In recent years, intelligent manufacturing has gradually entered the public eye and has become a breakthrough for the steel industry to implement innovation-driven development. Temperature measurement, oxygen determination, and slag breaking are important links in the iron and steel metallurgical process. At present, most of them are done manually. The labor intensity is high, the working environment is harsh, the temperature measurement accuracy is not high, and the sampling success rate is low. The "warm sampling robot" is of great significance to promote the intelligentization of China's steel industry.
WISDRI Automation takes
the lead in adopting an integrated intelligent temperature measurement and
sampling program that closely cooperates with robots and automatic feeding
systems, which completely replaces manual labor. While improving the operating
safety factor and effectively avoiding safety accidents, it ensures the
accuracy of temperature measurement and sampling data. The real-time nature has
improved the efficiency of on-site operations and realized unmanned and
intelligent operation of temperature measurement and sampling, which has taken
an important step towards the realization of fully intelligent production in
the steel industry.
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- System equipment based on the whole-process intelligent design concept
Based on advanced control
concepts, MCC Automation's full-process intelligent robot temperature
measurement and sampling system integrates innovatively designed automatic
feeding system equipment and six-axis robot control technology, and makes full
use of the flexibility of the robot to drive the temperature measurement and
sampling gun. The automatic feeding equipment performs temperature measurement
and sampling and probe removal and replacement. Information interaction is
seamlessly connected, and the functional structure is coordinated, so as to
complete the entire temperature measurement and sampling process with high
efficiency and high precision.
The operation cycle of
the system is fully automatic. The operator can start automatic temperature
measurement, oxygen determination, sampling, and slag breaking with one button.
The intermediate process does not need to intervene again. The operation time
of a single temperature measurement and sampling cycle can be controlled within
50s, and the laser measurement The distance meter accurately measures the
liquid level depth of the ladle, calculates instantly according to the feedback
data, and dynamically adjusts the depth of the robot to ensure the accuracy of
temperature measurement and sampling. According to the project site data
feedback, the measurement rate of molten steel temperature is ≥98%, the success
rate of molten steel sampling is ≥98%, the success rate of probe automatic
clamping and removal is ≥99%, the detection accuracy of molten steel level is
+20mm, and the probe is inserted into molten steel to repeat positioning
deviation ≤2mm, each index of the temperature measurement sampling system is at
the leading domestic level.
1.1 Fully automatic intelligent silo with advanced functions
Different from other
simple "storage cabinets" or "shelf-type" silos, the
automatic and intelligent system silos pioneered by MCC Automation are
controlled by PLC and are controlled by the silos, distribution mechanism, and
screening The mechanism, the probe automatic positioning and pushing system and
the electric control system are composed. According to the appearance error
prevention, feature recognition and the signal of the measuring gun system, the
material qualified and positive and negative monitoring can be judged, and the
internal and external unqualified probe recovery mechanism of the material
warehouse can be used to recover or reject the unqualified or negative
materials under different conditions of the equipment. At the same time, check
whether the probe set is in place during the installation of the probe and
automatically adjust it. Figure one
The silo can store
various types of probes according to project requirements, adapting to different
process requirements such as temperature measurement, sampling, oxygen
determination, hydrogen determination, etc. It can store up to 200 or more at a
time, and can automatically divide materials according to job requirements.
Push and install different types of probes, and identify the margins of various
probes, and provide timely feedback of material shortage alarms.
In addition, the silo
adopts a double discharge port design, which can discharge materials at the
same time or alternately. It can not only ensure the high frequency discharge
efficiency, but also can be mutually redundant systems. When one of the
discharge devices fails or is overhauled, the other discharge mechanism will
complete the production work.
1.2 Domestic original temperature measurement sampling gun
The temperature measurement and sampling gun barrel system independently designed and developed by MCC Automation can be compatible with functions such as temperature measurement, sampling and oxygen determination according to different functional requirements. The system adopts a split design and is installed at the front end of the sixth axis of the robot, which is convenient for installation and maintenance. It can cooperate with the quick-change mechanism to realize automatic replacement of gun bodies with different functions. (figure 2)
The surface of the
temperature measuring gun barrel is made of nano materials, which is resistant
to high temperature and can reduce the adhesion of steel slag. The gun body is
made of high-quality steel and has high temperature resistance, strong grinding
and high hard grinding. A unique mechanical structure is set on the straight
rod of the gun body to effectively prevent the probe from falling off during
temperature measurement and sampling. At the same time, the gun calibration
reminder function has been added to the electronic control system. After
receiving the reminder, the field maintenance personnel can manually calibrate
the gun. The technology of the system is domestically original.
- Good scalability can meet various process requirements
In order to meet various
process requirements on site and fully consider the integrity of system
functions, MCC Southern Automation fully considers the actual needs of
temperature measurement and sampling processes in the design and system
integration process, and adds "menu-based" service items, including: robots
And protective clothing, automatic silo, gun measuring system, laser distance
measurement, robot anti-collision system, gun body quick change device, gun
barrel cleaning device, automatic pulling mechanism, probe fire extinguishing
device, waste probe automatic collection device, gun calibration Tips, probe
anti-skid fall, etc., can be selected according to various working conditions
and environments to ensure the stability and reliability of the system. For
example, an automatic collection device for waste probes is added, which can
sort multiple types of waste probes such as temperature measurement, oxygen
determination, sampling, hydrogen determination, etc., to facilitate subsequent
processing; the gun barrel slag cleaning device can effectively remove the
steel slag attached to the gun barrel for a long time. , Effectively ensure the
accuracy of the follow-up probe set.
Based on the integrity of the system, the system can be applied to LF furnace, RH furnace, tapping platform molten iron detection, converter argon blowing station, continuous casting platform and other areas, and can realize temperature measurement, sampling, hydrogen determination, oxygen determination, slag breaking, etc. Features. Based on the better expansibility of the platform, a system can be added according to process requirements to realize functions such as automatic addition of covering agents and automatic sample delivery, and further promote the unmanned and intelligent construction of the entire process platform. (Picture Three)
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- Technological innovation to ensure the safety of the system
Safety is no small
matter. For steel mill applications, in addition to system performance, safety
is the priority. MCC Southern Automation has carried out technological
innovations in three aspects: personnel safety protection, equipment safety
protection, and fire safety protection, and has implemented safety throughout
the entire design process.
3.1 Safety protection of personnel
In the project layout design, rationally plan the main area of the equipment work and the personnel passage to realize the separation of man and machine. Configure area safety sensors, electronic fences, and alarm prompts in the robot working area to prevent safety accidents caused by passers-in. When a person enters the work area, the control system will automatically recognize it according to the security level (such as: warning area, deceleration area, shutdown area, etc.), and the robot's movement is limited to ensure the safety of the personnel. In extreme cases, if the area safety sensor fails, the emergency stop button near the person can be pressed to make the system stop running.
3.2 Safety protection of equipment
In order to ensure the safety of the system, fully consider the impact of the on-site environment on the equipment. The robot is equipped with a heat-insulating suit made of special heat-insulating materials to effectively prevent damage to the robot due to splashing of molten steel. A circulating air cooling system is installed inside the suit to ensure the safe and stable operation of the robot. The automatic storage bins and robot control cabinets are equipped with dust-proof cabinets and thermal insulation materials to improve the protection level, effectively avoid the adverse effects of the charged dust on the work site on the components in the cabinet, and ensure the safe operation of the equipment.
For the different working areas of the robot, a multi-zone emergency stop method has been developed to ensure the safety of the equipment while taking into account the safety of the personnel. Time stopped in the ladle. At the same time, in view of the collisions that may occur during the movement of the robot, a multi-condition detection and anti-collision mechanism has been developed, using torque detection and running time detection to determine whether the robot is moving normally, and return to the original position in time if there is an abnormality.
3.3 Fire safety protection
In the actual operation process, after the temperature measurement sampling probe leaves the molten steel, the paper rod of the probe may catch fire or carry a flame. These probes are likely to ignite other objects on the scene and cause fire hazards. The fire extinguishing mechanism designed in the robot temperature measurement and sampling system of China Metallurgical South Automation, cools down the probe after the robot completes temperature measurement, oxygen determination, and sampling to avoid fire.
- Leading technological advantages are fully recognized by steel companies
With the continuous
deepening of the market, the technical standardization of MCC Southern's
automated temperature measurement and sampling system has been continuously
improved, and successful experience that can be promoted and replicated has
been formed. The project implementation and commissioning speed has been
gradually accelerated. Yegang 4#LF furnace, Baowu Group Echeng Iron and Steel
1#, 2#, 3# converter argon blowing station, Baowu Group Echeng Iron and Steel
billet continuous casting platform, HBIS Shijiazhuang Iron and Steel LF furnace
and other processes have been successfully promoted , The system application
effect has been widely praised. (Figure 4)
In the wave of the country's vigorous promotion of intelligent manufacturing, "dazzle", "big", and "fast" seem to be the direction that technology follows. MCC Southern Automation insists on the craftsman spirit of "doing a project, building a monument" is particularly valuable. The road ahead is long and long, and we look forward to MCC Southern Automation's continuing to take solid new steps on the road of intelligent transformation to help China. Intelligent manufacturing move from concept to practice and build a better future.
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