MLC-V235 Continuous Casting Mold Level Automatic Measurement System
MLC-V235Continuous Casting Mold Level Automatic Measurement System
Overview
The automatic controlforthe molten steel level of the mold is one of the key technologies of continuous casting production. Itis very important toreduce the labor intensity of workers, improve production efficiency, improve the quality and output of casting billet, reduce overflow and breakout of steeland improvethe management level of steelmaking and continuous casting.
The molten steel is poured into the mold. In order to prevent overflow, the molten steel level must be kept stable. Otherwise, during the casting process,ifthelevel will fluctuate too much, and slag will be involved, forming surface slag inclusionon the surface of thecastingbillet, affecting the quality of the billet. The test points out that the relationship between thelevel fluctuation and the depthof casting billetsurfaceslag inclusion is as follows:
The experience has shown thatsurfaceslag inclusions can be eliminated when thelevel fluctuation is within ±10mm. At the same time,ifthelevelfluctuationis more than 10mm, therateof longitudinal cracks on thecasting billetsurfaceis 30%.It means thatthe levelfluctuationdirectly affects the surface quality of thecasting billet.
The principle of the system
The eddy currenttypemolten steel level gauge is the key to the system.Thesystem operates reliably and has excellent performance: high temperature resistance, strong anti-interference ability, fast dynamic response (lag time <0.10s), high detection accuracy (<±05mm), and large measurement range (0-150mm). The selected electromagnetic field frequency ensures that the level detection probe only detects thelevelchange of themoldand does not detect the moldfluxor steel slag layer. The system has the advantages of simple operation and no radiation protection problems. The system is insensitive to argon blowing, and its sensors can be mounted on the tundishcaror on the platform.
The sensor is cooled by compressed air during use.
The principle is shown in the figure
A high-frequency exciting windingis installed above the molten steel surface of the mold. Themagnetic fieldproduced byexciting winding make induced eddy current appear. Themagnetic field generated by theinduced eddy currentis in the opposite direction to the magnetic field generated by the high-frequency exciting winding, which changes the impedance of the high-frequency exciting winding.Under the condition that thewindingmaterial and structure, steel grade, temperatureremain unchanged, the coil impedance change only has a single-value function relationship with the height of the molten steellevel. As long as the impedancechange of the high-frequencywindingis detected, the change of the molten steel levelinthe mold can be converted.
The components of the system
Continuous casting mold level automatic control system is composed of eddy current tyoe molten steel level gauge, controller and digital actuator for adjusting the opening of tundish stopper.
The detection end of the mold level automatic control system is①eddy current displacement sensor, which uses the eddy current mutual inductance effect between the energized coil and the metal conductor to detect the distance. The effective signal of the eddy current sensor is amplified and linearized by the circuit of②mold level gauge, which converts the 0-150mm change in the molten steel level of the mold into a standard signal of 4-20mA.DC, and then transmits it to the③control computer to complete data processing and system control functions. We can also control the actuator manually and automatically through the④on-site operation display control panel, and the opening of the stopper is controlled by the⑤actuator to realize the automatic control of the molten steel level.
1 Eddy current sensor;
2 mold level gauge;
3 control computer;
4 On-site operation display control panel;
5 digital actuator;
The control principle of the system
The system can be set to four control modes: automatic, semi-automatic, manual and motor clutch. The automatic mode is the closed-loop control system of the molten steel level, and control the opening of the stopper by the digital actuator; the semi-automatic mode uses opening degree setter and digital actuator to set the opening of the stopper manually; the manual mode is to open and close the button directly to control the opening of the stopper; the motor clutch mode is quickly changed from any of the above control methods to manual stopper operation.
The functions of the system also include: display and record of molten steel level, nozzle opening and casting speed; setting of molten steel level and nozzle opening; alarm of molten steel level at limit value etc.
In addition to taking the detection of molten steel level as the main feedback signal of the control system, the control system also considers various interference factors that have an impact on the level control. These interference factors include:
1. The influence of the change of the flow characteristics on the control system after the melt loss of the stopper
2. The influence of the weight change of molten steel in the tundish on the control system
3. The influence of the change of the casting speed of the continuous casting machine on the control system
4. The influence of the mold width change (the mold width is adjustable) on the control system
5. The influence of the vibration frequency and amplitude of the mold on the molten steel level gauge
The function and software implementation
In order to overcome these disturbances, themoldlevel control strategy adopts PID control. And on the basis of PID control, self-adaptive correction and feedforward control are introduced to form an advanced control system. Thelevel control is the main loop, and there is a proportional gain of the main loop controller. According to the self-adaptive correctionof themold widthchangeand feedforwardcompensation of casting speed, so as tofurther reduce and eliminate liquid level fluctuations caused by mold width adjustment andcastingspeed changes.
In order to reduce the frequent action of the stopper, the system adopts the intergarting time change of the controller, and automatically selects a longer intergarting time when the molten steel level fluctuateslightly.And the system will choose a shorter intergrating time whenmolten steel level fluctuatesgreatly.Thereby, the fluctuation of the controlled object caused by the frequent action of the stopper rod is suppressed.
In the signal processing of molten steel levelgauge, an appropriate filtering link is added and the vibration frequency synchronous filter is used for filtering processing, which can overcomethe interference ofmoldvibration frequency and amplitude variation.
The technicalindexes
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