein the deformation prediction result comprises a single-point deformation moment point and deformation degree;
and determining whether to execute operation early warning or not based on the deformation prediction result.
2. A method according to claim 1, wherein the crystallizer copper tube is subjected to local geometry inspection, the method comprising:
performing section segmentation on the crystallizer copper pipe to determine a straight section and a curve section;
based on the straight section processing branch, screening and linearly fitting the deformation monitoring points aiming at the straight section to determine a linear coefficient;
based on the curved section processing branch, performing curve fitting and Gaussian curvature calculation on the curved section to determine a curvature coefficient;
the segment geometry data is determined based on the linear coefficients and the curvature coefficients.
3. The method of claim 2, wherein the curve fitting and gaussian curvature calculation is performed for the curve segment, the method comprising:
carrying out symmetry judgment on the curve section and mapping the symmetry section;
based on the mapping symmetrical sections, extracting a first symmetrical section, and calculating and obtaining curvature coefficients by combining the curved section processing branches;
the second symmetric segment is mapped based on the curvature coefficient.
4. The deformation monitoring and early warning system for a copper tube of a crystallizer, which is characterized by being used for implementing the deformation monitoring and early warning method for the copper tube of the crystallizer according to any one of claims 1-3, wherein the method comprises the following steps:
the deformation monitoring point determining module is used for determining deformation monitoring points positioned on the crystallizer copper pipe, and the sections of the deformation monitoring points at equidistant positions are randomly distributed;
the deformation monitoring point monitoring module is used for carrying out temperature monitoring and stress monitoring of the deformation monitoring points by combining a sensing monitoring device, carrying out the same coordinate system conversion of monitoring data and constructing a situation chemotaxis curve;
the single-point deformation data module is used for carrying out deformation analysis on the deformation monitoring points in a continuous heat exchange environment by combining with the deformation analysis module to determine single-point deformation data, wherein the deformation analysis module is embedded with the situation trend deformation curve, and the single-point deformation data comprises a crystallization softening coefficient and a plastic deformation coefficient;
the geometric state detection module is used for detecting the local geometric state of the crystallizer copper pipe based on the copper pipe geometric detection module and determining section geometric data, and the copper pipe geometric detection module comprises a straight section processing branch and a curved section processing branch;
the deformation reference table configuration module is used for configuring a diversified deformation reference table, and the diversified deformation reference table comprises a mapping index sequence under a multi-level deformation standard;
the deformation early warning information module is used for traversing the diversified deformation reference table, matching the single-point deformation data with the section geometric data, determining the overall deformation grade and generating deformation early warning information.
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