CN106289037B - A kind of continuous casting steel billet shell thickness eddy current detection method - Google Patents
A kind of continuous casting steel billet shell thickness eddy current detection method Download PDFInfo
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Abstract
本发明公开了一种连铸钢坯坯壳厚度电涡流检测方法,属于连铸钢坯检测技术领域。目的是为了解决现有技术测量连铸凝固坯壳厚度的不足,提供一种将钢坯内部按照温度所对应的电导率分层,用多频电涡流测量法测得连铸钢坯坯壳厚度的方法。该方法具体为:在连铸结晶器出口处的铸坯表面放置电涡流传感器,传感器为互感差动式,电涡流传感器通过数字频率合成器进行混频激发,激发的多个不同的频率信号通过加法器进行混频,测量信号经过信号调理电路的放大、滤波,在相关器中分别与不同频率的参考信号进行互相关运算,将信号分离并进行涡流阻抗信号的幅相分离,分离出来的信号经采集和转换,传输到计算机进行数据的处理,得到连铸钢坯坯壳的厚度。
The invention discloses an eddy current detection method for the shell thickness of a continuous casting billet, belonging to the technical field of continuous casting billet detection. The purpose is to solve the deficiency of the prior art in measuring the thickness of the continuous casting solidified slab shell, and provide a method for measuring the thickness of the continuous casting slab shell by using the multi-frequency eddy current measurement method to layer the inside of the slab according to the electrical conductivity corresponding to the temperature . The method is specifically as follows: place an eddy current sensor on the surface of the slab at the outlet of the continuous casting mold. The sensor is a mutual induction differential type. The adder performs frequency mixing, the measurement signal is amplified and filtered by the signal conditioning circuit, and the cross-correlation operation is performed with the reference signals of different frequencies in the correlator, the signal is separated and the amplitude and phase separation of the eddy current impedance signal is performed, and the separated signal After collection and conversion, it is transmitted to the computer for data processing to obtain the thickness of the continuous casting billet shell.
Description
技术领域technical field
本发明具体涉及一种连铸钢坯坯壳厚度电涡流检测方法,属于连铸钢坯检测技术领域。The invention specifically relates to an eddy current detection method for the shell thickness of a continuous casting billet, belonging to the technical field of continuous casting billet detection.
背景技术Background technique
钢铁连铸生产过程中,通过结晶器出口处的凝固坯壳厚度的在线无损检测测量和控制,为连铸生产过程中的漏钢和坯壳厚度的均匀性进行了及时高效的检测,以提高连铸钢坯的生产质量,提高连铸自动化水平,具体体现在以下两个方面:实时检测结晶器出口处坯壳厚度承受钢水的静压能力,预防连铸过程中发生漏钢生产事故;在线无损检测凝固坯壳厚度变化趋势,以在线调节二冷水的冷却强度,闭环控制二冷水冷却水量。In the process of continuous casting of iron and steel, through the online non-destructive detection measurement and control of the thickness of the solidified billet shell at the outlet of the crystallizer, timely and efficient detection of breakouts and the uniformity of billet shell thickness in the continuous casting production process is carried out to improve The production quality of continuous casting slabs and the improvement of continuous casting automation level are embodied in the following two aspects: real-time detection of the thickness of the billet shell at the exit of the crystallizer to withstand the static pressure of molten steel, and prevention of steel breakout production accidents in the continuous casting process; online non-destructive Detect the change trend of the thickness of the solidified billet shell, adjust the cooling intensity of the secondary cooling water online, and control the cooling water volume of the secondary cooling water in a closed loop.
由于连铸生产的现场环境恶劣、高温热辐射、冷却水喷雾、粉尘等的影响,而且在结晶器出口处的坯壳存在着固相区、两相区、液相区。这些因素决定了连铸坯壳厚度在线无损检测要求能在高温、高水雾环境中能长期的运行。Due to the harsh on-site environment of continuous casting production, the influence of high-temperature heat radiation, cooling water spray, dust, etc., there are solid-phase, two-phase and liquid-phase regions in the billet shell at the outlet of the crystallizer. These factors determine that the on-line non-destructive testing of continuous casting slab shell thickness requires long-term operation in high temperature and high water mist environments.
目前,连铸过程中凝固坯壳厚度检测方法主要有实验测量法、数值模型法、应变传感检测法等三类。实验测量法中主要采用射钉法,在二冷区将含硫示踪剂的钢钉射入连铸坯,采用硫印分析、低倍检测射钉在铸坯固相、液相区内的形貌来确定凝固坯壳厚度和液相穴位置,这种实验方法技术成熟,精度高,结果直观可靠,但是属于离线有损检测,测量工作量大。穿刺坯壳测量法,在连铸二冷区刺穿凝固坯壳,使未凝固的液态钢水流出,再对凝固坯壳厚度进行在线检测,这种检测方法属于破坏性检测,现场操作难度很大。鼓肚法是通过检测连铸坯鼓肚的位置来确定液芯位置,该测量方法直观,装置简单,但只能粗略估计液芯末端位置。辐射法主要根据采用钻射线源,通过盖格计数器检测射线源穿过连铸坯后射线强度的变化来探测凝固坯壳的厚度,该方法技术思路可行,但放射源的放射性污染对人体和环境造成一定的影响。数值模型法是基于一维或二维非稳态传热控制方程,使用有限元差分计算法计算连铸坯内部温度场,进而确定连铸坯内部形貌,这种方法成本低,但模型求解精度依赖于准确的边界条件,但非稳态的连铸生产决定了难以确定准确的边界条件,同时模型计算收敛时间长,难以在线实时预测凝固坯壳厚度的变化。应变测试法通过在连铸坯相关扇形段上安装箔式电阻应变片,通过在线监测应变量变化突变点来确定连铸坯凝固末端的位置,这种方法可靠性、敏感性差,但受现场高温辐射、二冷区水雾、扇形段或工作辊受力复杂等影响,测试结果重复性较差,在工业生产现场无法推广应用。At present, there are three main methods for detecting the thickness of the solidified slab shell in the continuous casting process: experimental measurement method, numerical model method, and strain sensor detection method. In the experimental measurement method, the nail shooting method is mainly used. The steel nail containing sulfur tracer is injected into the continuous casting slab in the secondary cooling zone, and the sulfur print analysis and low magnification are used to detect the concentration of the nail in the solid phase and liquid phase area of the casting slab. Determining the thickness of the solidified shell and the position of the liquid phase hole by using the topography is a mature experimental method with high precision and intuitive and reliable results, but it belongs to off-line destructive testing, and the measurement workload is heavy. Piercing slab shell measurement method, pierces the solidified slab shell in the secondary cooling zone of continuous casting, so that the unsolidified liquid steel flows out, and then conducts online detection of the thickness of the solidified slab shell. This detection method is a destructive test, and the on-site operation is very difficult . The bulge method is to determine the position of the liquid core by detecting the position of the bulge of the continuous casting slab. This measurement method is intuitive and the device is simple, but it can only roughly estimate the position of the end of the liquid core. The radiation method is mainly based on the use of drilling ray sources, and the thickness of the solidified slab shell is detected by Geiger counters to detect the changes in the ray intensity after the ray source passes through the continuous casting slab. cause a certain impact. The numerical model method is based on one-dimensional or two-dimensional unsteady-state heat transfer control equations, using the finite element difference calculation method to calculate the internal temperature field of the continuous casting slab, and then determine the internal shape of the continuous casting slab. This method is low in cost, but the model solution Accuracy depends on accurate boundary conditions, but unsteady continuous casting production determines that it is difficult to determine accurate boundary conditions. At the same time, the model calculation takes a long time to converge, and it is difficult to predict the change of solidified slab shell thickness online in real time. The strain test method determines the position of the solidification end of the continuous casting slab by installing foil resistance strain gauges on the relevant sectors of the continuous casting slab and monitoring the mutation point of the strain change online. This method has poor reliability and sensitivity. Due to the influence of radiation, water mist in the secondary cooling zone, complex forces on the fan section or work rolls, etc., the repeatability of the test results is poor, and it cannot be popularized and applied in industrial production sites.
基于结晶器出口处的凝固坯壳的重要性,准确表征其厚度和均匀性,对于优化连铸结晶器工艺和设备,提高连铸坯质量和连铸生产效率至关重要。目前国内外针对凝固坯壳厚度检测方法都没有从根本上解决工业生产现场应用问题。Based on the importance of the solidified slab shell at the exit of the mold, accurate characterization of its thickness and uniformity is essential for optimizing the continuous casting mold process and equipment, improving the quality of the continuous casting slab and continuous casting production efficiency. At present, the detection methods for the thickness of the solidified billet shell at home and abroad have not fundamentally solved the problem of field application in industrial production.
发明内容Contents of the invention
因此,针对现有技术测量连铸凝固坯壳厚度的上述不足,本发明旨在提供一种连铸钢坯坯壳厚度电涡流检测方法。本发明能有效克服连铸生产现场的表面高温辐射、水雾坏境等恶劣环境的影响,分别适合测量铸坯不同表面温度、不同浇注钢种的薄板连铸要求。Therefore, aiming at the above-mentioned shortcomings of measuring the thickness of the continuous casting solidified slab shell in the prior art, the present invention aims to provide an electric eddy current detection method for the thickness of the continuous casting slab shell. The invention can effectively overcome the influence of harsh environments such as surface high temperature radiation and water mist environment in the continuous casting production site, and is respectively suitable for measuring thin-slab continuous casting requirements of different surface temperatures of casting slabs and different pouring steel types.
本方法的原理是根据连铸钢坯表面温度在居里点之上,而钢坯材料的电阻率随温度变化,并且在钢熔化为液态时其电阻率发生跃变其电阻率为固态时的2-3倍,因此可将钢坯按照电阻率划分为三层,凝固层,固液层及液态层,进而运用电涡流技术,测量凝固层的厚度。The principle of this method is based on the fact that the surface temperature of the continuous casting billet is above the Curie point, and the resistivity of the billet material changes with the temperature, and when the steel is melted into a liquid state, its resistivity changes abruptly, and its resistivity is 2- 3 times, so the steel billet can be divided into three layers according to the resistivity, the solidified layer, the solid-liquid layer and the liquid layer, and then use the eddy current technology to measure the thickness of the solidified layer.
本方案的目的是通过以下方案实现的:The purpose of this program is achieved through the following programs:
在连铸结晶器出口处的铸坯表面放置电涡流传感器,传感器为互感差动式。电涡流传感器通过数字频率合成器进行混频激发,激发的三个不同的频率信号通过加法器进行混频,测量信号经过信号调理电路的放大、滤波,在三个相关器中分别与三个不同频率的参考信号进行互相关运算,将信号分离并进行涡流阻抗信号的幅相分离,分离出来的信号经采集和转换,传输到计算机进行数据的处理。计算机处理的数据过程如下:当标定时,首先通过利用有限元仿真软件预先建立的温度场及电磁场耦合测量模型进行仿真模拟标定,获得测量数据与层厚度关系曲线。再用变厚度的热钢板代替凝固层,另一种热钢板代替固液层,钢液为液态层,所测得的数据通过最小二乘算法,完成对凝固层厚度及固液层测量数据的拟合的修正,获得测量反演数学模型。测量时,测量数据带入测量反演数学模型即可得到连铸钢坯坯壳的厚度。An eddy current sensor is placed on the surface of the slab at the outlet of the continuous casting crystallizer, and the sensor is a mutual induction differential type. The eddy current sensor is excited by mixing frequency through a digital frequency synthesizer, and the excited three different frequency signals are mixed by an adder, and the measurement signal is amplified and filtered by a signal conditioning circuit, and is respectively different from three different The frequency reference signal is subjected to cross-correlation calculation, the signal is separated and the amplitude and phase of the eddy current impedance signal are separated, and the separated signal is collected and converted, and then transmitted to the computer for data processing. The process of data processing by the computer is as follows: When calibrating, firstly, simulate calibration by using the temperature field and electromagnetic field coupling measurement model pre-established by the finite element simulation software, and obtain the relationship curve between the measurement data and the layer thickness. Then use a hot steel plate with variable thickness to replace the solidified layer, and another hot steel plate to replace the solid-liquid layer. The molten steel is a liquid layer. The measured data is calculated by the least square algorithm to complete the measurement data of the solidified layer thickness and the solid-liquid layer. The correction of the fit is obtained by measuring the inversion of the mathematical model. During the measurement, the measurement data is brought into the measurement inversion mathematical model to obtain the thickness of the continuous casting billet shell.
进一步的,所述方法中电涡流传感器的放置在距离连铸结晶器出口处的铸坯表面2mm位置。Further, in the method, the eddy current sensor is placed at a position 2mm away from the surface of the slab at the outlet of the continuous casting mold.
进一步的,所述方法中数字频率合成器为AD9959数字频率合成器。Further, the digital frequency synthesizer in the method is an AD9959 digital frequency synthesizer.
进一步的,所述方法中在电涡流传感器的电涡流线圈的参数设置中,激励为700HZ至12KHZ,内半径为12mm,外半径为17mm至19mm,高度为4mm,原副边匝数为60匝。Further, in the method, in the parameter setting of the eddy current coil of the eddy current sensor, the excitation is 700HZ to 12KHZ, the inner radius is 12mm, the outer radius is 17mm to 19mm, the height is 4mm, and the number of primary and secondary turns is 60 .
进一步的,测量模型的建立方法为通过有限元仿真软件ANSYS对结晶器出口处的铸坯进行温度场根据公式一及边界条件进行模拟计算,计算可以得出铸坯内部温度梯度分布云图,结合钢种的化学成分和固液相线温度的计算公式二,可以得出钢种的固相线温度值和液相线温度值,计算时铸坯参数为:Further, the establishment method of the measurement model is to use the finite element simulation software ANSYS to simulate and calculate the temperature field of the slab at the exit of the mold according to formula 1 and the boundary conditions. The calculation can obtain the cloud map of the temperature gradient distribution inside the slab. The calculation formula 2 of the chemical composition and solid-liquidus temperature of the steel type can obtain the solidus temperature value and liquidus temperature value of the steel type, and the billet parameters during calculation are:
结晶器壁厚:20mm,有效长度:1000mm,拉坯速度:2—5.5m/min,浇注温度:1547℃,铸坯厚度:50mm。Mold wall thickness: 20mm, effective length: 1000mm, billet casting speed: 2-5.5m/min, pouring temperature: 1547°C, billet thickness: 50mm.
式中λ—材料的热传导系数(w/m.℃),C—比热(J/Kg.℃),ρ—密度(Kg/m3),τ—铸坯凝固时间(s),Lf-钢水凝固潜热(J/kg)。In the formula, λ—heat conductivity coefficient of material (w/m.℃), C—specific heat (J/Kg.℃), ρ—density (Kg/m 3 ), τ—slab solidification time (s), L f - latent heat of solidification of molten steel (J/kg).
T l=Tf-∑ΔT·i% (公式二) T l =T f -∑ΔT·i% (Formula 2)
式中:Tl为固液相线温度、Tf为钢种熔点、ΔT为铁中没加入1%元素i使熔点降低值。In the formula: T l is the solid-liquidus temperature, T f is the melting point of the steel, and ΔT is the lowering value of the melting point without adding 1% element i to the iron.
根据仿真计算,确定所需的测量范围。选择被测对象为薄板铸坯,铸坯厚度范围为20-100毫米,坯壳厚度范围为5-20毫米范围。根据金属的电磁特性随温度变化,连铸结晶器下方出口处坯表面温度高于居里温度,而当钢熔化为液态时,电阻率发生跃变的特性,将钢坯按照电阻率与材料温度的对应,将连铸结晶器出口处的铸坯进行分层。According to the simulation calculation, determine the required measurement range. The object to be tested is selected as a thin slab, the thickness of the slab is 20-100 mm, and the shell thickness is 5-20 mm. According to the change of the electromagnetic properties of the metal with temperature, the billet surface temperature at the outlet below the continuous casting crystallizer is higher than the Curie temperature, and when the steel melts into a liquid state, the resistivity changes abruptly, and the billet is divided according to the resistivity and material temperature. Correspondingly, the slab at the outlet of the continuous casting mold is stratified.
所述方法中对测量模型进行仿真标定的过程具体包括:The process of carrying out simulation calibration to the measurement model in the method specifically includes:
步骤一:在MATLAB中采用相位旋转相减算法对三组不同的阻抗值进行数据处理;Step 1: Use phase rotation and subtraction algorithm in MATLAB to process data of three groups of different impedance values;
步骤二:改变凝固坯壳层的厚度,其余两层的厚度相应变化,重复步骤一多次,得到多频测多层板的标定数据;通过最小二乘法获得不同频率对应的测量曲线及数学模型。数学模型如公式三Step 2: Change the thickness of the solidified slab shell layer, and the thickness of the other two layers will change accordingly. Repeat the steps one or more times to obtain the calibration data of the multi-frequency multi-layer board; obtain the measurement curves and mathematical models corresponding to different frequencies by the least square method . Mathematical model such as formula three
其中ufi为不同频率下测量信号相位对应的电压值。αi,βi,χi通过多组数据及最小二乘法获得,di为层厚度。然后解方程组得到厚度反演模型如公式四Where u fi is the voltage value corresponding to the phase of the measured signal at different frequencies. α i , β i , χ i are obtained through multiple sets of data and the least square method, and d i is the layer thickness. Then solve the equations to get the thickness inversion model as Equation 4
步骤三:用已知厚度两层热钢板和钢液组成坯壳厚度测量替代被测对象,只改变两层钢板的厚度,钢液的厚度保持不变,用方案所述测量系统获得传感器测量信号三个不同频率对应的幅值和相位,对测量模型进行修正。Step 3: Replace the measured object with two layers of hot steel plates and molten steel to measure the thickness of the billet shell, only change the thickness of the two layers of steel plates, and keep the thickness of the molten steel unchanged, and use the measurement system described in the plan to obtain the sensor measurement signal The magnitude and phase corresponding to three different frequencies are used to correct the measurement model.
本发明的有益效果在于:本发明将多频电涡流技术应用在连铸钢坯测厚中,其优点在于能够在高温、多水雾的连铸生产环境下,非接触的在线测量连铸坯的凝固厚度,具体体现在以下几点:The beneficial effect of the present invention is that: the present invention applies the multi-frequency eddy current technology to the continuous casting slab thickness measurement, and its advantage is that it can measure the thickness of the continuous casting slab on-line without contact in the continuous casting production environment of high temperature and water mist. Solidification thickness, specifically reflected in the following points:
1、采用耐高温型扁平型激励线圈,线圈为互感差动形式,线圈材质为金属钨,绝缘采用陶瓷漆一边绕制一边刷漆,线圈外加水冷套能有效克服连铸生产现场的表面高温辐射、水雾环境等恶劣环境的影响,同时确保涡流线圈在1000℃以上的高温金属表面可靠工作。1. High temperature resistant flat excitation coil is adopted. The coil is in the form of mutual inductance and differential. The coil material is metal tungsten. The insulation is made of ceramic paint while winding and painting. The coil is added with a water cooling jacket to effectively overcome the high temperature radiation on the surface of the continuous casting production site. , water mist environment and other harsh environments, and at the same time ensure that the eddy current coil can work reliably on high-temperature metal surfaces above 1000 °C.
2、首次对结晶器出口处的铸坯内部根据温度所对应的材料电阻率进行分层,利用电涡流多频测量法获得坯壳厚度,使铸坯内部更加直观明了,可以使凝固坯壳测厚更加精准。2. For the first time, the interior of the billet at the exit of the mold is stratified according to the material resistivity corresponding to the temperature, and the thickness of the billet shell is obtained by using the eddy current multi-frequency measurement method, which makes the interior of the billet more intuitive and clear, and can measure the solidified billet shell Thick is more precise.
3、采用有限元仿真软件,对连铸坯内温度场分析,获得结晶器下方坯壳厚度测量范围。根据该测量范围要求设计了探头线圈尺寸、结构及激励频率范围,更加具有针对性,它使得在连铸生产高温坏境铸坯厚度的测量,有了较为可行的方案。3. Use finite element simulation software to analyze the temperature field inside the continuous casting slab, and obtain the thickness measurement range of the slab shell under the crystallizer. According to the measurement range requirements, the size, structure and excitation frequency range of the probe coil are designed, which is more targeted, and it makes it possible to measure the thickness of the slab in the high temperature environment of continuous casting production.
4、第一次采用多频多层导电结构测厚对连铸铸坯壳厚度进行测量,使得多频涡流检测理论应用在高温环境实践中得到验证。4. For the first time, the multi-frequency multi-layer conductive structure thickness measurement is used to measure the thickness of the continuous casting slab shell, so that the application of the multi-frequency eddy current detection theory is verified in practice in high temperature environments.
附图说明Description of drawings
图1拉速V=4.5m/min下铸坯横截面温度等值线图Fig.1 Contour diagram of cross-section temperature of slab at casting speed V=4.5m/min
图2为本发明连铸结晶器出口处铸坯内部分层示意图。Fig. 2 is a schematic diagram of the stratification inside the slab at the outlet of the continuous casting crystallizer of the present invention.
图3为本发明连铸铸坯多层板涡流传感器测量示意图。Fig. 3 is a schematic diagram of measurement by the eddy current sensor of the continuous casting slab multi-layer plate of the present invention.
图4为本发明凝固坯壳厚度电涡流测量装置设置示意图。Fig. 4 is a schematic diagram of the installation of the eddy current measuring device for the thickness of the solidified shell of the present invention.
图5为本发明中频率在4kHZ激励下,电涡流的渗透深度示意图。Fig. 5 is a schematic diagram of the penetration depth of eddy current under the excitation frequency of 4kHZ in the present invention.
图6为本发明高温探头水冷套外形图。Fig. 6 is an outline drawing of the water cooling jacket of the high temperature probe of the present invention.
图7为本发明有限元仿真软件进行模拟标定的计算原理图。Fig. 7 is a calculation schematic diagram of simulation calibration performed by the finite element simulation software of the present invention.
图8为本发明不同频率下厚度与电压变化值的关系曲线图。Fig. 8 is a graph showing the relationship between thickness and voltage variation at different frequencies in the present invention.
图9为本发明方法的测量系统总体原理框图。Fig. 9 is an overall principle block diagram of the measurement system of the method of the present invention.
具体实施方式Detailed ways
下面结合附图对本发明的具体实施方式进行说明:The specific embodiment of the present invention is described below in conjunction with accompanying drawing:
本发明在线测量连铸结晶器出口处凝固坯壳的厚度,本发明的涡流线圈是测量连铸结晶器出口处的凝固铸坯的厚度,由于对象的特殊性,因此对涡流线圈进行自主设计。在铸坯刚出连铸结晶器时,铸坯内部为固态区、固液两相区、液相区,这些区间的厚度是难以进行测量的。首先需要知道坯壳厚度的范围,根据测量范围设计探头及测量系统。The invention measures the thickness of the solidified slab shell at the exit of the continuous casting mold online. The eddy current coil of the invention measures the thickness of the solidified slab at the exit of the continuous casting mold. Due to the particularity of the object, the eddy current coil is independently designed. When the slab just leaves the continuous casting mold, the interior of the slab is a solid region, a solid-liquid two-phase region, and a liquid phase region, and the thickness of these regions is difficult to measure. First of all, it is necessary to know the thickness range of the billet shell, and design the probe and measurement system according to the measurement range.
通过有限元仿真软件ANSYS对结晶器出口处的铸坯进行温度场根据公式一及一系列边界条件进行模拟计算,计算可以得出铸坯内部温度梯度分布云图如图1所示,结合钢种的化学成分和固液相线温度的计算公式二,可以得出钢种的固相线温度值和液相线温度值。计算时铸坯参数如表1所示。Through the finite element simulation software ANSYS, the temperature field of the slab at the outlet of the mold is simulated and calculated according to formula 1 and a series of boundary conditions. The calculation can get the cloud diagram of the temperature gradient distribution inside the slab as shown in Figure 1, combined with the steel type. The calculation formula 2 of chemical composition and solid-liquidus temperature can get the solidus temperature value and liquidus temperature value of the steel grade. The billet parameters during calculation are shown in Table 1.
表1Table 1
式中λ—材料的热传导系数(w/m.℃),C—比热(J/Kg.℃),ρ—密度(Kg/m3),τ—铸坯凝固时间(s),Lf-钢水凝固潜热(J/kg)。In the formula, λ—heat conductivity coefficient of material (w/m.℃), C—specific heat (J/Kg.℃), ρ—density (Kg/m 3 ), τ—slab solidification time (s), L f - latent heat of solidification of molten steel (J/kg).
T l=Tf-∑ΔT·i% 公式二 T l =T f -∑ΔT·i% Formula 2
式中:Tl为固液相线温度、Tf为钢种熔点、ΔT为铁中没加入1%元素i使熔点降低值。In the formula: T l is the solid-liquidus temperature, T f is the melting point of the steel, and ΔT is the lowering value of the melting point without adding 1% element i to the iron.
根据仿真计算,确定所需的测量范围。选择被测对象为薄板铸坯,铸坯厚度范围为20-100毫米,坯壳厚度范围为5-20毫米范围。According to the simulation calculation, determine the required measurement range. The object to be tested is selected as a thin slab, the thickness of the slab is 20-100 mm, and the shell thickness is 5-20 mm.
根据金属的电磁特性随温度变化,连铸结晶器下方出口出坯表面温度高于居里温度,而当钢熔化为液态时,电阻率发生跃变的特性,将钢坯按照电阻率与材料温度的对应,可使连铸结晶器出口处的铸坯进行分层,所建模型如图2所示,其中4为固态区,5为固液两相区,6为液相区。According to the change of the electromagnetic properties of the metal with the temperature, the surface temperature of the billet at the outlet below the continuous casting crystallizer is higher than the Curie temperature, and when the steel melts into a liquid state, the resistivity changes abruptly. Correspondingly, the cast slab at the outlet of the continuous casting crystallizer can be stratified, and the built model is shown in Figure 2, in which 4 is the solid zone, 5 is the solid-liquid two-phase zone, and 6 is the liquid phase zone.
在检测对象模型上建立传感器模型,所建模型如图3所示。其中,R1为线圈内半径、R2为线圈外半径、D为涡流线圈高度、H为提离距离、t1为固态去板层厚度、t2为固液两相区的厚度、t3为液相区的厚度。在该模型上进行传感器优化计算。The sensor model is established on the detection object model, as shown in Figure 3. Among them, R 1 is the inner radius of the coil, R 2 is the outer radius of the coil, D is the height of the eddy current coil, H is the lift-off distance, t 1 is the thickness of the solid-state layer removed, t 2 is the thickness of the solid-liquid two-phase region, t 3 is the thickness of the liquid phase region. Sensor optimization calculations are performed on this model.
计算结果支持将电涡流传感器的放置位置如图4所示,图4中1为中间包,2为结晶器,3为电涡流传感器。通过有限元仿真软件ANSYS得出当提离距离为2mm时,涡流密度可满足测量要求。因此把电涡流传感器3放置在距连铸结晶器2处下方距铸坯表面2mm位置处。The calculation results support the placement of the eddy current sensor as shown in Figure 4. In Figure 4, 1 is the tundish, 2 is the crystallizer, and 3 is the eddy current sensor. Through the finite element simulation software ANSYS, it is concluded that when the lift-off distance is 2mm, the eddy current density can meet the measurement requirements. Therefore, the eddy current sensor 3 is placed at a position 2 mm below the continuous casting crystallizer 2 and away from the surface of the slab.
依据被测目标的特殊性和涡流检测的相关理论,运用有限元仿真软件和阻抗分析法对涡流线圈进行仿真,以使涡流线圈可以在线检测凝固坯壳的厚度和电涡流线圈的效率可以达到最优。According to the particularity of the measured target and the relevant theory of eddy current detection, the eddy current coil is simulated by using finite element simulation software and impedance analysis method, so that the eddy current coil can detect the thickness of the solidified shell on-line and the efficiency of the eddy current coil can reach the best excellent.
式中f为涡流线圈的主激励频率,ρ为磁导率,μ为相对磁导率,d为趋肤深度,R为线圈内半径。Where f is the main excitation frequency of the eddy current coil, ρ is the magnetic permeability, μ is the relative magnetic permeability, d is the skin depth, and R is the inner radius of the coil.
基于公式五、公式六可以得出电涡流线圈主激励频率和线圈内半径,以上述两个因素为基准,分别对涡流线圈的外半径、高度和匝数进行有限元仿真计算,计算所得到的结果数据导入到MATLAB中,通过MATLAB对其进行分析处理,最终得到了电涡流线圈的激励为700HZ至12KHZ,内半径为12mm,外半径为17mm至19mm,高度为4mm,原副边匝数为60匝可以获得最大效率,有限元仿真趋肤深度如图5所示。Based on Formula 5 and Formula 6, the main excitation frequency of the eddy current coil and the inner radius of the coil can be obtained. Based on the above two factors, the finite element simulation calculation is performed on the outer radius, height and number of turns of the eddy current coil respectively. The calculated The result data is imported into MATLAB, analyzed and processed by MATLAB, and finally the excitation of the eddy current coil is 700HZ to 12KHZ, the inner radius is 12mm, the outer radius is 17mm to 19mm, the height is 4mm, and the number of primary and secondary turns is 60 turns can obtain the maximum efficiency, and the finite element simulation skin depth is shown in Figure 5.
本发明为了适用于连铸现场高温、多水雾等环境,所用激励线圈绕线采用耐高温的钨丝及陶瓷漆以螺旋型缠绕形成,传感器的探头外壳采用具有水冷作用的金属外壳,探头外壳水冷设计如图6所示。In order to be suitable for the environment of high temperature and water mist in the continuous casting site, the excitation coil winding is formed by spiral winding of high temperature resistant tungsten wire and ceramic paint, the probe shell of the sensor adopts a metal shell with water cooling effect, and the probe shell The water cooling design is shown in Figure 6.
先采用有限元仿真软件进行模拟标定,然后利用热钢板及液态钢液对测量模型进行修正。Firstly, finite element simulation software is used for simulation calibration, and then the measurement model is corrected by using hot steel plate and liquid steel.
多频涡流检测中,电涡流传感器用三个频率波形合成的信号来激励,由于叠加原理应用到线圈线性系统,所以在混合频率激励下探头的阻抗变化是各个频率单独激励下阻抗变化的线性合成。其效应与三台独立的涡流仪器控制同一探头,然后将三台仪器的输出相加是一样的,因此在有限元仿真时,采用三个单独的频率去激励线圈。In multi-frequency eddy current detection, the eddy current sensor is excited by the signal synthesized by three frequency waveforms. Since the superposition principle is applied to the coil linear system, the impedance change of the probe under the mixed frequency excitation is the linear synthesis of the impedance change under the separate excitation of each frequency. . The effect is the same as three independent eddy current instruments controlling the same probe, and then summing the outputs of the three instruments, so in the finite element simulation, three separate frequencies are used to excite the coil.
步骤一:不同的激励频率会产生不同的阻抗值,三组不同的激励频率将会产生三组不同的阻抗值,在MATLAB中采用相位旋转相减算法对三组不同的阻抗值进行数据处理;Step 1: Different excitation frequencies will produce different impedance values, and three different excitation frequencies will produce three different impedance values. Use the phase rotation subtraction algorithm in MATLAB to process the data of the three different impedance values;
步骤二:改变凝固坯壳层的厚度,其余两层的厚度相应变化,重复步骤一多次,得到多频测多层板的标定数据;通过最小二乘法获得不同频率对应的测量曲线及数学模型。数学模型如公式三Step 2: Change the thickness of the solidified slab shell layer, and the thickness of the other two layers will change accordingly. Repeat the steps one or more times to obtain the calibration data of the multi-frequency multi-layer board; obtain the measurement curves and mathematical models corresponding to different frequencies by the least square method . Mathematical model such as formula three
其中ufi为不同频率下测量信号相位对应的电压值。αi,βi,χi通过多组数据及最小二乘法获得,di为层厚度。只需获得上面两层的厚度。然后解方程组得到厚度反演模型如公式四Where u fi is the voltage value corresponding to the phase of the measured signal at different frequencies. α i , β i , χ i are obtained through multiple sets of data and the least square method, and d i is the layer thickness. Just get the thickness of the top two layers. Then solve the equations to get the thickness inversion model as Equation 4
采用有限元仿真软件进行模拟标定的计算原理如图7所示,图中,由于铸坯表面温度高于居里点,相对磁导率μi为1,电导率根据温度对应,线圈为互感差动式。探头线圈参数:r1,r2-探头线圈内径和外径,(12-l1,)-探头长度;l1-提离;材料电导率:σ1,σ2,…,σm,σm+1,σm+2;材料相对磁导率:μ1,μ2,…,μm,μm+1,μm+2各层交界处z方向坐:z1,z2,…,zm,z1+m,zi=-(dm+dm-1,…di+2+di+1),i=1,2,3…m-1,dm+dm-1,…di+2+di+1-各层的厚度。The calculation principle of simulation calibration using finite element simulation software is shown in Figure 7. In the figure, since the surface temperature of the slab is higher than the Curie point, the relative magnetic permeability μ i is 1, the electrical conductivity corresponds to the temperature, and the coil is the mutual inductance difference dynamic. Probe coil parameters: r 1 , r 2 - inner diameter and outer diameter of probe coil, (1 2 -l 1 ,) - probe length; l 1 - lift-off; material conductivity: σ 1 , σ 2 ,…,σ m , σ m+1 ,σ m+2 ; material relative permeability: μ 1 , μ 2 ,…, μ m , μ m+1 , μ m+2 at the junction of each layer in the z direction: z 1 , z 2 , …, z m , z 1+m , z i =-(d m +d m-1 ,…d i+2 +d i+1 ), i=1,2,3…m-1,d m + d m-1 ,...d i+2 +d i+1 - the thickness of the individual layers.
步骤三:用已知厚度两层热钢板和钢液组成坯壳厚度测量替代被测对象,只改变两层钢板的厚度,钢液的厚度保持不变,用方案所述测量系统获得传感器测量信号三个不同频率对应的幅值和相位,对测量模型进行修正,最终得到的不同频率下厚度与电压变化值的关系曲线如图8所示。Step 3: Replace the measured object with two layers of hot steel plates and molten steel to measure the thickness of the billet shell, only change the thickness of the two layers of steel plates, and keep the thickness of the molten steel unchanged, and use the measurement system described in the plan to obtain the sensor measurement signal The amplitude and phase corresponding to the three different frequencies are corrected to the measurement model, and finally the relationship curve between the thickness and the voltage change value at different frequencies is shown in Figure 8.
本发明涡流线圈在线测量凝固坯壳的厚度原理图,如图9所示。它由多频信号激励源AD9959、涡流探头线圈、信号处理电路、相关器、信号采集与转换和计算机组成。The schematic diagram of the online measurement of the thickness of the solidified shell by the eddy current coil of the present invention is shown in FIG. 9 . It consists of multi-frequency signal excitation source AD9959, eddy current probe coil, signal processing circuit, correlator, signal acquisition and conversion and computer.
电涡流传感器需要三个不同的激励频率同时对涡流检测线圈进行激励。因此,由AD9959产生的三路不同频率的激励信号必须通过加法器进行混频,从而满足多频同时对涡流检测线圈进行激励,本设计采用叠加原理的同向求和运算电路完成不同频率信号的混频。The eddy current sensor requires three different excitation frequencies to simultaneously excite the eddy current detection coil. Therefore, the excitation signals of three different frequencies generated by the AD9959 must be mixed by an adder, so as to satisfy the multi-frequency excitation of the eddy current detection coil at the same time. mixing.
对于坯壳厚度测量单频信号激励是无法实现的,传统的阻抗分析法只能抑制一个干扰因素。因此,想要获得更多被检工件的信息需要用多个频率对电涡流传感器进行激励。对三层导电结构厚度测量则需要三个不同频率的正弦信号混频激励,并且必须保证每一个激励信号都能透过坯壳厚度,因此采用三个正交相关器能将频率混叠的涡流响应信号所包含的信息分离,得到单频激励下的直流信号。It is impossible to realize single-frequency signal excitation for shell thickness measurement, and the traditional impedance analysis method can only suppress one interference factor. Therefore, in order to obtain more information about the inspected workpiece, it is necessary to excite the eddy current sensor with multiple frequencies. For the measurement of the thickness of the three-layer conductive structure, three sinusoidal signals with different frequencies are required to be mixed and excited, and it must be ensured that each excitation signal can pass through the shell thickness. The information contained in the response signal is separated to obtain a DC signal under single-frequency excitation.
本发明在线测量凝固坯壳的厚度是这样的进行测定的:在连铸结晶器出口处距离铸坯表面2mm处放置上述的电涡流传感器,电涡流传感器通过AD9959进行混频激发,三个不同的频率通过加法器进行混频,测量端信号经过信号调理电路的放大、滤波,在相关器中进行的互相关运算,实现了不同频率信号的分离以及涡流阻抗信号的幅相分离,分离出来的信号经采集和转换,最终传输到计算机进行数据的处理。The online measurement of the thickness of the solidified slab shell of the present invention is carried out in such a way: the above-mentioned eddy current sensor is placed at the outlet of the continuous casting mold at a distance of 2mm from the surface of the slab, and the eddy current sensor is excited by AD9959. Three different The frequency is mixed by the adder, the signal at the measuring end is amplified and filtered by the signal conditioning circuit, and the cross-correlation operation in the correlator realizes the separation of different frequency signals and the amplitude and phase separation of the eddy current impedance signal. The separated signal After collection and conversion, it is finally transmitted to a computer for data processing.
用已知厚度两层热钢板和钢液组成坯壳厚度测量替代被测对象,用图9所述传感器及测量系统获得数据。在计算机进行处理的数据,对事先仿真标定的测量模型进行修正,获得实用测量模型。The measured object is replaced by two layers of hot steel plates and molten steel with known thickness to measure the thickness of the billet shell, and the sensor and measurement system shown in Figure 9 are used to obtain data. The data processed by the computer is used to correct the measurement model calibrated by simulation in advance to obtain a practical measurement model.
当测量时,上述传感器及测量系统获得测量值带入测量模型即可计算出凝固壳厚度。当钢种改变时,需重新标定。When measuring, the measured values obtained by the above-mentioned sensors and measurement system are brought into the measurement model to calculate the thickness of the solidified shell. When the steel type is changed, it needs to be re-calibrated.
为了提高测量精度,钢坯内分层可进一步细分,但测量频率需添加更多频率,测量速度将降低。此问题在标定时需要折中考虑。In order to improve the measurement accuracy, the stratification in the billet can be further subdivided, but more frequencies need to be added to the measurement frequency, and the measurement speed will be reduced. This problem needs to be considered as a compromise when calibrating.
以上所述是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明所述原理的前提下,还可以作出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。The above description is a preferred embodiment of the present invention, it should be pointed out that for those of ordinary skill in the art, without departing from the principle of the present invention, some improvements and modifications can also be made, and these improvements and modifications can also be made. It should be regarded as the protection scope of the present invention.
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