EP3456436B1 - Inspection system and process for the monitoring of the functionnality of a spray nozzle in particular in a continuous casting machine - Google Patents
Inspection system and process for the monitoring of the functionnality of a spray nozzle in particular in a continuous casting machine Download PDFInfo
- Publication number
- EP3456436B1 EP3456436B1 EP18194726.8A EP18194726A EP3456436B1 EP 3456436 B1 EP3456436 B1 EP 3456436B1 EP 18194726 A EP18194726 A EP 18194726A EP 3456436 B1 EP3456436 B1 EP 3456436B1
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- camera
- spray
- image
- laser light
- light source
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- 239000007921 spray Substances 0.000 title claims description 141
- 238000009749 continuous casting Methods 0.000 title claims description 19
- 238000007689 inspection Methods 0.000 title claims description 15
- 238000000034 method Methods 0.000 title description 5
- 238000012544 monitoring process Methods 0.000 title description 3
- 238000011156 evaluation Methods 0.000 claims description 19
- 230000007547 defect Effects 0.000 claims description 17
- 239000007788 liquid Substances 0.000 claims description 14
- 238000004891 communication Methods 0.000 claims description 10
- 238000001454 recorded image Methods 0.000 claims description 9
- 238000001816 cooling Methods 0.000 claims description 5
- 238000003860 storage Methods 0.000 claims description 4
- 238000005507 spraying Methods 0.000 claims description 2
- 238000005259 measurement Methods 0.000 description 25
- 238000005266 casting Methods 0.000 description 13
- 238000011109 contamination Methods 0.000 description 5
- 239000013256 coordination polymer Substances 0.000 description 4
- 238000013500 data storage Methods 0.000 description 4
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- 238000012360 testing method Methods 0.000 description 3
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- 238000004458 analytical method Methods 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 239000002826 coolant Substances 0.000 description 2
- 238000004364 calculation method Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
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- 238000003384 imaging method Methods 0.000 description 1
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- 230000007774 longterm Effects 0.000 description 1
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- 230000005499 meniscus Effects 0.000 description 1
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
- B05B12/08—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means
- B05B12/082—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means responsive to a condition of the discharged jet or spray, e.g. to jet shape, spray pattern or droplet size
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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
- B22D11/12—Accessories for subsequent treating or working cast stock in situ
- B22D11/124—Accessories for subsequent treating or working cast stock in situ for cooling
- B22D11/1246—Nozzles; Spray heads
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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
- B22D11/22—Controlling or regulating processes or operations for cooling cast stock or mould
- B22D11/225—Controlling or regulating processes or operations for cooling cast stock or mould for secondary cooling
Definitions
- the invention relates to a strand guide with an inspection system.
- a device and a method for optically inspecting a spray nozzle in a continuous casting plant is in the prior art, for example from the German published patent application DE 10 2011 005 860 A1 known.
- this publication discloses a device for testing a spray nozzle in a continuous casting plant, the device having a running member, e.g. B. has a roller checker or cold strand for passing through the continuous casting system.
- An optoelectronic sensor in particular a video camera, is attached to the running member, with the help of which the properties of the spray nozzle can be measured. With the help of the optical sensor, the spray pattern of the spray nozzle is recorded and then evaluated using a preferably automatic image evaluation method.
- nozzle parameters in particular the coolant pressure of the nozzle, are varied and then a recording of the spray pattern is also made in response to this variation of the nozzle parameters.
- the published publication discloses that the light source is assigned a lamp in order to accordingly illuminate the cooling nozzles to be photographed.
- the Chinese patent application CN 104722735 A and the Korean patent application KR 2009/0039 165 A describe the use of lasers and cameras to check the functionality of a spray nozzle in a continuous casting plant.
- four lasers and four cameras are mounted at different points on a cold strand head.
- the lasers and cameras take on different tasks, such as checking the surface of the mold, centering the guide roller or checking the functionality of the cooling nozzles.
- the collected information is forwarded to a server in real time and then wirelessly forwarded to a monitoring system.
- the invention is based on the object of developing a strand guide with a known inspection system in such a way that the checking of the functionality of the spray nozzle is further improved.
- This task is solved by the subject matter of claim 1.
- the first camera 120 and the first laser light source 130 are arranged to check the spray nozzles 110 on the loose side of the strand guide 220 and / or that the second camera and the second laser light source are arranged to check the spray nozzles on the fixed side of the strand guide ;
- the laser light source is designed to emit a plurality of preferably parallel laser light beams 132, which span the projection surface 134 to generate the image of at least one spray spot 136 generated in the projection surface by the sprayed liquid 115; and that the projection surface 134 is arranged between the camera and the outlet opening of the spray nozzle 110.
- the camera is positioned at a suitable location to record the image in the projection surface. It does not necessarily have to be arranged opposite the spray nozzle; rather, it can be installed at any angle to the projection surface in front of and behind it. The possibly slightly distorted image can - if necessary - be transformed using subsequent image processing.
- the projection surface is preferably formed between the outlet opening of the spray nozzles and the camera and is aligned perpendicular to the main spray direction of the spray nozzle.
- the core feature of the present invention is therefore the generation of the projection surface by the laser beams.
- This quasi-virtual projection surface which is formed only by the laser light beams, advantageously enables good imaging and visualization of the spray spots of the liquid sprayed by the spray nozzle, because due to the virtuality or transparency of the projection surface, the liquid can pass through the projection plane unhindered.
- a material projection surface such as B. a screen, which would also represent an actual obstacle for the liquid
- the spray spots in the projection surface according to the invention from laser light beams are not distorted or falsified by back-reflected liquid components. Represent the spray spots in the projection surface Therefore, the actual functionality of the respective spray nozzle is very accurate.
- the evaluation of the spray spot recorded by the camera represents an actual image of a cross section through the spray cone of the spray nozzle to be tested.
- the image can be evaluated with regard to a defect or incorrect alignment of the spray nozzle either by an appropriately experienced operator or automatically.
- the camera is designed as a digital camera and a module is provided, preferably a software module, for automatically evaluating the recorded image with regard to a defect and/or incorrect alignment of the spray nozzle.
- the laser light source is arranged such that the projection surface extends as a projection plane perpendicular to the spraying direction of the spray nozzle. This has the advantage that the image of the spray spot is not distorted by an inclined position of the projection surface.
- the projection surface is arranged at a distance from the camera.
- the camera can then advantageously be focused on the projection plane to record the image of the spray spot in the projection plane, so that a sharp image of the spray spot can then be recorded.
- the space, especially within a cable guide, is limited, which is why the combination of camera and light source to create the projection surface should be as space-saving and compact as possible.
- a certain minimum distance is required Focusing the camera helpful.
- a distance value a between, for example, 1 - 2 cm has proven useful in practice as a compromise value.
- the camera is designed as a digital camera and has a communication interface, preferably a read/write module.
- the data from the captured images can then be exchanged very easily with other digital devices, especially in a cyber-physical environment.
- the data can then be transmitted very easily from the digital camera to the module for evaluating the recorded image as a digital device.
- the image data can also be transferred to a digital memory, preferably wirelessly, for storage.
- the data memory can be arranged, for example, on a segment of the strand guide. This has the advantage that when servicing the segment, its assigned data memory can be read out and information about a possible defect or incorrect alignment of individual spray nozzles is then immediately available.
- the recorded actual image of the spray spot can be evaluated by comparing this actual image with a predetermined target image for the spray spot when the spray nozzle is functioning properly. Any image deviation that may be detected during this comparison then allows conclusions to be drawn about a defect and/or incorrect alignment of the spray nozzle.
- the specified target image of an optimally functioning spray nozzle can possibly be taken from the specification of the respective spray nozzle issued by the manufacturer or can be determined by recording the spray spot of the optimally functioning spray nozzle in the projection plane.
- Figure 1 shows a continuous casting system 200 known in the prior art. It comprises a mold 210 for casting a casting strand and a strand guide 220 downstream of the mold 210 in the casting direction with a plurality of pairs of rollers for deflecting the casting strand cast in the mold 210 from the vertical to the horizontal.
- the pairs of strand guide rollers can be combined in so-called strand guide segments 225.
- FIG 2 shows a detailed view of the strand guide 220 Figure 1 .
- a large number of pairs of rollers can be seen, of which a first strand guide roller is arranged on the loose side, ie further inside in relation to the curvature of the strand guide, and a second strand guide roller of the pair of rollers is arranged in each case on the fixed side, ie further outwards in relation to the curvature.
- Spray nozzles 110 are clearly arranged in the casting direction between the strand guide rollers 228. These each spray a liquid 115, typically a coolant, onto a casting strand (not shown here) between the pairs of rollers via an outlet opening 112.
- a preferably mobile carrier device 260 which carries the camera 120 according to the invention and the laser light source 130.
- the carrier device can be, for example, a known roll testing device (roll checker) typically used for checking the strand guide, or a cold strand.
- a module 140 for automatically evaluating the image recorded by the camera 120 with regard to a defect and/or incorrect alignment of the spray nozzle 110 can be arranged on the carrier device 260. Alternatively, this module can also be arranged away from the carrier device 260, for example. B. in a row of segments.
- the camera 120 and the laser light source 130 are only arranged on the top of the carrier device 260 for checking the spray nozzles 110 on the loose side of the strand guide.
- a camera 120 and a laser light source 130 can also be mounted on the underside of the carrier device 260 in order to be able to check the functionality of the spray nozzles 110 on the fixed side of the strand guide 220.
- FIG 3 shows a detailed view of the Figure 2 already known inspection system 100 according to the invention.
- the spray nozzle 110 can be seen again with an outlet opening 112, from which the liquid 115 to be sprayed emerges in the form of a spray cone.
- the liquid sprayed in this way hits a projection surface 134 generated by the laser light source 130.
- This projection surface preferably extends as a plane perpendicular to the main spray direction of the spray nozzle 110.
- the distance a between the projection surface 134 and the at least one camera 120 is, for example, 1-2 cm.
- the constellation of camera 120 and projection surface 134 shown, according to which the projection surface 134 is arranged between the camera and the outlet opening of the spray nozzle, is merely an example. Rather, the camera 120 can be installed at any other location from which the projection plane or the image therein can be recorded.
- the projection surface 134 is generated from a plurality of parallel laser light beams, which are emitted by a laser light source 130.
- the projection surface 134 can also be generated directly from the laser light source 130 as a laser light plane.
- the spray spot in the projection plane 134 is ideally circular in terms of its contour and uniformly or harmoniously "colored” inside;
- the uniform "coloring” indicates an even intensity distribution of the sprayed liquid.
- the image of such an ideal spray spot recorded by the camera is also referred to below as the target image 138 of the spray spot.
- spray nozzle 110 If the spray nozzle 110 is not functioning properly, its spray spots typically do not have a clean circular border or several spray spots form in the projection plane 134.
- the camera 120 can be connected to one or more signal transmitters that give a command to record the spray spots of the spray cones.
- Figure 4 shows examples of such different actual images of spray spots.
- Figure 4 (a) shows an actual image 136 of a properly functioning spray nozzle 110.
- the actual image 136 has a clean border, its contour corresponds exactly to the contour of a target image 138 of an optimally functioning spray nozzle 110.
- the actual image 136 is also inside homogeneous; There are no differences in density of the sprayed liquid.
- Figure 4 (b) Here you can clearly see a deviation in the actual image 136 of the spray spot recorded by the camera from a spray nozzle 110 that does not function optimally compared to the target image 138 of an optimal spray nozzle. In particular, the edges of the actual image 136 do not correspond to the desired target contour.
- Figure 4 (c) The actual image 136 shows two separate partial spray spots that should actually be connected. In addition, here too the edge is not designed according to the target image shown.
- Figure 5 shows two actual images of spray spots from neighboring spray nozzles. Overlapping the spray spots may or may not be desired.
- the camera 120 in particular if it is designed as a digital camera, can be assigned a communication interface 122 for preferably wireless communication with other digital devices, in particular in a cyber-physical system.
- the digital device can be, for example, the module 140 for evaluating the recorded image, with the communication interface then being designed to transmit the recorded actual image to the module 140, preferably wirelessly.
- the digital device can be a digital data storage 252.
- the communication interface 122 can also transmit image data to this data memory, then typically for storage, preferably also for long-term storage.
- Storing the actual images of spray spots advantageously offers the possibility of documenting the change in the spray spots of one and the same spray nozzle 110 depending on the operating hours of the spray nozzle. From a given degree of deterioration, a replacement of the spray nozzle can then be recommended, for example.
- the method according to the invention enables the dimensions of the spray spot to be measured as a cross section of the spray cone for each individual spray nozzle in a few millimeters above the plane of the strand surface.
- the measurement of the spray cones can be carried out for a single nozzle, but also for a row of nozzles or the entire carpet of nozzles on the loose and/or fixed side of the strand guide with just a single measuring run of the carrier device.
- the evaluation of the actual images also makes it possible to determine the percentage spray performance of each individual nozzle in relation to a specified target spray performance for each individual nozzle type with regard to the respective installation position in the strand guide. This is done by evaluating the respective cross-section or the respective cross-sectional area of the respective spray spot. If the entire area of the actual image of a spray spot is smaller than the area of the target image of the spray spot, then this indicates a reduced spray performance of the spray nozzle. Depending on the extent of the reduced performance, replacing the spray nozzles is recommended.
- the device generates ad hoc images of the spray spot of the entire row of nozzles.
- the area of the depicted spray spot is compared with the calculated target area of the spray spot using the opening angles (in the casting direction and across the strand width) noted in the specification of the system and the nozzle carpet, for each individual nozzle or nozzle type.
- a percentage comparison of the measured actual and target areas of the spray spot can be recorded as an index of the nozzle condition.
- An average (or deviation) of all calculated states of the nozzles of a segment and the entire nozzle carpet can serve as an index of the state of the strand guide segment.
- the image recording can easily be seen as an explanation and proof of the measured values achieved, including outliers.
- the overlap of the spray spots and the size of the spray spot created by the individual spray nozzle can be evaluated using design data instead of the previous evaluation using reference values.
- the splash water formed at the edge of the spray spot or on the roller underneath will not prevent the measurement results from being recorded.
- the condition of the nozzle can be clearly identified based on the spray spot of each individual spray nozzle.
- the device is able to verify any positioning of the nozzles in the width direction with the same degree of evaluation.
- the incorrectly oriented spray cones of the installed nozzles can be easily identified if the results of the individual nozzle measurement in the segment workshop and in the continuous casting machine differ.
- the camera of the inspection device is not only designed to determine the functionality of spray nozzles, but also to record the condition of mold plates and strand guide rollers within a continuous casting plant. Compared to a new condition, in particular contamination, limescale deposits or wear can be detected, each of which represents a deteriorated condition or a defect.
- Figure 6 shows such detected defects or contamination on a strand guide roller 228. Such defects lead to different errors in the dimensions or the surface of the cast strand produced during casting. The defects identified in this way can then be used as an opportunity to replace the corresponding components.
- the current actual state of a spray nozzle 110, a segment 225, or a mold 210 is regularly documented in order to recognize its changes over time.
- Figure 7 shows the changes in defects or contamination on a strand guide roller 228. These changes in conditions or defects over time can also be a decision criterion for changing a spray nozzle, strand guide roller, segment or mold.
- the provision of the laser light source and the formation of the projection planes are not necessary.
- the camera is preferably used during dry test runs, i.e. H. when the secondary cooling is switched off.
- the camera then provides good photo and/or video recordings of the mold plates or the strand guide rollers. These image recordings then represent very well the current condition of the continuous casting system, but also possible roller misalignments or roller rotations, possible roller runout, possible roller deflection or outliers in the jaw width measurements.
- Figure 9 Images of the mold surface on the fixed or loose side of the strand guide taken during a measurement run, as shown in Figure 9 are shown in the module for image evaluation according to the above-mentioned plausibility check algorithm evaluated. For example, an evaluation of Figure 9 You can see how closely the mold was adjusted or mounted to the foot roller during setup.
- the recorded actual images of a strand guide segment, of the mold or of a strand guide roller can be supplemented with measured values, such as those determined during a roller checker measurement run, for example. These measured values are, for example, values from a crack, spray spot or limescale analysis.
- Figure 8 shows an image of a strand guide roller 228, which is available to the viewing operator with various measured values, e.g. B. Mouth width 249.4 mm, roller misalignment 0.7 mm or roller mobility 3/6 was enriched.
- the images supplemented with these values can then be transmitted to the personnel in the workshop, the casting platform or the control center within an augmented reality AR application.
- the images or the supplemented images can be assigned to a digital profile of a specific component, a cyber twin of the component in a CP system and other applications, e.g. B. for condition monitoring, can be submitted for evaluation.
- a collection of images created in this way represents a detailed visual documentation of the changes in the condition of individual components of a continuous casting plant during its operating time.
- the resulting and collected life records of the individual components for example segments of the strand guide, can be used as a template for a subsequent analysis of changes serve the individual components. For example, the formation of cracks on the mold surface with different coatings and the formation of limescale deposits on the roll surface in the area of the strand guide with different formats of the casting strand can be documented.
- a cyber-physical CP module of the respective individual component e.g. B. of a segment or the mold, the images are sent with the component to the relevant workshop and are then available to the staff there for repairs and work preparation.
- the carrier device 260 or the roll checker can be expanded by installing an electric motor for rotating strand guide rollers in the segment. With it is possible to check the entire roller surface for cracks, wear of the coating or deflection of the rollers.
- a remote control can be provided for the mobile carrier device 260 in order to control its passage through the continuous casting plant in the desired manner.
- the camera on the carrier device can be used as a high-resolution endoscope for a careful inspection of the individual components of the continuous casting system.
- misalignments of the rollers can be detected, which could not be detected using a traditional test method in which the measurement of the cast strand is used to determine whether the rollers are misaligned.
- the images can provide important information about replacing individual segments the next time the strand guide is repaired.
- the digital camera system can be expanded by setting up a reading and writing module in order to save the recorded images in so-called smart labels, which are assigned to the individual components of the strand guide, such as the segments or the mold. With this expansion, the measuring system can establish active communication with other intelligent devices on, for example, the segments, the mold or the cold bar car, or with a cyber-physical environment.
- the CP system, the CP environment, decentralized data processors and the measurement system described can also optionally be connected to a cloud.
- the decentralized data storage described does not exclude a connection to a cloud service. All captured images, measurement and calculation results can be stored in a cloud-based data storage for later use using IoT technologies.
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Description
Die Erfindung betrifft eine Strangführung mit einem Inspektionssystem.The invention relates to a strand guide with an inspection system.
Eine Vorrichtung und ein Verfahren zur optischen Prüfung einer Spritzdüse in einer Stranggießanlage ist im Stand der Technik beispielsweise aus der deutschen Offenlegungsschrift
Die chinesische Patentanmeldung
Ausgehend von diesem Stand der Technik liegt der Erfindung die Aufgabe zugrunde, eine Strangführung mit einem bekannten Inspektionssystem dahingehend weiterzubilden, dass die Überprüfung der Funktionsfähigkeit der Spritzdüse weiter verbessert wird.Based on this prior art, the invention is based on the object of developing a strand guide with a known inspection system in such a way that the checking of the functionality of the spray nozzle is further improved.
Diese Aufgabe wird durch den Gegenstand des Anspruchs 1 gelöst. Dieser ist dadurch gekennzeichnet, dass die erste Kamera 120 und die erste Laserlichtquelle 130 angeordnet sind zum Überprüfen der Spritzdüsen 110 auf der Losseite der Strangführung 220 und/oder dass die zweite Kamera und die zweite Laserlichtquelle angeordnet sind zum Überprüfen der Spritzdüsen auf der Festseite der Strangführung; dass die Laserlichtquelle ausgebildet ist zum Aussenden einer Mehrzahl von vorzugsweise parallelen Laserlichtstrahlen 132, welche die Projektionsfläche 134 aufspannen zum Erzeugen des Bildes von mindestens einem in der Projektionsfläche durch die versprühte Flüssigkeit 115 erzeugten Sprühflecken 136; und dass die Projektionsfläche 134 zwischen der Kamera und der Austrittsöffnung der Spritzdüse 110 angeordnet ist.This task is solved by the subject matter of claim 1. This is characterized in that the
Die Kamera ist an geeigneter Stelle positioniert zum Aufnehmen des Bildes in der Projektionsfläche. Sie muss dafür keineswegs zwingend notwendig gegenüberliegend zu der Spritzdüse angeordnet sein; vielmehr kann sie in beliebigem Winkel zu der Projektionsfläche vor und hinter dieser installiert sein. Das eventuell etwas verzerrte Bild kann - falls erforderlich - mittels nachträglicher Bildverarbeitung transformiert werden. Vorzugsweise ist die Projektionsfläche zwischen der Austrittsöffnung der Spritzdüsen und der Kamera ausgebildet und senkrecht zur Hauptspritzrichtung der Sprühdüse ausgerichtet.The camera is positioned at a suitable location to record the image in the projection surface. It does not necessarily have to be arranged opposite the spray nozzle; rather, it can be installed at any angle to the projection surface in front of and behind it. The possibly slightly distorted image can - if necessary - be transformed using subsequent image processing. The projection surface is preferably formed between the outlet opening of the spray nozzles and the camera and is aligned perpendicular to the main spray direction of the spray nozzle.
Kernmerkmal der vorliegenden Erfindung ist somit die Erzeugung der Projektionsfläche durch die Laserstrahlen. Diese quasi virtuelle, weil nur durch die Laserlichtstrahlen gebildete Projektionsfläche ermöglicht vorteilhafterweise eine gute Abbildung und Sichtbarmachung der Sprühflecken der von der Spritzdüse versprühten Flüssigkeit, weil aufgrund der Virtualität bzw. Transparenz der Projektionsfläche die Flüssigkeit ungehindert durch die Projektionsebene hindurchtreten kann. Im Unterschied zu einer materielten Projektionsfläche, wie z. B. einer Leinwand, die auch ein tatsächliches Hindernis für die Flüssigkeit darstellen würde, werden die Sprühflecken in der erfindungsgemäßen Projektionsfläche aus Laserlichtstrahlen nicht durch zurückreflektierte Flüssigkeitsanteile verzerrt oder verfälscht. Die Sprühflecken in der Projektionsfläche repräsentieren deshalb sehr genau die tatsächliche Funktionsfähigkeit der jeweiligen Spritzdüse. Aufgrund der realistischeren Sprühflecken ist auch eine genauere Überprüfung der Funktionsfähigkeit der jeweiligen Spritzdüse möglich. Durch Auswertung der aufgenommenen Bilder der Sprühflecken kann insbesondere eine Verstopfung oder ein vollständiger Ausfall der jeweiligen Sprühdüse zuverlässig erkannt werden. Dies ist wichtig, um zu verhindern, dass der in einer Stranggießanlage zu kühlende Gießstrang nicht mehr ausreichend oder nur ungleichmäßig gekühlt wird, was zu unerwünschten thermischen Spannungen in dem Strang, beispielsweise zu Längsrissen in der Strangoberfläche, führen kann.The core feature of the present invention is therefore the generation of the projection surface by the laser beams. This quasi-virtual projection surface, which is formed only by the laser light beams, advantageously enables good imaging and visualization of the spray spots of the liquid sprayed by the spray nozzle, because due to the virtuality or transparency of the projection surface, the liquid can pass through the projection plane unhindered. In contrast to a material projection surface, such as B. a screen, which would also represent an actual obstacle for the liquid, the spray spots in the projection surface according to the invention from laser light beams are not distorted or falsified by back-reflected liquid components. Represent the spray spots in the projection surface Therefore, the actual functionality of the respective spray nozzle is very accurate. Due to the more realistic spray spots, a more precise check of the functionality of the respective spray nozzle is also possible. By evaluating the recorded images of the spray spots, a blockage or a complete failure of the respective spray nozzle can be reliably detected. This is important in order to prevent the casting strand to be cooled in a continuous casting system from being cooled insufficiently or only unevenly, which can lead to undesirable thermal stresses in the strand, for example longitudinal cracks in the strand surface.
Die Auswertung des von der Kamera aufgenommenen Sprühfleckens repräsentiert ein Ist-Bild eines Querschnitts durch den Sprühkegel der zu prüfenden Spritzdüse.The evaluation of the spray spot recorded by the camera represents an actual image of a cross section through the spray cone of the spray nozzle to be tested.
Die Auswertung des Bildes im Hinblick auf einen Defekt oder eine falsche Ausrichtung der Sprühdüse kann entweder durch eine entsprechend erfahrene Bedienperson oder automatisch erfolgen.The image can be evaluated with regard to a defect or incorrect alignment of the spray nozzle either by an appropriately experienced operator or automatically.
Gemäß einem ersten Ausführungsbeispiel des erfindungsgemäßen Inspektionssystems ist die Kamera als Digitalkamera ausgebildet und es ist ein Modul vorgesehen, vorzugsweise ein Softwaremodul zur automatischen Auswertung des aufgenommenen Bildes im Hinblick auf einen Defekt und/oder eine fehlerhafte Ausrichtung der Spritzdüse.According to a first exemplary embodiment of the inspection system according to the invention, the camera is designed as a digital camera and a module is provided, preferably a software module, for automatically evaluating the recorded image with regard to a defect and/or incorrect alignment of the spray nozzle.
Weiterhin ist es vorteilhaft, wenn die Laserlichtquelle derart angeordnet ist, dass sich die Projektionsfläche als Projektionsebene senkrecht zu der Aufspritzrichtung der Spritzdüse erstreckt. Dies hat den Vorteil, dass das Abbild des Sprühfleckens nicht durch eine schiefe Lage der Projektionsfläche verzerrt wird.Furthermore, it is advantageous if the laser light source is arranged such that the projection surface extends as a projection plane perpendicular to the spraying direction of the spray nozzle. This has the advantage that the image of the spray spot is not distorted by an inclined position of the projection surface.
Weiterhin ist es vorteilhaft, wenn die Projektionsfläche beabstandet zu der Kamera angeordnet ist. Die Kamera kann dann vorteilhafterweise zur Aufnahme des Bildes des Sprühfleckens in der Projektionsebene auf die Projektionsebene fokussiert werden, so dass dann ein scharfes Bild des Sprühfleckens aufgenommen werden kann. Der Raum insbesondere innerhalb einer Strangführung ist begrenzt, weshalb die Kombination aus Kamera und Lichtquelle zur Erzeugung der Projektionsfläche möglichst raumsparend und kompakt gebaut werden sollte. Andererseits ist ein gewisser Mindestabstand zur Fokussierung der Kamera hilfreich. Als Kompromisswert hat sich ein Abstandswert a zwischen beispielsweise 1 - 2 cm in der Praxis bewährt.Furthermore, it is advantageous if the projection surface is arranged at a distance from the camera. The camera can then advantageously be focused on the projection plane to record the image of the spray spot in the projection plane, so that a sharp image of the spray spot can then be recorded. The space, especially within a cable guide, is limited, which is why the combination of camera and light source to create the projection surface should be as space-saving and compact as possible. On the other hand, a certain minimum distance is required Focusing the camera helpful. A distance value a between, for example, 1 - 2 cm has proven useful in practice as a compromise value.
Es ist vorteilhaft, wenn die Kamera als Digitalkamera ausgebildet ist und eine Kommunikationsschnittstelle, vorzugsweise ein Lese-Schreib-Modul aufweist. Die Daten der aufgenommenen Bilder können dann sehr einfach mit anderen digitalen Einrichtungen, insbesondere in einer cyber-physikalischen Umgebung ausgetauscht werden. So können die Daten dann beispielsweise sehr einfach von der Digitalkamera an das Modul zur Auswertung des aufgenommenen Bildes als digitaler Einrichtung übermittelt werden. Alternativ oder zusätzlich können die Bilddaten auch an einen digitalen Speicher, vorzugsweise drahtlos zur Speicherung übertragen werden. Der Datenspeicher kann beispielsweise auf einem Segment der Strangführung angeordnet sein. Dies hat den Vorteil, dass bei der Wartung des Segmentes dessen zugeordneter Datenspeicher ausgelesen werden kann und dann sofort auch Informationen über einen möglichen Defekt oder eine fehlerhafte Ausrichtung einzelner Spritzdüsen vorliegen.It is advantageous if the camera is designed as a digital camera and has a communication interface, preferably a read/write module. The data from the captured images can then be exchanged very easily with other digital devices, especially in a cyber-physical environment. For example, the data can then be transmitted very easily from the digital camera to the module for evaluating the recorded image as a digital device. Alternatively or additionally, the image data can also be transferred to a digital memory, preferably wirelessly, for storage. The data memory can be arranged, for example, on a segment of the strand guide. This has the advantage that when servicing the segment, its assigned data memory can be read out and information about a possible defect or incorrect alignment of individual spray nozzles is then immediately available.
Das Auswerten des aufgenommenen Ist-Bildes des Sprühfleckens kann durch einen Vergleich dieses Ist-Bildes mit einem vorgegebenen Soll-Bild für den Sprühflecken bei ordnungsgemäßer Funktionsweise der Sprühdüse erfolgen. Eine bei diesem Vergleich eventuell festgestellte Bildabweichung lässt dann Rückschlüsse auf einen Defekt und/oder eine fehlerhafte Ausrichtung der Spritzdüse zu. Das vorgegebene Soll-Bild einer optimal funktionsfähigen Spritzdüse kann eventuell der vom Hersteller herausgegebenen Spezifikation der jeweiligen Spritzdüse entnommen werden oder durch Aufnahme des Sprühfleckens der optimal funktionsfähigen Sprühdüse in der Projektionsebene ermittelt werden.The recorded actual image of the spray spot can be evaluated by comparing this actual image with a predetermined target image for the spray spot when the spray nozzle is functioning properly. Any image deviation that may be detected during this comparison then allows conclusions to be drawn about a defect and/or incorrect alignment of the spray nozzle. The specified target image of an optimally functioning spray nozzle can possibly be taken from the specification of the respective spray nozzle issued by the manufacturer or can be determined by recording the spray spot of the optimally functioning spray nozzle in the projection plane.
Der Beschreibung sind 9 Figuren beigefügt, wobei
- Figur 1
- eine Strangführung nach dem Stand der Technik;
- Figur 2
- eine Detailansicht der Strangführung nach
Figur 1 mit dem erfindungsgemäßen Inspektionssystem; - Figur 3
- eine Detailansicht des erfindungsgemäßen Inspektionssystems;
- Figur 4 (a), (b) und (c)
- Ist-Bilder von aufgenommenen Sprühflecken von Spritzdüsen mit unterschiedlicher Funktionsfähigkeit;
- Figur 5
- zwei überlappende Sprühflecken von Spritzdüsen;
- Figur 6
- ein mit der Kamera aufgenommenes Bild von Kalkablagerungen und/oder Verschmutzungen an einer Strangführungsrolle in der Strangführung;
- Figur 7
- zwei von der Kamera nach unterschiedlichen Betriebszeiten aufgenommenen Bilder von Ablagerungen und Verschmutzungen an der Oberfläche derselben Strangführungsrolle;
- Figur 8
- Bild einer Strangführungsrolle in einer Fehlstellung; und
- Figur 9
- von der Kamera aufgenommenes Bild der Oberfläche einer Kokillenplatte und Fußrolle mit erkennbaren Rissen im Meniskus- und Ausgangsbereich der Kokille
- Figure 1
- a strand guide according to the state of the art;
- Figure 2
- a detailed view of the strand guide
Figure 1 with the inspection system according to the invention; - Figure 3
- a detailed view of the inspection system according to the invention;
- Figure 4 (a), (b) and (c)
- Actual images of recorded spray spots from spray nozzles with different functionality;
- Figure 5
- two overlapping spray spots from spray nozzles;
- Figure 6
- an image recorded by the camera of limescale deposits and/or contamination on a strand guide roller in the strand guide;
- Figure 7
- two images of deposits and contamination on the surface of the same strand guide roller taken by the camera after different operating times;
- Figure 8
- Image of a strand guide roller in a misalignment; and
- Figure 9
- Image taken by the camera of the surface of a mold plate and foot roller with visible cracks in the meniscus and exit area of the mold
Die Erfindung wird nachfolgend unter Bezugnahme auf die genannten Figuren in Form von Ausführungsbeispielen detailliert beschrieben.The invention is described in detail below with reference to the figures mentioned in the form of exemplary embodiments.
Anstelle eines Gießstrangs ist in
In
Die in
Die Projektionsfläche 134 ist generiert aus einer Mehrzahl von parallelen Laserlichtstrahlen, welche von einer Laserlichtquelle 130 ausgesendet werden. Alternativ kann die Projektionsfläche 134 als Laserlichtebene auch direkt von der Laserlichtquelle 130 generiert werden.The
Bei ordnungsgemäß funktionierender Spritzdüse 110 ist der Sprühflecken in der Projektionsebene 134 bezüglich seiner Kontur idealerweise kreisrund und in seinem Innern gleichmäßig bzw. harmonisch "gefärbt" ausgebildet; die gleichmäßige "Färbung" deutet auf eine gleichmäßige Intensitätsverteilung der versprühten Flüssigkeit hin. Das von der Kamera aufgenommene Bild eines solchen idealen Sprühfleckens wird nachfolgend auch als Soll-Bild 138 des Sprühfleckens bezeichnet.When the
Bei nicht ordnungsgemäß funktionierender Sprühdüse 110 ist deren Sprühflecken typischerweise nicht sauber kreisförmig umrandet oder es bilden sich mehrere Sprühflecken in der Projektionsebene 134.If the
Die Kamera 120 kann mit einem oder mehreren Signalgebern verbunden sein, die einen Befehl zur Aufnahme der Sprühflecken der Sprühkegel geben.The
Nochmals zurückkehrend zu
Die Speicherung der Ist-Bilder von Sprühflecken bietet vorteilhafterweise die Möglichkeit, die Veränderung der Sprühflecken ein und derselben Spritzdüse 110 in Abhängigkeit der Betriebsstunden der Sprühdüse zu dokumentieren. Ab einem vorgegebenen Grad der Verschlechterung kann dann beispielsweise ein Austausch der Sprühdüse empfohlen werden.Storing the actual images of spray spots advantageously offers the possibility of documenting the change in the spray spots of one and the
Das erfindungsgemäße Verfahren zum Betreiben des erfindungsgemäßen Inspektionssystems weist folgende Teilschritte auf:
Generieren einer Projektionsfläche 134 aus Laserlichtstrahlen 132 zwischen derAustrittsöffnung 112 der Spritzdüse und derKamera 120.Betreiben der Spritzdüse 110,wobei eine Flüssigkeit 115 aus der Austrittsöffnung der Spritzdüse austritt und in derProjektionsfläche 134 einen für die jeweilige Spritzdüse charakteristischen Sprühflecken 130 als Ist-Bild erzeugt, wobei dieses Bild einen Querschnitt durch denSprühkegel der Spritzdüse 110 repräsentiert.- Aufnehmen des Bildes des Sprühfleckens. Das so aufgenommene Bild kann dann nachfolgend entweder durch eine erfahrene Bedienperson oder automatisch im Hinblick auf einen Defekt oder eine fehlerhafte Ausrichtung der Spritzdüse 110 ausgewertet werden.
- Generating a
projection surface 134 from laser light beams 132 between the outlet opening 112 of the spray nozzle and thecamera 120. - Operating the
spray nozzle 110, with a liquid 115 emerging from the outlet opening of the spray nozzle and producing aspray spot 130 characteristic of the respective spray nozzle as an actual image in theprojection surface 134, this image representing a cross section through the spray cone of thespray nozzle 110. - Capturing the image of the spray spot. The image recorded in this way can then be subsequently evaluated either by an experienced operator or automatically with regard to a defect or incorrect alignment of the
spray nozzle 110.
Der Schritt des Auswertens des Ist-Bildes kann folgende Teilschritte aufweisen:
- Vergleichen des
von der Kamera 120 aufgenommenen Bildes des Sprühfleckens als Ist-Bild 136 mit einem vorgegebenen Soll-Bild 138 für den Sprühflecken bei ordnungsgemäßer Funktionsweise der Spritzdüse 110 zum Ermitteln einer Bild-Abweichung; und - Rückschließen auf einen Defekt und/oder eine fehlerhafte Ausrichtung der Spritzdüse 110 nach Maßgabe der ermittelten Bild-Abweichung.
- Comparing the image of the spray spot recorded by the
camera 120 as theactual image 136 with apredetermined target image 138 for the spray spot when thespray nozzle 110 is functioning properly to determine an image deviation; and - Inference about a defect and/or incorrect alignment of the
spray nozzle 110 based on the determined image deviation.
Das erfindungsgemäße Verfahren ermöglicht die Vermessung der Abmaße des Sprühflecks als Querschnitt des Sprühkegels für jede einzelne Spritzdüse in wenigen Millimetern über der Ebene der Strangoberfläche. Die Vermessung der Spritzkegel kann, wie gesagt, für eine einzelne Düse jedoch auch für eine Düsenreihe oder den gesamten Düsenteppich an der Los- und/oder Festseite der Strangführung alleine bereits mit einer einzigen Messfahrt der Trägereinrichtung durchgeführt werden.The method according to the invention enables the dimensions of the spray spot to be measured as a cross section of the spray cone for each individual spray nozzle in a few millimeters above the plane of the strand surface. As mentioned, the measurement of the spray cones can be carried out for a single nozzle, but also for a row of nozzles or the entire carpet of nozzles on the loose and/or fixed side of the strand guide with just a single measuring run of the carrier device.
Die Auswertung der Ist-Bilder ermöglicht auch die Ermittlung der prozentualen Sprühleistung jeder einzelnen Düse im Verhältnis zu einer vorgegebenen Soll-Sprühleistung für jeden einzelnen Düsentyp bezüglich der jeweiligen Einbauposition in der Strangführung. Dazu dient die Auswertung des jeweiligen Querschnitts bzw. der jeweiligen Querschnittsfläche des jeweiligen Sprühfleckens. Ist die gesamte Fläche des Ist-Bildes eines Sprühfleckens kleiner als die Fläche des Soll-Bildes des Sprühfleckens, dann lässt dies auf eine verminderte Sprühleistung der Spritzdüse schließen. Je nach Ausmaß der Minderleistung ist dann ein Auswechseln der Spritzdüsen zu empfehlen.The evaluation of the actual images also makes it possible to determine the percentage spray performance of each individual nozzle in relation to a specified target spray performance for each individual nozzle type with regard to the respective installation position in the strand guide. This is done by evaluating the respective cross-section or the respective cross-sectional area of the respective spray spot. If the entire area of the actual image of a spray spot is smaller than the area of the target image of the spray spot, then this indicates a reduced spray performance of the spray nozzle. Depending on the extent of the reduced performance, replacing the spray nozzles is recommended.
Die Vorrichtung erzeugt ad hoc Bildaufnahmen des Sprühflecks der gesamten Düsenreihe. Die Fläche des abgebildeten Sprühflecks wird mit der ausgerechneten Soll-Fläche des Sprühflecks anhand der in der Spezifikation der Anlage und des Düsenteppichs notierten Eröffnungswinkel (in der Gießrichtung und über der Strangbreite) verglichen, und zwar für jede einzelne Düse oder jeden Düsentyp. Einen prozentualen Vergleich der gemessenen Ist- und Soll-Flächen des Sprühflecks kann als Index des Düsenzustandes aufgenommen werden. Einen Mittelwert (bzw. Abweichung) aller berechneten Zustände der Düsen eines Segmentes und des kompletten Düsenteppichs können als Index des Zustandes des Segments der Strangführung dienen.The device generates ad hoc images of the spray spot of the entire row of nozzles. The area of the depicted spray spot is compared with the calculated target area of the spray spot using the opening angles (in the casting direction and across the strand width) noted in the specification of the system and the nozzle carpet, for each individual nozzle or nozzle type. A percentage comparison of the measured actual and target areas of the spray spot can be recorded as an index of the nozzle condition. An average (or deviation) of all calculated states of the nozzles of a segment and the entire nozzle carpet can serve as an index of the state of the strand guide segment.
Die Bildaufnahme kann ohne Weiteres als Erklärung und Nachweis der erzielten Messwerte inkl. Ausreißer gelten. Die Überlappung der Sprühflecken sowie die Größe des von der einzelnen Spritzdüse erzeugten Sprühflecks kann anhand von Konstruktionsdaten ausgewertet werden, anstatt der bisherigen Auswertung mittels Referenzwerten. Das gebildete Schwallwasser am Rand des Sprühflecks oder an der darunter liegenden Rolle wird die Aufnahme der Messergebnisse nicht verhindern.The image recording can easily be seen as an explanation and proof of the measured values achieved, including outliers. The overlap of the spray spots and the size of the spray spot created by the individual spray nozzle can be evaluated using design data instead of the previous evaluation using reference values. The splash water formed at the edge of the spray spot or on the roller underneath will not prevent the measurement results from being recorded.
Anhand des Sprühflecks jeder einzelnen Spritzdüse lässt sich der Zustand der Düse eindeutig identifizieren. Die Vorrichtung ist in der Lage, beliebige Positionierungen der Düsen in der Breitenrichtung mit gleichem Auswertungsgrad zu verifizieren. Die falsch orientierten Sprühkegel der eingebauten Düsen lassen sich gut identifizieren, falls die Ergebnisse der Einzeldüsenmessung in der Segmentwerkstatt und in der Stranggießmaschine sich unterscheiden.The condition of the nozzle can be clearly identified based on the spray spot of each individual spray nozzle. The device is able to verify any positioning of the nozzles in the width direction with the same degree of evaluation. The incorrectly oriented spray cones of the installed nozzles can be easily identified if the results of the individual nozzle measurement in the segment workshop and in the continuous casting machine differ.
Gegenüber den gängigen Sprühwasser-Messsystemen verfügt das erfindungsgemäße Messsystem über folgende Vorteile:
- die Vorrichtung kann direkt in der Stranggießmaschine eingesetzt werden und misst den Zustand des realen Düsenteppichs, bei dem aktuellen Anlagenzustand,
- die Vorrichtung ist in der Lage, eine Auswertung der Bilder von vorzugsweise allen Einzeldüsen des Düsenteppichs durchzuführen und zwar in einer Messfahrt für den gesamten Strang,
- die Messergebnisse liefern das ad hoc Abbild des Querschnittes der Sprühkegel wenige mm über der Ebene der Strangoberfläche und zwar für die Los- und Festseite der Strangführung,
- die Messergebnisse können sowohl im Vergleich zu einer Referenzmessung bei voller Funktionsfähigkeit des Inspektionssystems und der Düsen als auch zur Umrechnung auf die Sollfläche des Sprühflecks an der Düsenposition verwendet werden,
- die Vermessung der Sprühflecken und -leistungen des gesamten Sekundarkühlungssystems kann sehr nah an den aktuellen Zustand der Stranggießmaschine, den verwendeten Spritzwassermengen, der eingestellten Gießdicke und Gießbreite, der eingeschalteten Regelkreise erfolgen,
- die Auswertung der Messergebnisse ist durch die realen Bildaufnahmen gut machbar (selbsterklärend),
- die Sollwerte für die Auswertung der Messergebnisse können aus der gelieferten Spezifikation der eingebauten Düsen und nicht unbedingt aus den Messergebnissen einer Referenz-Messfahrt umgerechnet werden,
- die Vorrichtung kann direkt an dem vorhandenen Rollchecker-Gerät befestigt werden. Während einer Messfahrt durch die
Stranggießanlage 200 können Bildaufnahmen von sowohl der Kokille als auch von allen in den Segmenten eingebauten Rollen und Spritzdüsen gemacht und ausgewertet werden. Die Ergebnisse der Auswertung stehen dann vorzugsweise noch während der Messfahrt in Echtzeit zur Verfügung. - die Vorrichtung kann die Messergebnisse des Rollenchecker-Geräts vorzugsweise selbst analysieren, um die denkbaren Augmented Reality AR-Anwendungen durch Ausgabe von Rollen-, Düsenaufnahmen mit angezeigten Werten der Rollenchecker-Messung zu versorgen,
- die Vorrichtung kann autonom agieren, in dem sie die ausgewerteten Bildaufnahmen in an den Segmenten oder Kokille angebauten Smart-Labels abspeichert und den Zustand des Bauteils bewertet, verändert und weiteren Informationssystemen mitteilt.
- the device can be used directly in the continuous casting machine and measures the condition of the real nozzle carpet, given the current system status,
- the device is able to carry out an evaluation of the images of preferably all individual nozzles of the nozzle carpet in one measurement run for the entire strand,
- The measurement results provide an ad hoc image of the cross section of the spray cones a few mm above the level of the strand surface for the loose and fixed sides of the strand guide,
- the measurement results can be used both in comparison to a reference measurement when the inspection system and the nozzles are fully functional and for conversion to the target area of the spray spot at the nozzle position,
- the measurement of the spray spots and performance of the entire secondary cooling system can be carried out very closely to the current state of the continuous casting machine, the amounts of spray water used, the set casting thickness and width, and the switched-on control circuits,
- The evaluation of the measurement results is easy to do thanks to the real image recordings (self-explanatory),
- the target values for the evaluation of the measurement results can be converted from the supplied specification of the installed nozzles and not necessarily from the measurement results of a reference measurement run,
- the device can be attached directly to the existing roll checker device. Images can be taken during a measurement run through the
continuous casting plant 200 are made and evaluated by both the mold and all the rollers and spray nozzles installed in the segments. The results of the evaluation are then preferably available in real time during the measurement drive. - the device can preferably analyze the measurement results of the roll checker device itself in order to supply the conceivable augmented reality AR applications with displayed values of the roll checker measurement by outputting roll and nozzle recordings,
- The device can act autonomously by storing the evaluated image recordings in smart labels attached to the segments or mold and evaluating the condition of the component, changing it and communicating it to other information systems.
Die Kamera des erfindungsgemäßen Inspektionsgerätes ist nicht nur ausgebildet die Funktionsfähigkeit von Sprühdüsen zu ermitteln, sondern auch den Zustand von Kokillenplatten und Strangführungsrollen innerhalb einer Stranggießanlage zu erfassen. Gegenüber einem Neuzustand können insbesondere eine Verschmutzung, Kalkablagerungen oder ein Verschleiß erkannt werden, die jeweils einen verschlechterten Zustand bzw. einen Defekt repräsentieren.
Vorzugsweise wird der jeweils aktuelle Ist-Zustand einer Spritzdüse 110, eines Segmentes 225, oder einer Kokille 210 regelmäßig dokumentiert, um dessen Veränderung über der Zeit zu erkennen.
Für die Erfassung der Zustände bzw. Defekte bei der Kokille und bei den Strangführungsrollen ist das Vorsehen der Laserlichtquelle und die Ausbildung der Projektionsebenen nicht erforderlich.In order to detect the conditions or defects in the mold and in the strand guide rollers, the provision of the laser light source and the formation of the projection planes are not necessary.
Der Einsatz der Kamera erfolgt vorzugsweise bei trockener Messfahrt, d. h. wenn die Sekundärkühlung abgeschaltet ist. Die Kamera liefert dann gute Foto- und/oder Videoaufnahmen der Kokillenplatten oder der Strangführungsrollen. Diese Bildaufnahmen repräsentieren dann sehr gut den aktuellen Zustand der Stranggießanlage, aber auch mögliche Rollenfehlstellungen oder Rollendrehungen, einen möglichen Rollenschlag, eine mögliche Rollendurchbiegung oder Ausreißer in den Messungen von Maulweiten.The camera is preferably used during dry test runs, i.e. H. when the secondary cooling is switched off. The camera then provides good photo and/or video recordings of the mold plates or the strand guide rollers. These image recordings then represent very well the current condition of the continuous casting system, but also possible roller misalignments or roller rotations, possible roller runout, possible roller deflection or outliers in the jaw width measurements.
Konkret können Bild- oder Videoaufnahmen jeder einzelnen Rolle zur Plausibilitätsprüfung verschiedener Messungen, z. B. einer Maulweiten- und Rollenfehlstellungsmessung, wie sie zuvor von einem Rollenchecker-Geräte durchgeführt wurde, verwendet werden. Der Algorithmus der Plausibilitätsprüfung besteht aus folgenden Schritten:
- 1. Bestimmung von Ausreißern in den Messdaten.
- 2. Heraussuchen von Bildern der Rollenoberfläche, die an den entsprechenden Positionen über die ganze Rollenlänge aufgenommen wurden.
- 3. Vergleich von mehreren unter verschiedenen Winkeln der nebeneinander angeordneten Kameras aufgenommenen Bilder mittels einer Stereoskopie-Methode.
- 4. Auswertung von erkannten Rissen insbesondere im Hinblick auf deren Abmaße durch Vergleich der Bilder der neuerlich erkannten Risse mit Bildern von bekannten Riss-Mustern bei vorzugsweise derselben Strangführungsrolle.
- 1. Determination of outliers in the measurement data.
- 2. Find images of the roll surface taken at the appropriate positions along the entire length of the roll.
- 3. Comparison of several images taken at different angles of the cameras arranged next to each other using a stereoscopy method.
- 4. Evaluation of detected cracks, particularly with regard to their dimensions, by comparing the images of the newly detected cracks with images of known crack patterns, preferably on the same strand guide roller.
Während einer Messfahrt aufgenommene Bilder der Kokillenoberfläche an der Fest- oder Losseite der Strangführung, wie sie in
Die aufgenommenen Ist-Bilder von einem Strangführungssegment, von der Kokille oder von einer Strangführungsrolle können nach ihrer Auswertung mit Messwerten, wie sie bei beispielsweise einer Rollchecker-Messfahrt ermittelt wurden, ergänzt werden. Bei diesen Messwerten handelt es sich beispielsweise um Werte aus einer Riss-, Sprühfleck- oder Kalkablagerungsanalyse.
Die Bilder bzw. die ergänzten Bilder können einem digitalen Profil eines bestimmten Bauteils, einem Cyber-Zwilling des Bauteils in einem CP-System zugeordnet und weiteren Anwendungen, z. B. für Condition Monitoring, zur Auswertung vorgelegt werden. Eine so entstehende Sammlung von Bildern stellt eine detaillierte visuelle Dokumentation der Veränderungen des Zustandes einzelner Bauteile einer Stranggießanlage während ihrer Betriebszeit dar. Die so entstehenden und gesammelten Lebensakten von den einzelnen Bauteilen, beispielsweise Segmenten der Strangführung, können als Vorlage für eine nachträgliche Analyse von Veränderungen an den einzelnen Bauteilen dienen. So kann beispielsweise die Bildung von Rissen auf der Kokillenoberfläche bei verschiedenen Beschichtungen, die Bildung von Kalkablagerungen an der Rollenoberfläche im Bereich der Strangführung bei verschiedenen Formaten des Gießstrangs dokumentiert werden. Abgespeichert in einem cyber-physikalischen CP-Modul des jeweiligen einzelnen Bauteils, z. B. eines Segmentes oder der Kokille, werden die Bilder mit dem Bauteil in die jeweils zuständige Werkstatt mitübermittelt und sie stehen dann dem dortigen Personal bei der Reparatur und Arbeitsvorbereitung zur Verfügung.The images or the supplemented images can be assigned to a digital profile of a specific component, a cyber twin of the component in a CP system and other applications, e.g. B. for condition monitoring, can be submitted for evaluation. A collection of images created in this way represents a detailed visual documentation of the changes in the condition of individual components of a continuous casting plant during its operating time. The resulting and collected life records of the individual components, for example segments of the strand guide, can be used as a template for a subsequent analysis of changes serve the individual components. For example, the formation of cracks on the mold surface with different coatings and the formation of limescale deposits on the roll surface in the area of the strand guide with different formats of the casting strand can be documented. Stored in a cyber-physical CP module of the respective individual component, e.g. B. of a segment or the mold, the images are sent with the component to the relevant workshop and are then available to the staff there for repairs and work preparation.
Die Trägereinrichtung 260 bzw. der Rollchecker kann durch den Einbau eines Elektromotors zum Drehen von Strangführungsrollen in dem Segment erweitert werden. Damit besteht die Möglichkeit, die komplette Rollenoberfläche im Hinblick auf Risse, eine Abnutzung der Beschichtung oder eine Durchbiegung der Rollen zu prüfen.The
Es kann eine Fernsteuerung für die mobile Trägereinrichtung 260 vorgesehen sein, um deren Durchfahrt durch die Stranggießanlage in gewünschter Weise zu steuern. Die Kamera an der Trägereinrichtung kann als hochauflösendes Endoskop für eine sorgfältige Inspektion der einzelnen Bauteile der Stranggießanlage verwendet werden.A remote control can be provided for the
Die durch die Auswertung der aufgenommenen Bilder möglichen Rückschlüsse auf Defekte oder eine fehlerhafte Ausrichtung der einzelnen Bauteile der Stranggießanlage, wie insbesondere der Kokille, der Strangführungsrollen oder der Spritzdüsen, stellen eine gute ergänzende Möglichkeit dar, um Rollenfehlstellungen zu erkennen. Insbesondere können auf diese Weise auch Rollenfehlstellungen erkannt werden, die bei einem traditionellen Prüfverfahren, bei dem aus der Vermessung des gegossenen Gießstrangs auf Fehlstellungen der Rollen rückgeschlossen wird, nicht erkannt werden konnten. Zusätzlich können die Bilder wichtige Hinweise zum Auswechseln einzelner Segmente bei der nächsten Reparatur der Strangführung liefern. Das Digitalkamerasystem kann durch Einrichtung eines Lese- und Schreib-Moduls erweitert werden, um die aufgenommenen Bilder in sogenannten Smart-Labels, die den einzelnen Bauteilen der Strangführung, wie den Segmenten oder der Kokille zugeordnet sind, abzuspeichern. Mit dieser Erweiterung kann das Messsystem mit weiteren intelligenten Einrichtungen auf beispielsweise den Segmenten, der Kokille oder dem Kaltstrangwagen, oder mit einer cyber-physikalischen Umgebung eine aktive Kommunikation aufbauen.The conclusions possible through the evaluation of the recorded images about defects or incorrect alignment of the individual components of the continuous casting system, such as in particular the mold, the strand guide rollers or the spray nozzles, represent a good additional option for detecting roller misalignments. In particular, in this way, misalignments of the rollers can be detected, which could not be detected using a traditional test method in which the measurement of the cast strand is used to determine whether the rollers are misaligned. In addition, the images can provide important information about replacing individual segments the next time the strand guide is repaired. The digital camera system can be expanded by setting up a reading and writing module in order to save the recorded images in so-called smart labels, which are assigned to the individual components of the strand guide, such as the segments or the mold. With this expansion, the measuring system can establish active communication with other intelligent devices on, for example, the segments, the mold or the cold bar car, or with a cyber-physical environment.
Das CP-System, die CP-Umgebung, dezentralisierte Daten-Verarbeiter sowie das beschriebene Messsystem können außerdem optional an eine Cloud angekoppelt werden. Hier schließt die beschriebene dezentralisierte Datenabspeicherung eine Anbindung an einen Cloud-Dienst nicht aus. Alle aufgenommenen Bilder, Mess- und Berechnungsergebnisse können mittels der IoT-Technologien in einem Cloud-basierten Datenspeicher für die spätere Nutzung abgelegt werden.The CP system, the CP environment, decentralized data processors and the measurement system described can also optionally be connected to a cloud. Here, the decentralized data storage described does not exclude a connection to a cloud service. All captured images, measurement and calculation results can be stored in a cloud-based data storage for later use using IoT technologies.
- 100100
- InspektionssystemInspection system
- 110110
- Spritzdüsespray nozzle
- 112112
- AustrittsöffnungExit opening
- 115115
- Flüssigkeitliquid
- 120120
- Kameracamera
- 122122
- KommunikationsschnittstelleCommunication interface
- 130130
- Lichtquellelight source
- 132132
- LaserlichtstrahlenLaser light beams
- 134134
- ProjektionsflächeProjection surface
- 136136
- Ist-Bild des SprühfleckensActual image of the spray patch
- 138138
- Soll-Bild des SprühfleckensTarget image of the spray spot
- 140140
- Modul zur automatischen Bild-AuswertungModule for automatic image evaluation
- 200200
- StranggießanlageContinuous casting plant
- 210210
- Kokillemold
- 220220
- Strangführungstrand guide
- 222222
- FußrolleFoot roller
- 225225
- StrangführungssegmentStrand guide segment
- 228228
- StrangführungsrolleStrand guide roller
- 252252
- DatenspeicherData storage
- 260260
- TrägereinrichtungCarrier facility
- 270270
- Defekt oder verschlechterter ZustandDefect or deteriorated condition
- aa
- AbstandDistance
Claims (7)
- Strip guide (220) for guiding a cast strip after leaving a mould (210) in a continuous casting plant (200), comprising:spray nozzles (110) with an outlet opening (112) for spraying a liquid (115) for cooling the cast strip; andan inspection system (100) for checking the functional capability of the spray nozzles (110), comprising:at least one camera (120) for recording an image in a projection area; anda light source (130), which is associated with the camera, in the form of a laser light source;wherein a first camera (120) and a first laser light source (130) of the inspection system are mounted on the upper side of a mobile support device (260) and/or a second camera and a second laser light source are mounted on the lower side of the mobile support device (260); andwherein the support device is constructed in the form of, for example, a roller checking device or a cold strip;characterised in thatthe first camera (120) and the first laser light source (130) are arranged for checking the spray nozzles (110) on the movable side of the strip guide (220) and/or the second camera and the second laser light source are arranged for checking the spray nozzles on the fixed side of the strip guide;the laser light source is constructed for emitting a plurality of preferably parallel laser light beams (132), which span the projection area (134) in order to produce the image of at least one spray spot (136) produced in the projection area by the sprayed liquid (115); andthe projection area (134) is arranged between the camera and the outlet opening of the spray nozzle (110).
- Strip guide (220) according to claim 1,
characterised in that
the inspection system further comprises a module (140) for automatic evaluation of the recorded image with respect to a defect and/or faulty orientation of the spray nozzle (110). - Strip guide (220) according to claim 1,
characterised in that
the laser light source (130) is arranged in such a way that the projection area (134) extends as a projection plane perpendicularly to the main spray direction of the spray nozzle (110). - Strip guide (220) according to any one of the preceding claims,
characterised in that
the projection area (134) is formed at a spacing a, wherein, for example, 1 cm < a < 2 cm, from the camera (120). - Strip guide (220) according to any one of the preceding claims,
characterised in that
the camera (120) comprises a communications interface (122), preferably with a read mode and write mode, for preferably wire-free exchange of data with at least one other digital device, particularly in a cyber-physical environment. - Strip guide (220) according to claim 5,
characterised in thatthe digital device is a module (140) for evaluation of the recorded image; andthe communications interface (122) is configured to transmit the image, which is recorded by the camera (120), preferably in wire-free manner to the module (140) for evaluation of the recorded images, particularly when the module is arranged remotely from the camera (120). - Strip guide according to at least one of claims 5 and 6,
characterised in thatthe digital device is a digital data memory (252), for example configured in the form of a cloud and/or in the form of a decentral data memory, arranged on a strip guide segment (225); andthe communications interface (122) is configured to transmit the image, which is recorded by the camera (120), preferably in wire-free manner for storage at the data memory (252).
Applications Claiming Priority (1)
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BY20170350 | 2017-09-19 |
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EP3456436A1 EP3456436A1 (en) | 2019-03-20 |
EP3456436B1 true EP3456436B1 (en) | 2023-11-08 |
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Application Number | Title | Priority Date | Filing Date |
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EP18194726.8A Active EP3456436B1 (en) | 2017-09-19 | 2018-09-17 | Inspection system and process for the monitoring of the functionnality of a spray nozzle in particular in a continuous casting machine |
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EP (1) | EP3456436B1 (en) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102020205740A1 (en) | 2020-05-07 | 2021-11-11 | Sms Group Gmbh | Inspection system and method for simultaneously checking the functionality of several spray nozzles in a continuous caster, in particular of the spray nozzles arranged between two strand guide rollers |
CN113290218B (en) * | 2021-05-19 | 2022-07-01 | 日照钢铁控股集团有限公司 | Design method of fan-shaped section nozzle of continuous casting machine |
Family Cites Families (5)
Publication number | Priority date | Publication date | Assignee | Title |
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DE102004041671A1 (en) * | 2004-08-27 | 2006-03-02 | Linde Ag | Coating spray monitor, for hot and cold spraying of coatings, has digital camera aligned at illuminated section of particle/droplet flight path to give images for display and processing/evaluation |
US20070242871A1 (en) * | 2006-03-23 | 2007-10-18 | Pratt & Whitney Canada Corp. | Method of computing spray parameters from optical patternation |
KR20090039165A (en) * | 2007-10-17 | 2009-04-22 | (주)윈티앤에스 | Segment roll checker of non-contact type |
DE102011005860A1 (en) | 2011-02-17 | 2012-08-23 | Sms Siemag Ag | Apparatus and method for testing a continuous casting plant |
CN104722735A (en) * | 2015-04-08 | 2015-06-24 | 安徽工业大学 | Detecting device of nozzle operating condition in continuous casting secondary cooling area with laser |
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