3. Design of Metallurgical Ladle On-line Monitoring System

3.1 On-line Infrared Thermal Imager

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) Free from visible light interference

3) Strong penetrating ability, able to penetrate smoke, high visibility in adverse weather and environment

4) Track temperature anomalies and give automatic alarm

3.2 Air-cooled Protective Cover

Made of double layer stainless steel, with good corrosion resistance, suitable for high temperature, high dust environment or temperature difference environment; All the wires are located on the rear cover plate and connected to the pipe through plastic wrap hose for protection. Therefore, it is widely used in metallurgy, electric power, glass, building materials and other industries to improve production efficiency, improve the working environment and reduce labor intensity.

Technical parameters of air-cooled shield:

Ambient temperature: ≤200℃ Relative humidity: ≤80% (40℃)

Atmospheric pressure: 86 ~ 106Kpa dust concentration: ≤200mg/ m3

Inlet compressed air temperature: ≤35℃ Pressure: 0.3 ~ 0.6mpa

Air volume: 0.3 ~ 0.6L/S

3.3 System Software

Real-time display: real-time display of all radiation heat map, watch the temperature at any position, record, take photos, analyze abnormal conditions, and issue professional test report.

Temperature tracking: Automatically analyze the temperature rise trend of the whole image or specific area of the thermal image to find hidden areas in advance.

Data capture: the thermal image data can be collected regularly for later analysis.

High temperature trigger shooting and alarm: When abnormal temperature occurs, the monitoring background can find it in time. When the alarm is triggered, the acousmo-optic alarm module will emit an alarm sound and the software background will take pictures in the process of the incident.

Fault self-diagnosis: the system can remind the personnel on duty when the terminal equipment fails.

Custom alarm thresholds and levels: Four different alarm thresholds and levels can be defined in the system to assist the staff to evaluate the emergency degree and development trend of hidden dangers.

Automatic classification storage: monitoring data, abnormal data and alarm information will be automatically stored in the corresponding device data column, which can be quickly and accurately called for analysis.

Report function: Various reports can be customized according to customer requirements, and can be exported to Word format.

Temperature curve: The software can observe the real-time temperature curve of the temperature measuring object, so as to determine the trend.

3.4 System Installation and Layout

4. Characteristics of Metallurgical Ladle On-line Monitoring System

By using metallurgical ladle on-line monitoring system, the temperature can be detected in real time and sound and light alarm signals can be sent according to the pre-set warning value, so that the watchman can take corresponding measures in time to ensure ladle safety production. It has the following advantages:

1） No impact on transportation and maintenance: non-contact temperature measurement does not affect the normal operation of ladle.

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: to achieve full coverage of ladle, all-weather monitoring.

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.