An Intelligent Logic-Based Mold Breakout Prediction System Algorithm for the Continuous Casting Process of Steel: A Novel Study

突破 铸工 模具 连铸 过程(计算) 中间包 铸造 工程类 工程制图 计算机科学 机械工程 结构工程 算法 材料科学 冶金 复合材料 操作系统 财务 经济
作者
Md Obaidullah Ansari,Joyjeet Ghose,Somnath Chattopadhyaya,Debasree Ghosh,Shubham Sharma,Prashant Sharma,Abhinav Kumar,Changhe Li,Rajesh Singh,Sayed M. Eldin
出处
期刊:Micromachines [MDPI AG]
卷期号:13 (12): 2148-2148 被引量:7
标识
DOI:10.3390/mi13122148
摘要

Mold breakout is one of the significant problems in a continuous casting machine (caster). It represents one of the key areas within the steel production facilities of a steel plant. A breakout event on a caster will always cause safety hazards, high repair costs, loss of production, and shutdown of the caster for a short while. In this paper, a logic-judgment-based mold breakout prediction system has been developed for a continuous casting machine. This system developed new algorithms to detect the different sticker behaviors. With more algorithms running, each algorithm is more specialized in the other behaviors of stickers. This new logic-based breakout prediction system (BOPS) not only detects sticker breakouts but also detects breakouts that takes place due to variations in casting speed, mold level fluctuation, and taper/mold problems. This system also finds the exact location of the breakout in the mold and reduces the number of false alarms. The task of the system is to recognize a sticker and prevent a breakout. Moreover, the breakout prediction system uses an online thermal map of the mold for process visualization and assisting breakout prediction. This is done by alerting the operating staff or automatically reducing the cast speed according to the location of alarmed thermocouples, the type of steel, the tundish temperature, and the size of the cold slab width. By applying the proposed model in an actual steel plant, field application results show that it could timely detect all 13 breakouts with a detection ratio of 100%, and the frequency of false alarms was less than 0.056% times/heat. It has the additional advantage of not needing a lot of learning data, as most neural networks do. Thus, this new logical BOPS system should not only detect the sticker breakouts but also detect breakouts taking place due to variations in casting speed and mold level fluctuation.
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