CN107096899B - A kind of crystallizer bleedout prediction electric thermo system that logic-based judges - Google Patents

A kind of crystallizer bleedout prediction electric thermo system that logic-based judges Download PDF

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CN107096899B
CN107096899B CN201710346785.1A CN201710346785A CN107096899B CN 107096899 B CN107096899 B CN 107096899B CN 201710346785 A CN201710346785 A CN 201710346785A CN 107096899 B CN107096899 B CN 107096899B
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temperature
thermocouple
alarm
row
data
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CN107096899A (en
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何飞
张玲颖
张林林
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Anhui University of Technology AHUT
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Anhui University of Technology AHUT
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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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Abstract

The invention belongs to metallurgical continuous casting controlling of production process field, the crystallizer bleedout prediction electric thermo system judged more specifically to a kind of logic-based.The hardware composition part of the present invention includes fourplatemold and thermocouple, steel leakage prediction system computer, PLC, interchanger, thermocouple compensation cable, audible-visual annunciator, relay, distant station, further includes that data acquisition unit, bleed-out data compress storage unit, self study and off-line analysis unit, alarm and execution unit automatically；Wherein, steel leakage prediction system computer includes client and server computer, and monitoring of the client computer for bleed-out data is shown；Wherein, the design of the embedded columns and rows spacing of thermocouple makes cohesive tearing port identical the time required to one thermocouple spacing of horizontal and vertical propagation.The present invention realizes the promptly and accurately forecast to bonding steel leakage, ensures continuous casting direct motion and improves slab quality.

Description

A kind of crystallizer bleedout prediction electric thermo system that logic-based judges
Technical field
The invention belongs to metallurgical continuous casting controlling of production process fields, judge more specifically to a kind of logic-based Crystallizer bleedout prediction electric thermo system.
Background technology
The fast development for modernizing high-efficient continuous casting technology, does not require nothing more than high-quality continuous casting billet, and require high pulling rate, bonds Bleed-out is always an important problem for restricting high casting speed continuous casting, solves bonding steel leakage to ensureing that continuous casting direct motion and production are high Quality strand is of great significance, and at present other than improving and inducing the process conditions that green shell bonds, main means are that exploitation is high The fast crystallizer bleedout prediction electric thermo system of forecast accuracy, low rate of false alarm, response.Common crystallizer bleedout prediction electric thermo system both at home and abroad Certain amount thermocouple measurement copper plate temperature variation is buried mainly in copper plate of crystallizer, is propagated based on V-type tearing port is bonded When electric thermo-couple temperature performance the spatial-temporal characteristics such as " time lag " and " temperature inversions ", using logic judgment algorithm or intelligently calculation Method identifies these features, realizes the forecast of bonding steel leakage.Wherein, although intelligent algorithm is solving actual nonlinear problem tool There is preferable performance, but in view of logic judgment algorithm realizes that simple, operability is strong, real-time is high, reliability is high, easy care The advantages that, by broad practice in major steel mill's steel leakage prediction system.
Various logic about breakout prediction judges algorithm, due to the difference of thermocouple arrangement and logic rules design, leads Algorithm performance and time of fire alarming is caused to have very big difference, especially in practical application, not due to thermocouple failure or shell growth Electric thermo-couple temperature fluctuation caused by uniformly equal, easily cause strike-alarm not in time, bond false alarm.Once strike-alarm is too late When, then it can not make to bond reparation by dropping pulling rate measure to avoid bleed-out；And false alarm can cause casting machine to drop suddenly each time Speed is shut down, and huge economy can all be caused as bleed-out accident by seriously affecting the high-efficiency reform of slab quality and casting machine Loss.So in the logic judgment algorithm of design bonding, cohesive behavior is not only quoted in time, consider alarm timeliness, contracting Short alarm time creates favorable conditions for the reparation of follow-up bonding steel leakage, while must reduce false alarm as far as possible again.
Patent document CN101332499A discloses a kind of slab continuous-casting bleedout forecast control method, the forecast control method It is to be based on Thermocouple temperature change, bonding steel leakage judgement is realized by logic judgment algorithm.The forecast control method It is representative temperature waveform when judging that single thermocouple bonds using temperature amplitude inspection and duration, and passes through neighboring thermocouple The time lag of temperature anomaly variation considers cohesive vertical and horizontal dissemination, finally determines that the bleed-out of every thermocouple is several Rate reduces pulling rate and stops cast when the bleed-out probability for certain branch thermocouple occur reaches 95%.Although the forecast control method one Determine the accuracy that degree improves breakout prediction, reduce error-alert degree, still, which does not account for viscous Alarm time and timeliness are tied, especially when being checked using temperature amplitude, to single thermocouple sticking temperature waveform It identifies that time of fire alarming is later, causes not necessarily quote cohesive behavior in time, if later alarm, even if directly shutdown It can not ensure the reparation for bonding breach without bleed-out, if alarmed earlier, keep lower green shell healing pulling rate that can make to glue Breach reparation is tied, and does not need to shut down, stop cast, and increases the unnecessary operating time, reduce production efficiency and increase Equipment loss.
Patent document CN102825234A discloses a kind of judgement alarm method of bonding steel leakage, which is Intersect (i.e. temperature is inverted) feature in the time lag and temperature curve of spatial variations based on multiple rows of electric thermo-couple temperature, is for bonding When representative temperature variation waveform pattern or theoretical temperatures variation waveform pattern and design, and in the actual production process, and Not all sticking temperature variation waveform pattern can all show " temperature inversion " phenomenon, and due to liquid steel level when actual production The influence of the factors such as fluctuation, covering slag performance, MOLTEN STEEL FLOW, thermocouple failure often will appear copper plate of crystallizer thermoelectricity up and down Even temperature is inverted, or in non-adherent such as unsteady statecalculation, thermocouple failures, also often has larger thermocouple Temperature fluctuation also easily generates temperature phenomena of inversion in this way, and institute's design in this way, which undoubtedly increases, to be reported by mistake and fail to report several Rate.
It is comprehensive that current steel leakage prediction system both at home and abroad and the investigation of logic judgment forecasting procedure are found, it is primarily present and asks as follows Topic：(1) thermocouple failure itself causes measured temperature anomalous variation, influences the judgement of breakout prediction algorithm and system.Such as：By In thermocouple quality problems itself, performance is unstable or thermocouple loses pyroelecthc properties, and temperature curve fluctuation is excessive；Thermocouple fills It is bad with mode mistake or sealing, cause greasy dirt or cooling water big into rear measuring temperature and actual temperature deviation, makes temperature Curve is in undulating；Distortion phenomenon occurs in thermocouple signal transmission process, temperature curve is made to fluctuate.(2) open pour, tundish In the case of the unsteady statecalculations such as replacing, pouring eventually, it is affected to electric thermo-couple temperature, can also increases the false alarm of algorithm；Theoretically As long as differentiating under various unsteady state conditions and can reduce wrong report, but real process as long as the electric thermo-couple temperature waveform of bonding process, Sometimes the very close bonding process temperature waveform of electric thermo-couple temperature variation under unsteady state condition, this adds increased breakout prediction models The difficulty of design.(3) some important parameters of logic judgment algorithm depend on specific technique and appointed condition, as equipment is damaged The casting condition variation such as consumption, material replacement, steel grade and covering slag, algorithm are more and more inaccurate.(4) although single thermoelectricity when bonding Even temperature changes over time feature, " time lag " and " temperature inversion " feature of the multiple rows of multiple row electric thermo-couple temperature variation in space has become Common recognition is the foundation of breakout prediction logical algorithm design, although the logic judgment algorithm according to these characteristic Designs is had nothing in common with each other, But there is deficiency to forecast accuracy and considering for time of fire alarming.
In conclusion how to overcome continuous casting breakout prediction method in the prior art and device forecast accuracy and alarm and It is insufficient present on when property, it is the technical barrier of urgent need to resolve in the prior art.
Invention content
1. technical problems to be solved by the inivention
It is an object of the invention to overcome continuous casting breakout prediction method in the prior art and device in forecast accuracy and report It is insufficient present on alert promptness, a kind of crystallizer bleedout prediction electric thermo system that logic-based judges is provided, is realized to bonding The promptly and accurately forecast of bleed-out ensures continuous casting direct motion and improves slab quality.
2. technical solution
In order to achieve the above objectives, technical solution provided by the invention is：
The crystallizer bleedout prediction electric thermo system that the logic-based of the present invention judges, the steel leakage prediction system hardware composition part packet Include fourplatemold and thermocouple, steel leakage prediction system computer, PLC, interchanger, thermocouple compensation cable, sound-light alarm Device, relay, distant station, wherein steel leakage prediction system computer includes client and server computer, client computer Monitoring for bleed-out data shows that server computer is used for breakout prediction model calculation, breakout prediction model and client The compression of information exchange and bleed-out data between breakout prediction graphical interfaces stores；
Wherein, the design of the embedded columns and rows spacing of thermocouple meets following condition：
In formula, txAnd tyTo bond tearing port the time required to one thermocouple spacing of horizontal and vertical propagation；DxAnd DyPoint It Wei not the embedded row and column spacing of copper plate of crystallizer thermocouple；VxAnd VyRespectively bond the horizontal and vertical spread speed of tearing port；β For the tear line for bonding breach and horizontal angle, 20 °~50 ° are taken；
The steel leakage prediction system carries out crystallizer bleedout prediction electric thermo using following steps：
Step 1: reading each logic judgment parameter of regularity in breakout prediction method from parameter configuration files；
Step 2: the acquisition of copper plate of crystallizer electric thermo-couple temperature time series data, storage and pretreatment；
Step 3: carrying out temperature rise inspection respectively to all thermocouples on copper plate of crystallizer simultaneously；
Step 4: carrying out temperature rate-of-rise inspection to the thermocouple for meeting temperature rise Rule of judgment in step 3；
Step 5：To 3 thermocouple TC (i, j-1), TC (i, j+1) and the TC around temperaturing lifting abnormality thermocouple TC (i, j) (i+1, j) carries out temperature change delay and checks, and judges whether to make according to result and bond light alarm；
Step 6：Meet thermocouple TC (i, j) constant temperature and declines inspection or surrounding's electric thermo-couple temperature change of TC (m, n) After changing delay inspection, then seven are entered step；
Step 7：Electric thermo-couple temperature, which is inverted, to be checked；
Step 8：According to alarm shielding condition, judge whether that make bonding steel leakage alarms again.
As further improvement of the present invention, each logic judgment parameter of regularity includes data prediction logic in step 1 Judge that parameter, electric thermo-couple temperature rise and checks that logic judgment parameter, electric thermo-couple temperature climbing speed check logic judgment parameter, heat The delay of galvanic couple temperature change checks that logic judgment parameter, electric thermo-couple temperature decline and checks that logic judgment parameter, electric thermo-couple temperature are fallen It sets and checks that logic judgment parameter, bonding steel leakage are gently alarmed and weight alarming logic judges parameter.
As further improvement of the present invention, in step 2, all electric thermo-couple temperatures in copper plate of crystallizer are acquired first Time series data is simultaneously numbered, the temperature of thermocouple of acquisition per second according to the scheduled row and column arrangement mode storage of thermocouple；
Then following data filtering and smooth pretreatment are carried out：
A) electric thermo-couple temperature is less than 50 DEG C or more than 200 DEG C, is not involved in algorithm calculating；
B) temperature fluctuation per second is more than 20 DEG C and every temperature fluctuation in 2 seconds is more than 38 DEG C, is not involved in algorithm calculating；
C) temperature data that thermocouple current time acquires is made comparisons with the temperature data of the previous second acquisition of the thermocouple, It is more than that 20% temperature data replaces with the temperature data of previous second acquisition by temperature change；
D) time series data of each electric thermo-couple temperature is smoothed using the method for moving average, above-mentioned movement is flat Equal method be with before and after current time one it is intersegmental every temperature data calculate average value and replace current time temperature value, if mobile interval Be positive integer for 2k, k, then the moving average at p momentFor：
In formula, T (p-k) is the electric thermo-couple temperature value at p-k moment.
As further improvement of the present invention, it is as follows to rise inspection for electric thermo-couple temperature in step 3：When thermocouple is normal When work, take check cycle period for temperature rise within every 4 seconds, if the 1st second temperature is a, the 2nd second temperature is b, the 3rd Second temperature is c, and the 4th second temperature is d；Every moment just checks first 3 seconds on a timeline and whether current time meets temperature Degree rises Rule of judgment：d>c>b>a；If certain moment the i-th row j row thermocouple TC (i, j) meets, then by the thermocouple, this is followed τ is labeled as in the ring period at the time of 1st second0(i, j) continues temperature rise inspection in next second if cannot meet；
Wherein：When some temperature rise inspection cycle meets above-mentioned temperature rise Rule of judgment, then next temperature is checked Rise whether inspection cycle still meets above-mentioned temperature rise Rule of judgment, still meets the τ before then maintaining0(i, j), if It is unsatisfactory for, continues temperature rise inspection in next second；
If there is the temperature rise inspection cycle within 4 is continuously unsatisfactory for temperature rise Rule of judgment, with the latter Temperature rise inspection cycle meets temperature rise Rule of judgment again, then the τ before still maintaining0(i, j)；If there is 5 or 5 A temperatures above rises inspection cycle and is continuously unsatisfactory for temperature rise Rule of judgment, then the τ before removing0(i, j), Zhi Houzai When meeting temperature rise Rule of judgment, then a τ is re-established0(i, j), subsequent algorithm is with new τ0On the basis of (i, j).
As further improvement of the present invention, temperature rate-of-rise checks as follows in step 4：When there is τ0(i, j) When, the value of thermocouple TC (i, j) temperature rate-of-rise u=(d-a)/3 is calculated, u and set temperature climbing speed threshold values u are comparedc Size；If u is more than or equal to uc, then it is assumed that the thermocouple TC (i, j) temperature rise is abnormal, while by τ0(i, j) is stored as this Electric thermo-couple temperature begins to ramp up moment t0(i, j), moment acquiescence is temperature change point at first, enters step five.
As further improvement of the present invention, in step 5, in t0Temperature change delay time threshold values after (i, j) In range, repeats the above steps and three and walk to 3 thermocouple TC (i, j-1), TC (i, j+1) and TC (i+1, j) around TC (i, j) Rapid four logic judgment inspection, numeration is marked in the thermocouple TC (m, n) for being satisfied by condition, and stores the temperature of TC (m, n) Begin to ramp up moment t0(m, n) sends out bonding steel leakage and gently alarms, enter back into step 6 when label count is more than 2.
As further improvement of the present invention, in step 6, thermocouple TC (i, j) constant temperature decline check it is as follows： In t0In 30 seconds after (i, j), temperature is carried out to thermocouple TC (i, j) and declines inspection, takes decline inspection for a temperature within every 4 seconds The period is looked into, if the 1st second temperature is a', the 2nd second temperature is b', and the 3rd second temperature is c', and temperature is d' within the 4th second, such as meets d' ﹤ c' ﹤ B' ﹤ a' then judge that temperature decline occurs in thermocouple TC (i, j), if persistently meeting 3 temperature declines inspection cycle, then it is assumed that There is constant temperature decline in thermocouple TC (i, j), is directly entered step 7；
Surrounding's electric thermo-couple temperature change delay of TC (m, n) checks as follows：In t0To institute in 3~15 seconds after (m, n) There are three thermocouple TC (m, n-1) around TC (m, n), TC (m, n+1) and TC (m-1, n) to repeat patrolling for step 3 and step 4 It collects and judges to check, wherein excluding to postpone to check to the temperature change of thermocouple TC (i, j), the equally thermocouple TC to meeting condition Numeration is marked in (x, y), and when marking count to be more than or equal to 3, thermocouple TC (i, j) is labeled as doubtful bonding Point, is directly entered step 7.
As further improvement of the present invention, in step 7, in t0It, will be where TC (i, j) in 30s after (i, j) Two row thermocouples fall into trip temperature under three thermocouple TC (i, j-1) of row, TC (i, j) and TC (i, j+1) corresponding column Logic judgment inspection is set, specially：
Situation (1)：First compare t0Before (i, j) in 10s, whether the mean temperature of i-th row some thermocouple is higher than same The mean temperature of one of lower two 2 thermocouples of row of row；
If it is, observation is in t0After (i, j) in 30s, the time-temperature curve of some thermocouple of i-th row Intersect with whether the time-temperature curve of one of two 2 thermocouples of row under the same column has on the image, if there is intersecting Then think temperature inversion occur, is directly entered step 8；
If be less than, compare t0The temperature for whether occurring i-th row some thermocouple after (i, j) in 30s is first higher than It is less than one of two 2 thermocouples of row under same column again afterwards, if there is, then it is assumed that there is temperature inversion, is directly entered step Rapid eight；
Situation (2)：When being unsatisfactory for situation (1), first compare t010s before (i, j), certain row i+1 row thermocouple are put down Whether equal temperature is higher than the mean temperature of i-th+2 row thermocouple of row；
If it is, in t0After (i, j) in 30s, observes the time-temperature curve of certain row i+1 row thermocouple and be somebody's turn to do Whether the time-temperature curve of the i-th+2 row thermocouple of row has intersection on the image, then thinks that temperature occur falls if there is intersecting It sets, is directly entered step 8；
If be less than, compare t0The temperature for certain row i+1 row thermocouple whether occur in 30s after (i, j) is first higher than It is less than i-th+2 row thermocouple of row after i-th+2 row thermocouple of row again, when there is described situation, still believes that appearance Temperature inversion, is directly entered step 8.
As further improvement of the present invention, alarm shielding condition below is provided in step 8, if discontented Foot alarm shielding condition below just makes bonding steel leakage and alarms again：
1. 120s interior crystallizer liquid levels exceed predetermined minimum and maximum range before alarm, system is not alarmed；
2. before alarm in 120s pulling rate less than it is default do not alarm pulling rate when, system is not alarmed；
3. pulling rate rate of change is more than when presetting not alarming pulling rate rate of change in 120s before alarm, system is not alarmed；
4. when cast length be less than it is default do not alarm cast length when, system is not alarmed；
5. bonding steel leakage is alarmed again after in 60s, system is not alarmed；
6. failure thermocouple number is more than the threshold values of setting, system is not alarmed.
As further improvement of the present invention, in step 2, k is set as 2；In step 4, temperature rate-of-rise threshold values ucIt is set as 0.15 DEG C/s；In step 5, t0Temperature change delay time threshold range after (i, j) is set as 3~15 seconds； In step 8, mould liquid level predetermined minimum, maximum value are respectively 80mm, 120mm；Default pulling rate of not alarming is 0.5m/ min；Default pulling rate rate of change of not alarming is 0.006m/min；Default cast length of not alarming is 3.0m；Failure thermoelectricity even number The threshold values that mesh is set as thermocouple sum 1/3；
The steel leakage prediction system further includes：Data acquisition unit, bleed-out data compress automatically storage unit, self study and from Line analysis unit, alarm and execution unit；
The data acquisition unit is for obtaining electric thermo-couple temperature real time data and casting process product practice, by counting It is formed according to measurement, data transmission and host computer three parts；
Wherein：DATA REASONING part includes sensor and A/D conversion circuits, and A/D conversion circuits are used for sensor measurement To analog signal be converted to digital signal；TCP data segment uses field bus technique, for sending data to distal end Host computer is retrieved as from oracle database by building wherein having from oracle database and from two kinds of acquisition data modes of PLC Vertical continuous casting second databases are connect with the DB links of steel leakage prediction system database, are accessed using synonym；Number is obtained from PLC According to directly to acquire Siemens S7-400 PLC using the OPC of Siemens's host computer Configuration software WinCC communications, acquire up Data are directly stored on the industrial personal computer of installation WinCC；
The bleed-out data compress storage unit for steel leakage prediction system is all during real time execution automatically Data are compressed according to certain file format by way of data flow, each casting cycle terminates to automatically save one File, each casting cycle start with regard to being recorded automatically；
The self study and off-line analysis unit can carry out breakout prediction model algorithm by off-line analysis module offline Emulation specially changes logic judgment parameter of regularity, is played back to bleed-out data, pass through forecast accuracy, rate of false alarm, alarm The performance indicator of frequency carries out study optimization to breakout prediction model on-line parameter；Corresponding steel leakage prediction system is in on-line operation When, each bonding steel leakage is alarmed again send out after, site operation personnel is confirmed whether it is correct bleed-out result and is confirmed whether it is just Really alarm, then system automatically record the correct alarm times of breakout prediction algorithm, error-alert degree, bonding steel leakage quote rate, Forecast accuracy rate of false alarm, reports the index of frequency by mistake, and quotes rate, forecast accuracy and false alarm with the bonding steel leakage of setting Frequency performance index threshold values is compared, once less than setting threshold values, system sends out Parameter Self-learning request；Wherein, leakage is bonded Steel quotes rate=correct alarm times/(failing to report number+correct alarm times), forecast accuracy, and=correct alarm times/(are failed to report Number+correct alarm times+error-alert degree), rate of false alarm=error-alert degree/(correct alarm times+error-alert degree), accidentally Report frequency=error-alert degree/casting furnace number；
The alarm and execution unit send out bleed-out alarm signal by audible-visual annunciator, and light alarm is that amber light is bright, is reported again Alert is when red, if attaching most importance to alarm, warning message uploads to the execution unit of casting speed control, is drawn by sending out reduction to PLC Speed or the instruction directly shut down；
The parameter configuration unit, for being arranged system operational parameters, including various logic judgment rule parameter, system The relevant parameter of username and password and system communication connecting interface, and these parameters are stored in parameter configuration files, Can change parameter in administrator right, and automatically update parameter configuration files, when steel leakage prediction system operation directly from Set file call parameters.
3. advantageous effect
Using technical solution provided by the invention, compared with prior art, there is following remarkable result：
(1) the crystallizer bleedout prediction electric thermo method and system that logic-based proposed by the present invention judges is using bleed-out theory as base Plinth relies on practical bleed-out data and produce reality to be designed, including：1. the design of various logic rule combines, reality is utilized Border various temperature change features when bonding, fully consider balance, that is, when a certain Rule of judgment is more stringent, other Part needs suitably relax, and find equalization point between improving forecast accuracy and reducing rate of false alarm, and also consider alarm response Time and timeliness；2. the determination of breakout prediction algorithm and system core parameter, first by bleed-out data to temperature rise speed Rate threshold values bonds V-type breach horizontal and vertical propagation time, V-type tear line angle, the judgement parameter of data filtering, model screen The statistical analyses such as conditional parameter are covered, is continued to optimize then in conjunction with steel leakage prediction system operation result, makes overall system performance Reach best.
(2) present invention is under the premise of ensureing that bonding steel leakage is all quoted, and in order to reduce false alarm, carries out from many aspects Consider, such as：1. logic judgment algorithm designs, data filtering and smoothing processing, temperature rise inspection, temperature rise are taken Rate inspection, temperature change delay twice check, temperature declines inspection and temperature is inverted and is checked；2. to unsteady statecalculation, thermoelectricity Situations such as even number of defects is more increases alarm shielding condition.
(3) present invention is in order to reduce the shadow of the variation to breakout prediction algorithm and system of casting process and appointed condition etc. It rings, devises the function of systematic parameter self study, the production law to adapt to actual complex changes, to improve breakout prediction system The adaptivity and stability of system.
(4) the crystallizer bleedout prediction electric thermo method and system that logic-based proposed by the present invention judges, meets produce reality, reports Alert fast response time can send out alarm bonding in V-type tearing port propagation 30s, not fail to report, forecast accuracy is high, false alarm Number substantially reduces, and has preferable adaptivity and stability.
Description of the drawings
In order to illustrate the technical solution of the embodiments of the present invention more clearly, below will be to needed in the embodiment attached Figure is briefly described, it should be understood that the following drawings illustrates only certain embodiments of the present invention, therefore is not construed as pair The restriction of range for those of ordinary skill in the art without creative efforts, can also be according to this A little attached drawings obtain other relevant attached drawings.
Fig. 1 is the flow chart for the crystallizer bleedout prediction electric thermo method that logic-based judges in embodiment 1；
Fig. 2 is the thermocouple schematic diagram that breakout prediction logical check respectively walks on copper plate of crystallizer in embodiment 1；
Fig. 3 is the structural schematic diagram of crystallizer bleedout prediction electric thermo system in embodiment 1；
Fig. 4 is affixed side E row electric thermo-couple temperature change curves in embodiment 1；
Fig. 5 is affixed side F row electric thermo-couple temperature change curves in embodiment 1；
Fig. 6 is affixed side G row electric thermo-couple temperature change curves in embodiment 1；
Fig. 7 is affixed side H row electric thermo-couple temperature change curves in embodiment 1；
Fig. 8 is affixed side I row electric thermo-couple temperature change curves in embodiment 1.
Specific implementation mode
In order to make the object, technical scheme and advantages of the embodiment of the invention clearer, below in conjunction with the embodiment of the present invention In attached drawing, technical scheme in the embodiment of the invention is clearly and completely described, it is clear that described embodiment is A part of the embodiment of the present invention, instead of all the embodiments.Therefore, the embodiment of the present invention to providing in the accompanying drawings below Detailed description be not intended to limit the range of claimed invention, but be merely representative of the present invention selected embodiment. Based on the embodiments of the present invention, what those of ordinary skill in the art were obtained without creative efforts is all Other embodiment shall fall within the protection scope of the present invention.
To further appreciate that present disclosure, the present invention is described in detail in conjunction with the accompanying drawings and embodiments.
Embodiment 1
As shown in Figure 1, the crystallizer bleedout prediction electric thermo method that the logic-based of the present embodiment judges, includes the following steps：
Step 1: each logic judgment parameter of regularity from parameter configuration files reading breakout prediction method, including data are pre- Processing logic judgment parameter, electric thermo-couple temperature, which rise, checks that logic judgment parameter, electric thermo-couple temperature climbing speed check that logic is sentenced Disconnected parameter, electric thermo-couple temperature change delay check that logic judgment parameter, electric thermo-couple temperature decline and check logic judgment parameter, thermoelectricity Even temperature, which is inverted, checks that logic judgment parameter, bonding steel leakage are gently alarmed and weight alarming logic judges parameter.
Step 2: the acquisition of copper plate of crystallizer electric thermo-couple temperature time series data, storage and pretreatment.
All electric thermo-couple temperature time series datas in copper plate of crystallizer are acquired first and are arranged according to the scheduled row and column of thermocouple Row mode stores number, in the present embodiment, in copper plate of crystallizer inbuilt thermocouple line number be denoted as 1 successively from top to bottom, 2, 3 ..., row number by it is left-to-right be denoted as successively A, B, C ..., for example, 3B indicate the 3rd row B row thermocouples.
Then the temperature of thermocouple of acquisition per second carries out following data filtering and smooth pretreatment, to reduce mistake The accidentally influence of data and data fluctuations to breakout prediction method, it is specific as follows：
A) electric thermo-couple temperature is less than 50 DEG C or more than 200 DEG C, is not involved in algorithm calculating.
B) temperature fluctuation per second is more than 20 DEG C and every temperature fluctuation in 2 seconds is more than 38 DEG C, is not involved in algorithm calculating.
C) temperature data that thermocouple current time acquires is made comparisons with the temperature data of the previous second acquisition of the thermocouple, It is more than that 20% temperature data replaces with the temperature data of previous second acquisition by temperature change.
D) time series data of each electric thermo-couple temperature is smoothed using the method for moving average, is ensureing not lose While removing former electric thermo-couple temperature variation characteristic, reduce influence of the thermo-electric couple temperature data fluctuation to model.
Here the method for moving average be with before and after current time one it is intersegmental every temperature data to calculate average value substitution current Moment temperature value, if being divided into 2k between mobile, k is positive integer, then the moving average at p momentFor：
In formula, T (p-k) is the electric thermo-couple temperature value at p-k moment.K is set as 2 in the present invention.
Step 3: carrying out temperature rise inspection respectively to all thermocouples on copper plate of crystallizer simultaneously.All single heat Galvanic couple temperature rise checks as follows：
When thermocouple works normally, take check cycle period for a temperature rise within every 4 seconds, if the 1st second temperature is A, the 2nd second temperature is b, and the 3rd second temperature is c, and the 4th second temperature is d；Every moment just checks first 3 seconds on a timeline Whether meet temperature rise Rule of judgment with current time：d>c>b>a；If certain moment the i-th row j row thermocouple TC (i, j) is full Foot, then by the 1st second in the thermocouple this cycle period at the time of be labeled as τ0(i, j) continues next second if cannot meet Temperature rise inspection.
When some temperature rise inspection cycle meets above-mentioned temperature rise Rule of judgment, then next temperature rise inspection is checked It looks into whether the period still meets above-mentioned temperature rise Rule of judgment, still meets the τ before then maintaining0(i, j), if discontented Foot continues temperature rise inspection in next second.
(1) if there is the temperature rise inspection cycle within 4 is continuously unsatisfactory for temperature rise Rule of judgment, with latter A temperature rise inspection cycle meets temperature rise Rule of judgment again, then the τ before still maintaining0(i, j)；(2) if there is 5 A or 5 temperatures above rise inspection cycle and are continuously unsatisfactory for temperature rise Rule of judgment, then the τ before removing0(i, j), When meeting temperature rise Rule of judgment again later, then a τ is re-established0(i, j), subsequent algorithm is with new τ0(i, j) is base It is accurate.
Step 4: carrying out temperature rate-of-rise inspection to the thermocouple for meeting temperature rise Rule of judgment in step 3.Tool Body is as follows：
When there is τ0When (i, j), the value of thermocouple TC (i, j) temperature rate-of-rise u=(d-a)/3 is calculated, compares u and sets Determine temperature rate-of-rise threshold values ucSize.If u is more than or equal to uc, then it is assumed that the thermocouple TC (i, j) temperature rise is abnormal, Simultaneously by τ0(i, j) is stored as the electric thermo-couple temperature and begins to ramp up moment t0(i, j), moment acquiescence is temperature change point at first, Enter step five.Wherein, temperature rate-of-rise threshold values u in the present embodimentcIt is set as 0.15 DEG C/s.
Step 5：As shown in Fig. 2, to 3 thermocouple TC (i, j-1), TC around temperaturing lifting abnormality thermocouple TC (i, j) (i, j+1) and TC (i+1, j) carry out temperature change delay and check, and judge whether to make according to result and bond light alarm.Specifically For：
In t0It (is set as in the present embodiment in 3~15 seconds) in temperature change delay time threshold range after (i, j), The logic of step 3 and step 4 is repeated to 3 thermocouple TC (i, j-1), TC (i, j+1) and TC (i+1, j) around TC (i, j) Judge to check, when being satisfied by the temperature that the thermocouple TC (m, n) of condition is marked numeration, and stores TC (m, n) and beginning to ramp up Carve t0(m, n) sends out bonding steel leakage and gently alarms, enter step six when label count is more than 2.
Step 6：Meet thermocouple TC (i, j) constant temperature and declines inspection or surrounding's electric thermo-couple temperature change of TC (m, n) After changing delay inspection, then seven are entered step；
(1) it is as follows to decline inspection for thermocouple TC (i, j) constant temperature：
In t0In 30 seconds after (i, j), temperature is carried out to thermocouple TC (i, j) and declines inspection, it is a temperature to take every 4 seconds Degree declines inspection cycle, if the 1st second temperature is a', the 2nd second temperature is b', and the 3rd second temperature is c', and the 4th second temperature is d', such as full Sufficient d' ﹤ c' ﹤ b' ﹤ a', then judge that temperature decline occurs in thermocouple TC (i, j), and week is checked if persistently meeting 3 temperature and declining Phase, then it is assumed that constant temperature decline occurs in thermocouple TC (i, j), is directly entered step 7.
(2) as shown in Fig. 2, surrounding's electric thermo-couple temperature change delay of TC (m, n) checks following (wherein, exclude to thermoelectricity The temperature change delay of even TC (i, j) checks)：
In t0To three thermocouple TC (m, n-1), TC (m, n around all TC (m, n) in 3~15 seconds after (m, n) + 1) and TC (m-1, n) repeat step 3 and step 4 logic judgment inspection, the equally thermocouple TC (x, y) to meeting condition Numeration is marked, when marking count to be more than or equal to 3, thermocouple TC (i, j) is labeled as doubtful bonding point, directly Enter step seven.
Step 7：Electric thermo-couple temperature, which is inverted, to be checked.
In t0In 30s after (i, j), TC (i, j) is expert at three thermocouple TC (i, j-1), TC (i, j) and TC Two row thermocouples are inverted logic judgment inspection into trip temperature under (i, j+1) corresponding column, i.e., for example for TC (i, j), Two row thermocouple TC (i+1, j) and TC (i+2, j) under the corresponding columns of TC (i, j) are then inverted logic judgment into trip temperature It checks；Specially：
Situation (1)：First compare t0Before (i, j) in 10s, some thermocouple of the i-th row (i.e. thermocouple TC (i, j-1), TC Any one in (i, j) and TC (i, j+1)) mean temperature whether higher than one of two 2 thermocouples of row under same column Mean temperature.
If it is, just comparing t again0Whether occurs temperature inversion therewith in 30s after (i, j), i.e., in t0After (i, j) In 30s, one of two 2 thermocouples of row under the time-temperature curve and the same column of some thermocouple of i-th row (" one of them " selection herein is in t0Before (i, j) in 10s, mean temperature is less than described some thermocouple of i-th row That) time-temperature curve whether have intersection on the image, if there is intersect then think temperature inversion occur, directly into Enter step 8；
If be less than, compare t0Whether there is some thermocouple of the i-th row (i.e. thermocouple TC in 30s after (i, j) Any one in (i, j-1), TC (i, j) and TC (i, j+1)) temperature be first higher than it is rear again less than two rows, 2 thermoelectricity under same column It is one of even, i.e., for example for TC (i, j), t0Temperature after (i, j) in 30s is first higher than rear again less than two rows under same column One of 2 thermocouple TC (i+1, j) and TC (i+2, j), if there is, then it is assumed that there is temperature inversion, is directly entered Step 8.
Situation (2)：When being unsatisfactory for situation (1), just compare the heat of the thermocouple and i-th+2 row of row of certain row i+1 row Whether galvanic couple there is temperature inversion, i.e., first compares t0Whether 10s before (i, j), the mean temperature of certain row i+1 row thermocouple are high In the mean temperature of i-th+2 row thermocouple of row.
If it is, just comparing t again0Whether occurs temperature inversion therewith in 30s after (i, j), i.e., in t0After (i, j) In 30s, the time-temperature curve of certain row i+1 row thermocouple and the time-temperature curve of i-th+2 row thermocouple of row are being schemed Whether there is intersection as upper, then thinks temperature inversion occur if there is intersecting, be directly entered step 8；
If be less than, compare t0The temperature for certain row i+1 row thermocouple whether occur in 30s after (i, j) is first higher than It is less than i-th+2 row thermocouple of row after i-th+2 row thermocouple of row again, when there is described situation, still believes that appearance Temperature inversion, is directly entered step 8.
As long as above-mentioned temperature is inverted in logical check and 1 temperature occurs and be inverted, be directly entered step 8 preparation send out it is viscous Junction leakage steel is alarmed again.Temperature inversion is that the important change of cohesive tearing port communication process electric thermo-couple temperature is special in theory Sign, so having, temperature is inverted whether appearance by many breakout prediction algorithms and whether the inverted difference of temperature reaches setting value It as the necessary condition for judging bonding steel leakage, but is influenced by the condition of continuous casting actual complex, this temperature phenomena of inversion is simultaneously It is not regular appearance, the present invention is directed to a large amount of practical bleed-out data analysis found that bonding in the 30s occurred, certain is arranged Other row thermocouples are difficult temperature inversion occur with the first row thermocouple, and in actual continuous casting, it may appear that first The temperature of row thermocouple is lower than there is a phenomenon where before the row other row thermocouples bonding.In order to reduce these as far as possible Interference, and reduce dependence of the temperature inversion for breakout prediction algorithm, temperature is inverted by the breakout prediction method of the present embodiment As one of final condition, and condition is very loose, this is also the place that this method is different from other breakout prediction methods.
Step 8：According to alarm shielding condition, judge whether that make bonding steel leakage alarms again.
In order to reduce wrong report, it is provided with alarm shielding condition below, if being unsatisfactory for alarm shielding condition below Bonding steel leakage is just made to alarm again：
1. 120s interior crystallizer liquid levels exceed predetermined minimum (present embodiment is set as 80mm) and maximum value before alarm (present embodiment is set as 120mm) range, system are not alarmed；
2. before alarm in 120s pulling rate less than it is default do not alarm pulling rate (present embodiment is set as 0.5m/min) when, system It does not alarm；
3. pulling rate rate of change is more than default not alarm that (present embodiment is set as pulling rate rate of change in 120s before alarm When 0.006m/min), system is not alarmed；
Stage judgement is poured 4. opening：When cast length is less than default cast length of not alarming (present embodiment is set as 3.0m) When, system is not alarmed；
5. bonding steel leakage is alarmed again after in 60s, system is not alarmed.
6. failure thermocouple number is more than threshold values (present embodiment is set as the 1/3 of thermocouple sum) of setting, it is System judges without bleed-out, does not alarm.
When sending out bonding gently alarm, site operation personnel is needed to carry out the operations such as benefit slag, fishing slag in time, and observe bleed-out Thermocouple temperature variation curve in forecast system operation interface, when send out bond alarm again when, take drop pulling rate arrange It applies and avoids bleed-out.
Corresponding with the above method, the present embodiment also provides a kind of crystallizer bleedout prediction electric thermo system that logic-based judges, As shown in figure 3, specifically including：
Crystallizer bleedout prediction electric thermo system hardware component part includes：Modular panel billet crystallizer, totally four pieces of copper coins, conticaster The two pieces wide face copper coin of outer arc affixed side, two pieces of narrow copper plates of inner arc active side, crystallizer copper plate thickness are 41mm, copper coin surface Including 1mm nickel plating layer thicks, copper coin material is CuCrZr alloys.High-precision K-type armouring heat is buried in the system copper plate of crystallizer Galvanic couple, thermocouple are mounted positioning to detect the copper coin surface temperature contacted with molten steel, and measuring accuracy is measured up to 0.1 DEG C The form of thermocouple is using measurement point and compensating wire distributing installation, and thermocouple is using initial tension of spring crimping and clip fixation side Formula connects, external also to use rubber seal, prevents thermocouple from seeping water.Thermocouple insertion depth is 20.5mm on wide face copper coin, narrow Thermocouple insertion depth is 20mm on the copper coin of face.Thermocouple temperature measures and its accurate stability is steel leakage prediction system The premise and key of work, especially high casting speed continuous casting process.
Meanwhile the thermocouple arrangement of the steel leakage prediction system is arranged using high density thermocouple, wide face copper coin cloth Set m rows n1Row, narrow copper plate arrange m rows n2Embedded height is identical per a line thermocouple for row, leptoprosopy and wide face, and the first row thermoelectricity Occasionally it is arranged in away from the positions meniscus 50mm hereinafter, to reduce liquid fluctuating and slag circle etc. to the first row thermocouple temperature measurement accuracy With the influence of temperature fluctuation.Wherein, m >=3, n1Take the maximum integer less than (strand width/thermocouple buries column pitch+1), n2 Take the maximum integer less than (slab thickness/thermocouple buries column pitch+1).The present invention about the embedded row of thermocouple and column and row with The design of capable spacing in order to improve the accuracy rate of breakout prediction, and identifies that the behavior of bonding is alarmed, and should make thus as soon as possible Cohesive V-type tearing port matches in vertically and horizontally spread speed and the inbuilt columns and rows spacing of thermocouple, that is, ensures to bond V Type breach is approximately equivalent in the horizontal and vertical time for propagating a thermometric spacing.And from a large amount of bonding steel leakage green shell and thermoelectricity Laterally propagation is obviously faster than longitudinal propagation it is found that bonding breach for even temperature data, so the embedded column pitch of thermocouple must be than row Spacing is big.The design that the present invention buries columns and rows spacing particularly with regard to thermocouple must satisfy following condition：
In formula, txAnd tyTo bond tearing port the time required to one thermocouple spacing of horizontal and vertical propagation；DxAnd DyPoint It Wei not the embedded row and column spacing of copper plate of crystallizer thermocouple；VxAnd VyRespectively bond the horizontal and vertical spread speed of tearing port；β Tear line for bonding breach and horizontal angle, generally in 20 °~50 ° ranges.
In the present embodiment, about Thermocouple arrangement, the first row thermocouple is arranged in away from meniscus The positions 70mm, at the same measure according to bleed-out green shell and related bleed-out data statistics to determine β averagely be about 35 °, then in order to ensure to glue Knot V-type tearing port is equal the time required to one thermocouple spacing of horizontal and vertical propagation, and thermocouple line space is designed as 126mm, column pitch 180mm, two wide face copper coin are respectively arranged 5 rows 12 row, and two narrow copper plates are respectively arranged 5 rows 2 row, altogether 140 thermocouples.
Crystallizer bleedout prediction electric thermo system hardware component part provided by the invention further include fourplatemold and thermocouple, Steel leakage prediction system computer, PLC, interchanger, thermocouple compensation cable, audible-visual annunciator, relay, distant station etc..Wherein, Steel leakage prediction system computer includes client and server computer, and monitoring of the client computer for bleed-out data is aobvious Show, does not preserve any data, and server computer is used for core breakout prediction model calculation, breakout prediction model and client Into the exchange of row information and data and the compression storage of bleed-out data between steel leakage prediction system graphical interfaces.PLC is on the one hand Real-time data collection passes to steel leakage prediction system, and another aspect logic judgment algorithm sends out alarm signal to PLC, and PLC is sent out Drop pulling rate executes instruction, and prevents bleed-out.
Crystallizer bleedout prediction electric thermo system structure provided by the invention includes：
Data acquisition unit, for obtaining electric thermo-couple temperature real time data and casting process product practice, by data It measures, data transmission and host computer three parts form.DATA REASONING part is mainly made of sensor and A/D conversion circuits etc., Effect be by sensor measurement to analog signal be converted to digital signal, such as the temperature of thermocouple measurement.Data transfer part Divide and use field bus technique, effect is to send data to distal end host computer.Epigynous computer section is mainly software data interface Realization, it is contemplated that the existing data for coming from PLC of this system fetched data also have the data for coming from continuous casting database, So having from oracle database and from two kinds of acquisition data modes of PLC.It is obtained from oracle database, by establishing continuous casting two Level data library is connect with the DB links of steel leakage prediction system database, is accessed using synonym；Data are obtained from PLC, are utilized The OPC communications of the advanced host computer Configuration software WinCC of Siemens directly acquire Siemens S7-400 PLC, the number acquired up According to being directly stored on the industrial personal computer of installation WinCC, steel leakage prediction system can be directly read.In data acquisition, In order to eliminate interference of the site environment to signal, the measures such as compensating cable and digital filtering are taken, the influence of noise is reduced.
Bleed-out data compress storage unit automatically, for all numbers by steel leakage prediction system during real time execution According to being compressed by way of data flow according to certain file format, each casting cycle terminates to automatically save a text Part, each casting cycle start with regard to being recorded automatically, and the data volume of system operation over a year is after compression on the left sides 50G The right side, so 200G hard drive spaces can preserve 4 annual datas and not have to cleaning.
The breakout prediction model algorithm unit that logic-based judges, according to the electric thermo-couple temperature, pulling rate and crystallization received The casting processes real time data such as device liquid level, and each logic judgment parameter of regularity in systematic parameter configuration file is read, then transport Light alarm and the weight alarm decision of bonding steel leakage are carried out with model algorithm.
Steel leakage prediction system self study and off-line analysis unit, on the one hand can be used for the weight of history heat process data It puts, can check that history electric thermo-couple temperature, pulling rate and mould liquid level etc., continuous casting process personnel can be to casting by history playback Cause of accident is found out in journey crash analysis, optimizes casting process parameter.Prior one side also may be used by off-line analysis module Off-line simulation is carried out to the breakout prediction model algorithm of core, specially changes logic judgment parameter of regularity, to bleed-out data into Row plays back, and steel leakage prediction system passes through forecast accuracy, rate of false alarm, alert frequency etc. using the parameter operation just set at this time Performance indicator, which compares, constantly to carry out study optimization to breakout prediction model on-line parameter.Meanwhile corresponding breakout prediction system System in on-line operation, each bonding steel leakage is alarmed again send out after, site operation personnel is according to whether bleed-out result confirms in time Whether it is correctly to alarm, then system automatically records the correct alarm times of breakout prediction algorithm, error-alert degree, bonding steel leakage The performance indicators such as rate, forecast accuracy, rate of false alarm, wrong report frequency are quoted, and rate (this embodiment party is quoted with the bonding steel leakage of setting Taken in formula 100%), forecast accuracy (85% is taken in present embodiment) and false alarm frequency (0.15% is taken in present embodiment) Important performance indexes threshold values is compared, once less than setting threshold values, system can send out Parameter Self-learning request.It is glued in the present invention Junction leakage steel quotes rate=correct alarm times/(failing to report number+correct alarm times), and forecast accuracy=correct alarm times/ (failing to report number+correct alarm times+error-alert degree), rate of false alarm=error-alert degree/(correct alarm times+false alarm Number), report frequency=error-alert degree/casting furnace number by mistake.
Steel leakage prediction system is alarmed and execution unit, and bleed-out alarm signal is sent out by audible-visual annunciator, and light alarm is Huang Lamp is bright, and alarm again is when red, if attaching most importance to alarm, warning message can upload to the execution unit of casting speed control, by PLC Send out the instruction for reducing pulling rate or directly shutting down.Warning messages all simultaneously can all be transferred to system man-machine interface and show, and And these warning messages can be also saved in record file, preserve that steel leakage prediction system sends out in alarm logging file all goes through The details such as alarm moment of history, type of alarm, alert locations, are searched and statistical analysis convenient for follow-up accident.
Steel leakage prediction system parameter configuration unit, for system operational parameters, including various logic judgment rule ginseng is arranged The relevant parameter of several, system username and password etc. and system communication connecting interface, and these parameters are stored in parameter In configuration file, parameter can be changed in administrator right, and automatically update parameter configuration files, steel leakage prediction system operation When directly from configuration file call parameters.
The 3rd stove molten steel pours in slab caster in the present embodiment, company, and casting steel grade is SS400, casting section for 1550 × 230mm2, work pulling rate is 1.2m/min, first to collected Thermocouple temperature data by data filtering peace Sliding pretreatment, pretreated typical case's row electric thermo-couple temperature change curve is as shown in Fig. 4-Fig. 8, then, when according to these temperature Ordinal number is according to the logic judgment inspection for carrying out bonding steel leakage.
(1) electric thermo-couple temperature, which rises, checks.
Affixed side 1G thermocouples are 05:03:53 moment began to ramp up, in this temperature rise inspection cycle, a= 99.48 DEG C, b=99.68 DEG C, c=99.92 DEG C, d=100.24 DEG C, meet d>c>b>A then records τ0(1, G)=05:03: 53。
(2) electric thermo-couple temperature climbing speed inspection
Calculate affixed side 1G electric thermo-couple temperature climbing speed u=(100.24-99.48)/3=0.2533 DEG C/s>0.15℃/ S, then it is assumed that affixed side 1G electric thermo-couple temperature rise abnormities, while recording the electric thermo-couple temperature and beginning to ramp up moment t0(1, G)= 05:03:53。
(3) to 05:03:1F, 1H and 2G thermocouple after 53 in 3~15s around affixed side 1G thermocouples is into trip temperature Rise abnormity inspection.
05:04:04 moment affixed side 1F thermocouple is begun to ramp up, in this temperature rise inspection cycle, a= 102.58 DEG C, b=102.76 DEG C, c=103.00 DEG C, d=103.26 DEG C, meet d>c>b>A then records τ0(1, F)=05: 04:04.Moreover, affixed side 1F electric thermo-couple temperature climbing speed u=(103.26-102.58)/3=0.2267 DEG C/s>0.15℃/ S, then it is assumed that affixed side 1F electric thermo-couple temperature rise abnormities, while recording the electric thermo-couple temperature and beginning to ramp up moment t0(1, F)= 05:04:04。
05:03:56 moment affixed side 1H thermocouples are begun to ramp up, in this temperature rise inspection cycle, a= 94.58 DEG C, b=94.86 DEG C, c=95.66 DEG C, d=96.54 DEG C, meet d>c>b>A then records τ0(1, H)=05:03:56. Moreover, affixed side 1H electric thermo-couple temperature climbing speed u=(96.54-94.58)/3=0.6533 DEG C/s>0.15 DEG C/s, then it is assumed that Affixed side 1H electric thermo-couple temperature rise abnormities, while recording the electric thermo-couple temperature and beginning to ramp up moment t0(1, H)=05:03:56.
05:04:05 moment affixed side 2G thermocouple is begun to ramp up, in this temperature rise inspection cycle, a= 92.80 DEG C, b=93.02 DEG C, c=93.28 DEG C, d=93.58 DEG C, meet d>c>b>A then records τ0(2, G)=05:04:05. Moreover, affixed side 2G electric thermo-couple temperature climbing speed u=(93.58-92.80)/3=0.26 DEG C/s>0.15 DEG C/s, then it is assumed that Gu Determine side 2G electric thermo-couple temperature rise abnormities, while recording the electric thermo-couple temperature and beginning to ramp up moment t0(2, G)=05:04:05.
It gently alarms from the foregoing, it will be observed that temperature rise exception thermocouple quantity sends out bonding steel leakage for 3.
(4) affixed side 1G electric thermo-couple temperatures continue to decline surrounding's thermoelectricity of inspection or affixed side 1F, 1H and 2G thermocouple Even temperature change delay checks.
1) affixed side 1G electric thermo-couple temperatures, which continue to decline, checks：
From 05:03:53 moment start after 30 seconds in, if the 1st second temperature is a', the 2nd second temperature is b', the 3rd second temperature For c', temperature is d' within the 4th second, occurs a'=102.24 DEG C, b'=102.20 DEG C, c'=102.12 DEG C, d'=101.98 DEG C, Meet d' ﹤ c' ﹤ b' ﹤ a', and 05:04:12 moment continued 3 cycles, then 05:04:12 moment judged affixed side 1G heat Galvanic couple temperature continues to decline, and is directly entered " (5) electric thermo-couple temperature is inverted logical check ".
2) surrounding's electric thermo-couple temperature change delay inspection of affixed side 1F, 1H and 2G thermocouples, including：
Wherein, it with reference to figure 2, although surrounding's thermocouple of affixed side 1F, 1H and 2G thermocouple theoretically has 9, excludes (i.e. affixed side 2F, 2H thermocouple only carries out respectively for affixed side 1G thermocouples and affixed side 2F, the 2H thermocouple of repeat count Temperature change delay checks), the thermocouple that practical progress temperature change delay checks only has 5, uses cross in fig. 2 Lines have carried out filling mark)：
1. to 05:04:1E and 2F thermocouples after 04 in 3~15s around affixed side 1F thermocouples carry out temperature rise Abnormal examination.
05:04:11 moment affixed side 1E thermocouples are begun to ramp up, in this temperature rise inspection cycle, a= 92.52 DEG C, b=92.68 DEG C, c=92.84 DEG C, d=93.02 DEG C, meet d>c>b>A then records τ0(1, E)=05:04:11. Moreover, affixed side 1E electric thermo-couple temperature climbing speed u=(93.02-92.52)/3=0.1667 DEG C/s>0.15 DEG C/s, then it is assumed that Affixed side 1E electric thermo-couple temperature rise abnormities, while recording the electric thermo-couple temperature and beginning to ramp up moment t0(1, E)=05:04:11.
05:04:18 moment affixed side 2F thermocouples are begun to ramp up, in this temperature rise inspection cycle, a= 91.66 DEG C, b=91.80 DEG C, c=91.96 DEG C, d=92.14 DEG C, meet d>c>b>A then records τ0(1, E)=05:04:18. Moreover, affixed side 2F electric thermo-couple temperature climbing speed u=(92.14-91.66)/3=0.16 DEG C/s>0.15 DEG C/s, then it is assumed that Gu Determine side 2F electric thermo-couple temperature rise abnormities, while recording the electric thermo-couple temperature and beginning to ramp up moment t0(2, F)=05:04:18.
2. to 05:03:1I and 2H thermocouples after 56 in 3~15s around affixed side 1H thermocouples carry out temperature rise Abnormal examination.
05:04:06 moment affixed side 1I thermocouple is begun to ramp up, in this temperature rise inspection cycle, a= 99.62 DEG C, b=99.74 DEG C, c=99.94 DEG C, d=100.26 DEG C, meet d>c>b>A then records τ0(1, I)=05:04: 06.Moreover, affixed side 1I electric thermo-couple temperature climbing speed u=(100.26-99.62)/3=0.2133 DEG C/s>0.15 DEG C/s, then Think affixed side 1I electric thermo-couple temperature rise abnormities, while recording the electric thermo-couple temperature and beginning to ramp up moment t0(1, I)=05: 04:06。
05:04:04 moment affixed side 2H thermocouple is begun to ramp up, in this temperature rise inspection cycle, a= 93.20 DEG C, b=93.32 DEG C, c=93.48 DEG C, d=93.68 DEG C, meet d>c>b>A then records τ0(2, H)=05:04:04. Moreover, affixed side 2H electric thermo-couple temperature climbing speed u=(93.68-93.20)/3=0.16 DEG C/s>0.15 DEG C/s, then it is assumed that Gu Determine side 2H electric thermo-couple temperature rise abnormities, while recording the electric thermo-couple temperature and beginning to ramp up moment t0(2, H)=05:04:04.
3. to 05:04:It is abnormal that 3G thermocouples after 05 in 3~15s around affixed side 2G thermocouples carry out temperature rise It checks.
05:04:05 moment affixed side 3G thermocouple is begun to ramp up, in this temperature rise inspection cycle, a= 94.14 DEG C, b=94.28 DEG C, c=94.48 DEG C, d=94.70 DEG C, meet d>c>b>A, moreover, affixed side 3G electric thermo-couple temperatures Climbing speed u=(94.70-94.14)/3=0.28 DEG C/s>0.15 DEG C/s, but the electric thermo-couple temperature begins to ramp up the moment not 05:04:After 05 in 3~15s, so affixed side 3G thermocouples are not counted in sticking temperature exception thermocouple.
Thus, having 4 thermocouples to meet temperature change delay around affixed side 1F, 1H and 2G thermocouple checks item Part, quantity are more than 3, then affixed side thermocouple 1G are labeled as doubtful bonding point, into " (5) electric thermo-couple temperature is inverted logic It checks ".
It should be noted that above-mentioned " 1) affixed side 1G electric thermo-couple temperatures, which continue to decline, checks ", " 2) affixed side 1F, 1H and Surrounding's electric thermo-couple temperature change delay inspection of 2G thermocouples " is directly entered " (5) thermocouple as long as satisfaction wherein any one Temperature is inverted logical check ", in the present embodiment in order to become apparent from, comprehensively introduce entire breakout prediction method, be described.
(5) electric thermo-couple temperature is inverted logical check
With reference to figure 7,05:03:10s before 53 moment, (92.78 DEG C) of affixed side 2H thermocouples mean temperature, which is less than, fixes Side 1H thermocouples mean temperature (94.37 DEG C).05:03:After 53 moment in 30s, 05:04:13 moment affixed side 2H thermoelectricity It is even temperature inversion for the first time occur with 1H thermocouples, it sends out bonding and alarms again, used time 20s, than the practical bleed-out moment (05:04:40) It is advanced by about 27s.
In order to further verify the value of forecasting of the present invention, one month 1569 furnace electric thermo-couple temperature of collection in worksite are utilized Etc. casting processes data, to the present embodiment propose logic-based judge crystallizer bleedout prediction electric thermo method and system surveyed Examination, and compared with live steel leakage prediction system.Test obtains that the results are shown in Table 1.
The comparison of table 1 present invention and live steel leakage prediction system
From 1 test result of table it is found that the better than live bleed-out of the steel leakage prediction system items evaluation index of the present embodiment is pre- Reporting system.Live steel leakage prediction system, failing to report primary bond leads to bleed-out, and wrong report number reaches 20 times, the alarm used time 50s with Interior, alarm response speed is slower, increases the risk that follow-up drop pulling rate repairs bleed-out.The breakout prediction method of the present embodiment and it is System is reported by mistake 1 time without failing to report, and wrong report number substantially reduces, and bonding steel leakage quotes rate and reaches 100%, and forecast accuracy reaches 88.89%, rate of false alarm 11.11%, false alarm frequency is only 0.06% time/stove, and the alarm used time of all bonding steel leakages All within 30s, alarm response speed is fast, and repairing bleed-out for follow-up drop pulling rate provides time enough.
Schematically the present invention and embodiments thereof are described above, description is not limiting, institute in attached drawing What is shown is also one of embodiments of the present invention, and actual structure is not limited to this.So if the common skill of this field Art personnel are enlightened by it, without departing from the spirit of the invention, are not inventively designed and the technical solution Similar frame mode and embodiment, are within the scope of protection of the invention.

Claims (2)

1. the crystallizer bleedout prediction electric thermo system that a kind of logic-based judges, which is characterized in that the steel leakage prediction system hardware forms Part includes fourplatemold and thermocouple, steel leakage prediction system computer, PLC, interchanger, thermocouple compensation cable, sound Light crossing-signal, relay, distant station, wherein steel leakage prediction system computer includes client computer and server computer, Monitoring of the client computer for bleed-out data shows that server computer is for breakout prediction model calculation, breakout prediction The compression of information exchange and bleed-out data between model and client breakout prediction graphical interfaces stores；
Wherein, the design of the embedded columns and rows spacing of thermocouple meets following condition：
In formula, txAnd tyTo bond tearing port the time required to one thermocouple spacing of horizontal and vertical propagation；DxAnd DyRespectively Copper plate of crystallizer thermocouple buries row and column spacing；VxAnd VyRespectively bond the horizontal and vertical spread speed of tearing port；β is viscous The tear line of breach and horizontal angle are tied, takes 20 °~50 °；
The steel leakage prediction system carries out crystallizer bleedout prediction electric thermo using following steps：
Step 1: reading each logic judgment parameter of regularity in breakout prediction method from parameter configuration files；
In step 1 each logic judgment parameter of regularity include data prediction logic judgment parameter, electric thermo-couple temperature rise check patrol It collects and judges that parameter, electric thermo-couple temperature climbing speed check that logic judgment parameter, electric thermo-couple temperature change delay check logic judgment Parameter, electric thermo-couple temperature, which decline, checks that logic judgment parameter, electric thermo-couple temperature inversion check that logic judgment parameter, bonding steel leakage are light Alarm and weight alarming logic judge parameter；
Step 2: the acquisition of copper plate of crystallizer electric thermo-couple temperature time series data, storage and pretreatment；
In step 2, acquire in copper plate of crystallizer all electric thermo-couple temperature time series datas first and according to the scheduled row of thermocouple and Row arrangement mode storage number, the temperature of thermocouple of acquisition per second；
Then following data filtering and smooth pretreatment are carried out：
A) electric thermo-couple temperature is less than 50 DEG C or more than 200 DEG C, is not involved in algorithm calculating；
B) temperature fluctuation per second is more than 20 DEG C and every temperature fluctuation in 2 seconds is more than 38 DEG C, is not involved in algorithm calculating；
C) temperature data that thermocouple current time acquires is made comparisons with the temperature data of the previous second acquisition of the thermocouple, it will be warm Degree variation is more than that 20% temperature data replaces with the temperature data of previous second acquisition；
D) time series data of each electric thermo-couple temperature is smoothed using the method for moving average, the above-mentioned method of moving average Be with before and after current time one it is intersegmental every temperature data calculate average value and replace current time temperature value, if being divided between mobile 2k, k are positive integer, then the moving average at p momentFor：
In formula, T (p-k) is the electric thermo-couple temperature value at p-k moment；
Step 3: carrying out temperature rise inspection respectively to all thermocouples on copper plate of crystallizer simultaneously；
It is as follows to rise inspection for electric thermo-couple temperature in step 3：When thermocouple works normally, take examined for a temperature rise within every 4 seconds Cycle period is looked into, if the 1st second temperature is a, the 2nd second temperature is b, and the 3rd second temperature is c, and the 4th second temperature is d；In time shaft Upper every moment just checks first 3 seconds and whether current time meets temperature rise Rule of judgment：d>c>b>a；If some time Carve the i-th row j row thermocouple TC (i, j) satisfactions, then by the 1st second in the thermocouple this cycle period at the time of be labeled as τ0(i, J), if cannot meet, continue temperature rise inspection in next second；
Wherein：When some temperature rise inspection cycle meets above-mentioned temperature rise Rule of judgment, then corresponding temperature of next second is checked Degree rises whether inspection cycle still meets above-mentioned temperature rise Rule of judgment, still meets the τ before then maintaining0(i, j), such as Fruit is unsatisfactory for, and continues temperature rise inspection in next second；
If there is the temperature rise inspection cycle within 4 is continuously unsatisfactory for temperature rise Rule of judgment, with latter temperature Rise inspection cycle and meets temperature rise Rule of judgment again, then the τ before still maintaining0(i, j)；If there is 5 or 5 with Upper temperature rise inspection cycle is continuously unsatisfactory for temperature rise Rule of judgment, then the τ before removing0(i, j) meets again later When temperature rise Rule of judgment, then a τ is re-established0(i, j), subsequent algorithm is with new τ0On the basis of (i, j)；
Step 4: carrying out temperature rate-of-rise inspection to the thermocouple for meeting temperature rise Rule of judgment in step 3；
Temperature rate-of-rise checks as follows in step 4：When there is τ0When (i, j), thermocouple TC (i, j) temperature rate-of-rise is calculated The value of u=(d-a)/3 compares u and set temperature climbing speed threshold values ucSize；If u is more than or equal to uc, then it is assumed that the heat Galvanic couple TC (i, j) temperature rise is abnormal, while by τ0(i, j) is stored as the electric thermo-couple temperature and begins to ramp up moment t0(i, j), should Moment acquiescence is temperature change point at first, enters step five；
Step 5：To around temperaturing lifting abnormality thermocouple TC (i, j) 3 thermocouple TC (i, j-1), TC (i, j+1) and TC (i+1, J) it carries out temperature change delay to check, and judges whether to make according to result and bond light alarm；
In step 5, in t0In temperature change delay time threshold range after (i, j), to 3 thermocouples around TC (i, j) TC (i, j-1), TC (i, j+1) and TC (i+1, j) repeat the above steps the logic judgment inspection of three and step 4, are satisfied by condition Thermocouple TC (m, n) numeration is marked, and stores TC (m, n) temperature begin to ramp up moment t0(m, n), label numeration number When amount is more than 2, sends out bonding steel leakage and gently alarm, enter back into step 6；
Step 6：The surrounding's electric thermo-couple temperature variation for meeting thermocouple TC (i, j) constant temperature decline inspection or TC (m, n) is prolonged After checking late, then seven are entered step；
In step 6, it is as follows that thermocouple TC (i, j) constant temperature declines inspection：In t0In 30 seconds after (i, j), to thermocouple TC (i, j) carries out temperature and declines inspection, takes decline inspection cycle for a temperature within every 4 seconds, if the 1st second temperature is a', the 2nd second temperature Degree is b', and the 3rd second temperature is c', and temperature is d' within the 4th second, such as meets d' ﹤ c' ﹤ b' ﹤ a', then judges that thermocouple TC (i, j) occurs Temperature declines, if persistently meeting 3 temperature declines inspection cycle, then it is assumed that and there is constant temperature decline in thermocouple TC (i, j), It is directly entered step 7；
Surrounding's electric thermo-couple temperature change delay of TC (m, n) checks as follows：In t0To all TC in 3~15 seconds after (m, n) Three thermocouple TC (m, n-1), TC (m, n+1) and TC (m-1, n) repeat step 3 around (m, n) and the logic of step 4 is sentenced It is disconnected to check, wherein exclude to postpone to check to the temperature change of thermocouple TC (i, j), equally to meet condition thermocouple TC (x, Y) numeration is marked, when marking count to be more than or equal to 3, thermocouple TC (i, j) is labeled as doubtful bonding point, directly It taps into step 7；
Step 7：Electric thermo-couple temperature, which is inverted, to be checked；
In step 7, in t0In 30s after (i, j), by TC (i, j) be expert at three thermocouple TC (i, j-1), TC (i, j) and Two row thermocouples are inverted logic judgment inspection into trip temperature under TC (i, j+1) corresponding column, specially：
Situation (1)：First compare t0Before (i, j) in 10s, whether the mean temperature of i-th row some thermocouple is higher than under same column two The mean temperature of one of 2 thermocouples of row；
If it is, observation is in t0After (i, j) in 30s, the time-temperature curve of some thermocouple of i-th row with it is described Whether the time-temperature curve of one of two 2 thermocouples of row has intersection on the image under same column, then thinks if there is intersecting There is temperature to be inverted, is directly entered step 8；
If be less than, compare t0Whether occur in 30s after (i, j) i-th row some thermocouple temperature be first higher than it is rear and low One of two 2 thermocouples of row under same column, if there is, then it is assumed that there is temperature inversion, is directly entered step 8；
Situation (2)：When being unsatisfactory for situation (1), first compare t010s before (i, j), the mean temperature of certain row i+1 row thermocouple Whether the mean temperature of row i-th+2 row thermocouple is higher than；
If it is, in t0After (i, j) in 30s, observe the time-temperature curve of certain row i+1 row thermocouple and the row i-th+ Whether the time-temperature curve of 2 row thermocouples has intersection on the image, then thinks temperature inversion occur if there is intersecting, directly Enter step eight；
If be less than, compare t0Whether occur the temperature of certain row i+1 row thermocouple after (i, j) in 30s and first arranges the higher than this It is less than i-th+2 row thermocouple of row after i+2 rows thermocouple again, when there is described situation, still believes that temperature occurred It is inverted, is directly entered step 8；
Step 8：According to alarm shielding condition, judge whether that make bonding steel leakage alarms again；
Alarm shielding condition below is provided in step 8, if being unsatisfactory for alarm shielding condition below just makes bonding Bleed-out is alarmed again：
1. 120s interior crystallizer liquid levels exceed predetermined minimum and maximum range before alarm, system is not alarmed；
2. before alarm in 120s pulling rate less than it is default do not alarm pulling rate when, system is not alarmed；
3. pulling rate rate of change is more than when presetting not alarming pulling rate rate of change in 120s before alarm, system is not alarmed；
4. when cast length be less than it is default do not alarm cast length when, system is not alarmed；
5. bonding steel leakage is alarmed again after in 60s, system is not alarmed；
6. failure thermocouple number is more than the threshold values of setting, system is not alarmed.
2. the crystallizer bleedout prediction electric thermo system that logic-based according to claim 1 judges, which is characterized in that step 2 In, k is set as 2；In step 4, temperature rate-of-rise threshold values ucIt is set as 0.15 DEG C/s；In step 5, t0Temperature after (i, j) Degree change delay time threshold range is set as 3~15 seconds；In step 8, mould liquid level predetermined minimum, maximum value difference For 80mm, 120mm；Default pulling rate of not alarming is 0.5m/min；Default pulling rate rate of change of not alarming is 0.006m/min；It is default Cast length of not alarming is 3.0m；The threshold values that failure thermocouple number is set as thermocouple sum 1/3；
The steel leakage prediction system further includes：Data acquisition unit, bleed-out data are compressed storage unit, self study and are divided offline automatically Analyse unit, alarm and execution unit；
The data acquisition unit is surveyed for obtaining electric thermo-couple temperature real time data and casting process product practice by data Amount, data transmission and host computer three parts composition；
Wherein：DATA REASONING part includes sensor and A/D conversion circuits, what A/D conversion circuits were used to arrive sensor measurement Analog signal is converted to digital signal；TCP data segment uses field bus technique, upper for sending data to distal end Machine is retrieved as from oracle database through the company of foundation wherein having from oracle database and from two kinds of acquisition data modes of PLC Casting second databases are connect with the DBlinks of steel leakage prediction system database, are accessed using synonym；Obtaining data from PLC is Siemens S7-400 PLC, the data acquired up are directly acquired using the OPC communications of Siemens's host computer Configuration software WinCC It is directly stored on the industrial personal computer of installation WinCC；
The bleed-out data compress storage unit for all data by steel leakage prediction system during real time execution automatically, It being compressed by way of data flow according to certain file format, each casting cycle terminates to automatically save a file, Each casting cycle starts with regard to being recorded automatically；
The self study and off-line analysis unit can imitate breakout prediction model algorithm offline by off-line analysis module Very, specially change logic judgment parameter of regularity, bleed-out data are played back, pass through forecast accuracy, rate of false alarm, alarm frequency The performance indicator of rate carries out study optimization to breakout prediction model on-line parameter；Steel leakage prediction system is corresponded in on-line operation, Each bonding steel leakage is alarmed again send out after, site operation personnel is confirmed whether it is correct bleed-out result and is confirmed whether it is correct report Alert, then system automatically records the correct alarm times of breakout prediction algorithm, error-alert degree, bonding steel leakage and quotes rate, forecast Accuracy rate rate of false alarm, reports the index of frequency by mistake, and quotes rate, forecast accuracy and false alarm frequency with the bonding steel leakage of setting Performance indicator threshold values is compared, once less than setting threshold values, system sends out Parameter Self-learning request；Wherein, bonding steel leakage report Extracting rate=correct alarm times/(failing to report number+correct alarm times), forecast accuracy=correct alarm times/(fail to report number + correct alarm times+error-alert degree), rate of false alarm=error-alert degree/(correct alarm times+error-alert degree), wrong report frequency Rate=error-alert degree/casting furnace number；
The alarm and execution unit send out bleed-out alarm signal by audible-visual annunciator, and light alarm is that amber light is bright, and alarm again is When red, if attaching most importance to alarm, warning message uploads to the execution unit of casting speed control, by PLC send out reduce pulling rate or The instruction directly shut down；
The parameter configuration unit includes the user of various logic judgment rule parameter, system for system operational parameters are arranged The relevant parameter of name and password and system communication connecting interface, and these parameters are stored in parameter configuration files, in pipe Reason person's permission can change parameter, and automatically update parameter configuration files, directly from configuration text when steel leakage prediction system operation Part call parameters.
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