1. Project Background & Requirements
As a transport container for molten iron, the hot liquid molten iron is placed in the molten iron tank and transported to the steel-making process by a locomotive. Then, the molten iron in the tank is poured into the furnace by a train. During the use of iron water tank, the resistant material is continuously eroded by hot iron water. Too much resistant material may burn through the resistant material, causing safety accidents and economic losses. Therefore, when the erosion reaches a certain part, the resistant material must be rebuilt. If the resistant material is not corroded seriously, it will cause economic waste. Therefore, it is an important link to ensure the safety and reduce the production cost to make accurate judgement on the corrosion resistance of molten iron tank.
As the equipment connecting blast furnace with steelmaking and other production links, the reasonable management and call of each iron water tank is an important means to provide the production efficiency of steel mills. Finding an effective and effective iron water tank scheduling management method is an effective way to improve the production efficiency.
2. Introduction to Infrared Monitoring System of Iron Water Tank
Order to ensure the production safety and iron can improve the utilization efficiency of iron POTS, design the system scheme based on the electronic identification, in each of the iron can put equipment such as electronic tag through the card reader to identify each iron pot, and then through the scheduling system effective grasp its working state and location, improve production efficiency; In addition, infrared thermal camera was used to measure the outer wall temperature of the iron water tank at the front end to judge the erosion of the lining. The trend analysis of the erosion was made by continuously recording the wall temperature of the same iron water tank on the time axis, so as to ensure the safety of production for the safety classification of iron water tank.
The whole system is composed of tank number automatic identification system, iron water tank transportation system and tank display and temperature monitoring system. The tank number automatic identification system is the foundation, iron water tank transportation system is the focus, and tank display and temperature monitoring system is the core. Identify the tank number through the tank number automatic identification system, and then use each iron water tank in a reasonable and efficient way to ensure production efficiency; At the same time, tank display and temperature monitoring system real-time detection of tank temperature, timely detection of hidden dangers and early warning, to ensure production safety.
2.1.1 Tank number automatic identification system
The uhf electronic radio frequency technology in blast furnace and hot metal ladle location information between steelmaking and locomotive direction information, on the side of the blast furnace iron can bifurcate iron position, track and merge, cast iron side, steel side position, and other important node position in iron can position tracking, and judge the direction of movement, raise the utilization ratio of iron can improve production efficiency.
2.1.2 Iron water tank transportation system
Iron can call system to realize the real-time status of iron POTS and the location of the online tracking, improve before iron and steel production organization and scheduling management level, realize the real time status, and location of hot metal ladle online tracking, improve before iron and steel production organization and scheduling management level, shorten the hot metal ladle turnaround time, decreases the number of the online turnover can achieve iron can work efficiently.
2.1.3 Tank display and temperature monitoring system
In iron can through the specific location of the installation of on-line infrared thermal imager, by the temperature of the infrared thermal imaging detection iron pot, and then the temperature of the iron can and infrared thermal imager is passed on to the control of the computer, combined with the tank number automatic identification system will be different every time after the temperature of the iron tank information into specific folders, convenient for later analysis.
At the same time, in the process of real-time monitoring by on-line thermal imager, when the temperature of iron water tank is detected to be higher than a set value, the system will give an alarm signal to remind the staff to pay attention and carry out timely inspection or maintenance.
The infrared thermal imaging technology is used to detect the infrared radiation of the target object, and to convert the temperature distribution image of the target object into video image by means of photoelectric conversion, signal processing and other means.
Its characteristics are as follows:
1) Real-time display of temperature at each point within the detection range
2) Strong penetrating ability, able to penetrate smoke, high visibility in adverse weather and environment
3) Track temperature anomalies and give automatic alarm
3. System Functions and User Benefits
1. Internal resistant material thickness display
2. Tank analysis and trend management
3. Grading evaluation of tank state
4. Data and trend management
4.Characteristics of iron water tank on-line monitoring system
The on-line monitoring system of iron water tank can detect the temperature in real time and send sound and light alarm signal according to the pre-set warning value, so that the watchman can take corresponding measures in time to ensure the safe production of converter. It has the following advantages:
1) No impact on transportation and maintenance: non-contact temperature measurement does not affect the normal operation of the converter.
2)Alarm visualization: infrared thermal image is provided so that the personnel on duty can quickly locate the alarm position and deal with it.
3) High-resolution infrared thermal image automatic monitoring: realize full coverage and all-weather monitoring of the converter.
4) Intelligent analysis and alarm: Through the acquired temperature data, the system can intelligently analyze the current state and issue an alarm.
5) Automatic equipment identification management: The heat map collected by the system (whether automatic or manual) is automatically identified. The effective equipment target of the heat map can be identified through image registration method to ensure the effectiveness of temperature detection.
6) Detailed equipment working status management: Establish a management system for all equipment and equipment components, so that specific hidden dangers (fever) can be identified in detail when the alarm occurs.
7) Automatic warning: In the monitoring process, if abnormal temperature of the target device is found, it will automatically alarm. The alarm information includes text information and sound information, which will prompt the operator to tell the specific alarm location information, so as to track the hot spots, confirm the alarm situation and troubleshoot.
8) High detection accuracy: The sampling accuracy of the infrared thermal imager adopted is higher than that of the portable instrument in terms of precision and resolution, which is convenient for timely judging the specific hot spots of the equipment, thus gaining valuable time for accurate judging and taking corresponding measures.
9)The system has the advantages of high reliability and real-time performance: using this system, the natural environment will not have any impact, no matter wind and rain, or low temperature and high temperature can realize uninterrupted automatic monitoring.
10)Manpower saving: this system can realize automatic inspection, automatic warning, automatic output report and other functions of the equipment due to its high degree of automation. The frequency of personnel visiting the site was reduced and the work efficiency of on-duty personnel was improved.
Product Applications
Blast furnace burden surface, steel ladle, converter monitoring and others in harsh environment
Model |
M640D800/1600 |
M384D1600/800 |
|
Infrared resolution |
640x480 |
384x288 |
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Pixel size |
17um |
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Frame frequency |
30Hz |
50Hz |
|
Working band |
8~14um |
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Field angle |
100°* 78°, diagonal 115 ° |
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Temperature range |
80~800℃, 160-1600℃ (customizable) |
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Temperature accuracy |
±2℃ or ±2%, can be raised to ±0.4℃ |
Image |
|
Imaging distance |
About 20 times focal lengths to infinity |
Temp measuring template |
Global high and low temp tracking, point/line/rectangle/ellipse temp measuring template, and tracking in template |
Image enhancement |
Adaptive drawing, manual enhancement, electronic zoom |
Color palette |
White hot, black hot, iron red, red saturated, user-defined and others
|
Focus Mode |
Electric/manual, electric lens supports autofocus |
Data |
|
Single frame temp |
PNG / BMP/ JPG image format with temperature information
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Temperature flow |
Total radiant temperature information storage |
Digital video |
H.264, RTSP stream media protocol, MP4 files, HDMI output interface |
Electrical interface |
|
Power supply |
DC9~15V, typical power consumption 2.5W@25℃ |
Analog video |
NTSC/PAL compound video output |
Ethernet |
100/1000 Base, TCP, UDP, IP, DHCP, RTSP, ONVIF, etc.,provide SDK development kit |
Environmental parameters |
|
Humidity |
Non - Condensing 10%~95% |
Temp range |
Operating temp: -10~+60℃, Storage temp: -40ºC~+85℃ |
Level of protection |
IP54, Impact resistance: 25G, Vibration resistance: 2G |