阅读说明：本技术 熔融金属无人化检验系统和方法 (Molten metal unmanned inspection system and method ) 是由 万小丽 刘贵林 刘景亚 于 2021-09-13 设计创作，主要内容包括：本发明提供一种熔融金属无人化检验系统和方法,其中,熔融金属无人化检验系统包括：中央控制单元,用于按时序生成控制指令,所述控制指令包括取样指令、送样指令和检验指令；机器人站点,包括：第一机器人站点,用于执行所述取样指令；第二机器人站点,用于执行所述送样指令；第三机器人站点,用于执行所述检验指令；所述第一机器人站点、第二机器人站点以及第三机器人站点相互独立并依时序执行控制指令；所述中央控制单元根据各机器人站点实时反馈的执行结果,对各机器人站点进行统一调度。本方案实现了熔融金属无人化检验。(The invention provides a molten metal unmanned inspection system and a method, wherein the molten metal unmanned inspection system comprises: the central control unit is used for generating a control instruction according to a time sequence, wherein the control instruction comprises a sampling instruction, a sample sending instruction and a checking instruction; a robot station, comprising: a first robot station for executing the sampling instruction; the second robot station is used for executing the sample sending instruction; a third robot station for executing the inspection instructions; the first robot station, the second robot station and the third robot station are mutually independent and execute control instructions according to time sequence; and the central control unit carries out unified scheduling on each robot station according to the execution result fed back by each robot station in real time. The scheme realizes unmanned inspection of the molten metal.)

1. An unmanned inspection system for molten metal, comprising:

the central control unit is used for generating a control instruction according to a time sequence, wherein the control instruction comprises a sampling instruction, a sample sending instruction and a checking instruction;

a robot station, comprising:

a first robot station for executing the sampling instruction;

the second robot station is used for executing the sample sending instruction;

a third robot station for executing the inspection instructions;

the first robot station, the second robot station and the third robot station are mutually independent and execute control instructions according to time sequence; and the central control unit carries out unified scheduling on each robot station according to the execution result fed back by each robot station in real time.

2. The unmanned molten metal inspection system of claim 1, wherein each of the robot stations comprises:

the station control unit is used for controlling the station of the robot to work according to the control instruction;

and a plurality of executing devices are arranged in each robot station and are used for cooperatively executing the control instruction received by the corresponding station control unit.

3. The unmanned molten metal inspection system of claim 2, wherein the performing means in the first robotic station comprises a first robotic arm, a lance device, an automatic sample separation device, a sampler, a storage rack, and a first vision device for generating sampling point location information; the measuring gun device is fixed at the tail end of the first mechanical arm and driven by the first mechanical arm, and the sampler is placed on the storage rack.

4. The unmanned molten metal inspection system of claim 3, wherein the station control unit in the first robotic station comprises:

the butt joint control module is used for controlling the first mechanical arm to act after acquiring a sampling instruction, so that a gun measuring device at the tail end of the first mechanical arm is in butt joint with the sampler;

the sampling control module is used for controlling the first mechanical arm to act according to the position information of the sampling point so that the sampler samples at the corresponding sampling point;

and the sample separation control module controls the first mechanical arm to move to the sample automatic separation device, and controls the sample automatic separation device to separate the solidified sample from the sampler.

5. The unmanned molten metal inspection system of claim 3, wherein the first vision device comprises:

the furnace mouth state judging module is used for judging whether the furnace mouth is in an opening state or not according to the furnace mouth information, and if the furnace mouth is in the opening state, furnace mouth state information is generated;

and the sampling point position judging module is used for judging the position distance between the furnace mouth and the molten liquid level according to the molten liquid level information and the furnace mouth state information, generating a judging result and then generating sampling point position information according to the judging result.

6. The unmanned molten metal inspection system of claim 4, wherein the actuators of the second robotic station comprise a mobile cart, a second robotic arm carried by the mobile cart, a first motorized gripper mounted on and carried by the second robotic arm to grip the sample, and a second vision device for identifying a sample gripping location.

7. The unmanned molten metal inspection system of claim 6, wherein the station control unit of the second robot station comprises:

the sample grabbing control module is used for acquiring a sample sending instruction, controlling the movable trolley to move to the side of the sample automatic separation device according to the sample sending instruction, and grabbing the separated sample by the first electric gripper;

and the sample transfer control module is used for controlling the movable trolley to move to the pneumatic sample conveying device after acquiring the sample grabbing completion information, and then controlling the first electric gripper to place the sample to a pneumatic sample conveying inlet of the pneumatic sample conveying device, and the pneumatic sample conveying device conveys the sample.

8. The unmanned molten metal inspection system of claim 7, wherein said third robotic station actuator comprises a third robotic arm, a second motorized gripper mounted on and carried by the third robotic arm, a sampling machine, an analysis device, and a third vision device for identifying sample locations.

9. The unmanned molten metal inspection system of claim 8, wherein the station control unit of the third robot station comprises:

the polishing control module is used for acquiring a test instruction, controlling the third mechanical arm to drive the second gripper to a pneumatic sample conveying outlet of the pneumatic sample conveying device, and grabbing the sample to a sampling machine for polishing;

and the inspection control unit is used for controlling the third mechanical arm to drive the second gripper, and gripping the polished sample to the analysis device for inspection.

10. An unmanned inspection method for molten metal, comprising:

generating a sampling instruction, a sample sending instruction and a checking instruction according to a time sequence;

the first robot station executes a sampling instruction to sample molten metal;

the second robot station executes a sample sending command and sends the sample to a pneumatic sample sending inlet of the pneumatic sample sending device;

the third robot station executes a test instruction, picks up a sample from the outlet of the pneumatic sample conveying pipeline, polishes the sample and then performs test analysis;

and respectively obtaining the real-time feedback execution results of all the stations, and uniformly scheduling the first robot station, the second robot station and the third robot station according to the execution results.

Technical Field

The invention belongs to the technical field of smelting unmanned inspection, and particularly relates to an unmanned inspection system and method for molten metal.

Background

In the smelting process, the detection of the components of molten iron and molten steel is important for controlling the quality of a smelted finished product, such as the sampling detection of molten iron in a blast furnace casting yard, the sampling detection of molten steel in a converter, the sampling detection of molten steel in an electric furnace, the sampling detection of molten steel in a refining furnace, the sampling of a continuous casting tundish and the like. The general process flow of the molten metal sampling and detection in the smelting process comprises the following steps: inserting a sampler into the molten liquid to obtain a sample, cooling the sample, separating the sample from the sampler, conveying the sample to a pneumatic sample conveying device, conveying the sample to a sample inspection chamber through a pipeline by the pneumatic sample conveying device, processing the sample by a sample preparation device, carrying out component analysis on the processed sample by an analysis device, uploading a component analysis result to a production system, and guiding ingredient addition.

Because the sampling and detecting operation of molten metal faces severe environment factors such as high temperature, high splashing, high dust and the like, manual operation has higher danger and instability, and at present, partial links replace the manual operation by using robots or other automatic equipment, such as temperature measuring sampling robots, automatic separating devices, pneumatic sample conveying systems and inspection robots, but relevant systems and methods are still relatively deficient aiming at the unmanned operation of the whole sampling and detecting process, and complete unmanned operation is not realized.

Disclosure of Invention

In view of the above-mentioned shortcomings of the prior art, it is an object of the present invention to provide an unmanned inspection system and method for molten metal to realize the unmanned operation of the sampling and detecting process of molten metal.

To achieve the above and other related objects, the present invention provides an unmanned inspection system for molten metal, comprising:

the central control unit is used for generating a control instruction according to a time sequence, wherein the control instruction comprises a sampling instruction, a sample sending instruction and a checking instruction;

a robot station, comprising:

a first robot station for executing the sampling instruction;

the second robot station is used for executing the sample sending instruction;

a third robot station for executing the inspection instructions;

the first robot station, the second robot station and the third robot station are mutually independent and execute control instructions according to time sequence; and the central control unit carries out unified scheduling on each robot station according to the execution result fed back by each robot station in real time.

Further, each of the robot stations includes:

the station control unit is used for controlling the station of the robot to work according to the control instruction;

and a plurality of executing devices are arranged in each robot station and are used for cooperatively executing the control instruction received by the corresponding station control unit.

Further, the executing device in the first robot station comprises a first mechanical arm, a measuring gun device, an automatic sample separating device, a sampler, a storage rack and a first vision device for generating position information of a sampling point; the measuring gun device is fixed at the tail end of the first mechanical arm and driven by the first mechanical arm, and the sampler is placed on the storage rack.

Further, a station control unit in the first robot station includes:

the butt joint control module is used for controlling the first mechanical arm to act after acquiring a sampling instruction, so that a gun measuring device at the tail end of the first mechanical arm is in butt joint with the sampler;

the sampling control module is used for controlling the first mechanical arm to act according to the position information of the sampling point so that the sampler samples at the corresponding sampling point;

and the sample separation control module controls the first mechanical arm to move to the sample automatic separation device, and controls the sample automatic separation device to separate the solidified sample from the sampler.

Further, the first ocular device comprises:

the furnace mouth state judging module is used for judging whether the furnace mouth is in an opening state or not according to the furnace mouth information, and if the furnace mouth is in the opening state, furnace mouth state information is generated;

and the sampling point position judging module is used for judging the position distance between the furnace mouth and the molten liquid level according to the molten liquid level information and the furnace mouth state information, generating a judging result and then generating sampling point position information according to the judging result.

Further, the executing device of the second robot station comprises a moving trolley, a second mechanical arm, a first electric gripper and a second vision device, wherein the second vision device is used for identifying the sample grabbing position, the second mechanical arm is loaded on the moving trolley, and the second electric gripper is installed on the second mechanical arm and driven by the second mechanical arm to grab the sample.

Further, the station control unit of the second robot station includes:

the sample grabbing control module is used for acquiring a sample sending instruction, controlling the movable trolley to move to the side of the sample automatic separation device according to the sample sending instruction, and grabbing the separated sample by the first electric gripper;

and the sample transfer control module is used for controlling the movable trolley to move to the pneumatic sample conveying device after acquiring the sample grabbing completion information, and then controlling the first electric gripper to place the sample to a pneumatic sample conveying inlet of the pneumatic sample conveying device so that the pneumatic sample conveying device conveys the sample.

Further, the execution device of the third robot station comprises a third mechanical arm, a second electric gripper, a sampling machine, an analysis device and a third vision device for identifying the sample position, wherein the second electric gripper is mounted on the third mechanical arm and driven by the third mechanical arm.

Further, the station control unit of the third robot station includes:

the polishing control module is used for acquiring a test instruction, controlling the third mechanical arm to drive the second gripper to a pneumatic sample conveying outlet of the pneumatic sample conveying device, and grabbing the sample to a sampling machine for polishing;

and the inspection control unit is used for controlling the third mechanical arm to drive the second gripper, and gripping the polished sample to the analysis device for inspection.

To achieve the above and other related objects, the present invention provides an unmanned inspection method for molten metal, comprising:

generating a sampling instruction, a sample sending instruction and a checking instruction according to a time sequence;

the first robot station executes a sampling instruction to sample molten metal;

the second robot station executes a sample sending command and sends the sample to a pneumatic sample sending inlet of the pneumatic sample sending device;

the third robot station executes a test instruction, picks up a sample from the outlet of the pneumatic sample conveying pipeline, polishes the sample and then performs test analysis;

and respectively obtaining the real-time feedback execution results of all the stations, and uniformly scheduling the first robot station, the second robot station and the third robot station according to the execution results.

As described above, the unmanned inspection system and method for molten metal according to the present invention have the following advantages:

due to the arrangement of the central control unit, the first robot station, the second robot station and the third robot station, automation and unmanned inspection processes of sampling, sample sending and inspection of molten metal are realized. Compared with local automation and unmanned operation, the automatic control system can effectively reduce the operation safety of workers and improve the operation efficiency.

Drawings

FIG. 1 is a flow chart of a method for unmanned inspection of molten metal in an embodiment of the present invention.

FIG. 2 is a partial flow chart of a method for unmanned inspection of molten metal in an embodiment of the present invention.

FIG. 3 is a partial flow chart of a method for unmanned inspection of molten metal in an embodiment of the present invention.

FIG. 4 is a partial flow chart of a method for unmanned inspection of molten metal in an embodiment of the present invention.

Detailed Description

The following description of the embodiments of the present invention is provided for illustrative purposes, and other advantages and effects of the present invention will become apparent to those skilled in the art from the present disclosure.

Examples

Because the sampling and detecting operation of molten metal faces severe environment factors such as high temperature, high splashing, high dust and the like, manual operation has higher danger and instability, and at present, partial links replace the manual operation by using robots or other automatic equipment, such as temperature measuring sampling robots, automatic separating devices, pneumatic sample conveying systems and inspection robots, but relevant systems and methods are still relatively deficient aiming at the unmanned operation of the whole sampling and detecting process, and complete unmanned operation is not realized.

In order to solve the above problem, the present embodiment provides an unmanned inspection system for molten metal, including: the system comprises a plurality of robot stations and a central control unit, wherein the robot stations are mutually independent and execute control instructions according to time sequence; the central control unit is respectively communicated with the robot stations and carries out unified scheduling on the robot stations through the execution results fed back by the robot stations in real time. The central control unit is also used for generating control instructions according to time sequence, the control instructions comprise sampling instructions, sample sending instructions and inspection instructions, and then the control instructions respectively control the corresponding robot stations to execute the corresponding control instructions.

The robot station includes:

first, first robot station

And the first robot station is used for executing a sampling instruction and sampling the molten metal. The first robotic site includes: the system comprises a first mechanical arm, a measuring gun device, an automatic sample separating device, a sampler, a storage rack, a station control unit and a first vision device for generating sampling point position information; the measuring gun device is fixed at the tail end of the first mechanical arm and is driven by the first mechanical arm; the sampler is placed on a storage rack.

The first ocular device comprises:

and the image acquisition module is used for acquiring furnace mouth information and molten liquid level information, namely acquiring furnace mouth images and molten liquid level images.

And the furnace mouth state judging module is used for judging whether the furnace mouth is in an open state or not according to the furnace mouth information, and if the furnace mouth is in the open state, the furnace mouth state information is generated. The state of the furnace mouth is judged so as to judge whether the sampler can enter the furnace for sampling.

And the sampling point position judging module is used for judging the position distance between the furnace mouth and the molten liquid level according to the molten liquid level information and the furnace mouth state information, generating a judging result and then generating sampling point position information according to the judging result. When the sampler is used for sampling, the sampler needs to be inserted below the liquid level of the molten metal, and the distance between the liquid level of the molten metal and the furnace mouth is judged so as to control the sampler to reach the position corresponding to the sampling point.

The station control unit of the first robot station includes:

the butt joint control module is used for controlling the first mechanical arm to act after acquiring a sampling instruction, so that a gun measuring device at the tail end of the first mechanical arm is in butt joint with the sampler;

the sampling control module is used for controlling the first mechanical arm to act according to the position information of the sampling point so that the sampler samples at the corresponding sampling point;

and the sample separation control module controls the first mechanical arm to move to the sample automatic separation device, and the sample automatic separation device separates the solidified sample from the sampler.

According to the scheme, the butt joint control module, the sampling control module and the sample separation control module can be sequentially connected in a data mode, after the butt joint control module executes corresponding instructions, execution results are sent to the sampling control module, so that the sampling control module executes the corresponding instructions, after the sampling control module executes the corresponding instructions, the execution results are generated, the sample separation control module is controlled to work, and the butt joint control module, the sampling control module and the sample separation control module sequentially execute the corresponding instructions. In the scheme, the butt joint control module, the sampling control module and the sample separation control module can be respectively in data connection with the central control unit and are controlled in a unified mode through the central control unit.

Second and second robot stations

The second robot station comprises a second mechanical arm, a transfer trolley, a first electric gripper, an obstacle avoidance device, a station control unit and a second vision device for identifying the position of a sample, the second mechanical arm is arranged on the transfer trolley, the first electric gripper is arranged on the second mechanical arm and driven by the second mechanical arm to grip the sample, and the sample separated from the sampler is gripped and sent to the inlet of the pneumatic sample sending pipeline; the trolley is arranged to move so as to realize the movement of the second mechanical arm and avoid the influence of the second mechanical arm on the grabbing of the sample due to the self-driven range. In this embodiment, the second mechanical arm is a light-load cooperative robot, the moving trolley is an Automatic Guided Vehicle (AGV), the obstacle avoidance device is a laser radar, and the obstacle avoidance device is arranged on the moving trolley.

The station control module of the second robot station includes:

the sample grabbing control module is used for acquiring a sample sending instruction, controlling the movable trolley to move to the side of the sample automatic separation device according to the sample sending instruction, and grabbing the separated sample by the first electric gripper;

and the sample transfer control module is used for controlling the movable trolley to move to the pneumatic sample conveying device after acquiring the sample grabbing completion information, and then controlling the first electric gripper to place the sample to a pneumatic sample conveying inlet of the pneumatic sample conveying device so that the pneumatic sample conveying device conveys the sample.

In the scheme, the sample grabbing control module and the sample transferring control module can be sequentially connected in data, and an execution result is generated after the sample grabbing control module executes a corresponding instruction, so that the sample transferring control module acts after acquiring the execution result; in the scheme, the sample grabbing control module and the sample transferring control module can be respectively in data connection with the central control unit, and the central control unit controls the sample grabbing control module and the sample transferring control module to work in sequence.

The second ocular device comprises:

and the image acquisition module is used for acquiring the sample placement information, wherein the sample placement information is an acquired image for placing the sample.

And the sample position judging module is used for judging the position of the sample according to the sample placement information so that the first electric gripper can accurately grip the sample.

Third and third robot stations

The third robot station comprises a station control unit, a third mechanical arm, a second electric gripper, a sampling machine, an analysis device and a third vision device for identifying the position of the sample, wherein the third mechanical arm is used for grabbing the sample from a pneumatic sample conveying pipeline to the sampling machine for polishing, grabbing the polished sample and placing the sample in the analysis device to generate inspection data. The sample is polished by a sampling machine and then is tested, so that the test result is prevented from being influenced by the oxidation of the surface of the sample or other attachments.

The station control unit of the third robot station includes:

the polishing control module is used for acquiring a test instruction, controlling the third mechanical arm to drive the second gripper to a pneumatic sample conveying outlet of the pneumatic sample conveying device, and grabbing the sample to a sampling machine for polishing;

and the inspection control unit is used for controlling the third mechanical arm to drive the second gripper, and gripping the polished sample to the analysis device for inspection.

The third ocular device comprises:

and the image acquisition module is used for acquiring the sample placement information, wherein the sample placement information is an acquired image for placing the sample.

And the sample position judging module is used for judging the position of the sample according to the sample placement information so that the second electric gripper can accurately grip the sample.

In this embodiment, the image recognition modules in the first, second and third vision devices all include binocular cameras, and image acquisition is performed through the cameras, and images acquired by the binocular cameras are recognized through the existing image recognition technology. The image recognition technology can be an image recognition technology of a neural network, an image recognition technology of nonlinear dimension reduction and the like.

In specific implementation, the first robot station, the second robot station and the third robot station respectively execute corresponding control instructions, and the central control unit performs centralized control to realize unmanned operation of the whole inspection process. The central control unit and the station control unit in this embodiment may be disposed in the same controller, or may be disposed in different controllers.

As shown in fig. 1 to 4, in order to solve the above problem, the present embodiment further provides an unmanned inspection method for molten metal, including:

and S1, generating a sampling command, a sample sending command and a checking command according to time sequence.

The central control unit generates a sampling instruction, a sample sending instruction and a checking instruction according to a time sequence, receives an execution result fed back by the robot station and carries out unified scheduling on the robot station.

S2, executing a sampling instruction by the first robot station, and sampling molten metal;

s201, a first mechanical arm drives a measuring gun device to take a sampler from a zero position to a probe storage rack;

s202, generating sampling point position information by the first vision device;

the first vision device generates the sampling point position information, and comprises:

acquiring in-place information of the first mechanical arm reaching a stop point; whether the first mechanical arm reaches the stop point or not can be judged through detection by the first vision device, the in-place detection sensor and the like.

Furnace mouth information is judged through a first vision device, whether a furnace mouth is opened or not is judged, and furnace mouth state information is generated;

when the furnace mouth is opened, the first vision device judges the molten liquid level information, calculates the distance between the sampling point position and the furnace mouth, and generates the sampling point position information.

S203, the first mechanical arm samples the molten metal from the corresponding sampling point according to the position information of the sampling point;

and S204, cooling and demolding the sample on an automatic separation device, and separating the sample from the sampler.

And S205, returning the first mechanical arm to the zero position.

S3, the second robot station executes a sample sending command, and sends the sample to a pneumatic sample sending inlet of a pneumatic sample sending device;

s301, moving the transfer trolley from the zero position to a stop point beside the sampling device; whether the transfer trolley is parked in place or not can be judged by image recognition after the second vision device shoots images of the parking positions, and the image recognition can also be realized by arranging a travel switch, an in-place detection sensor and the like.

S302, the second vision device acquires the position of the sample on the sampling and separating device; in this embodiment, the second vision device captures an image of the sampling and separating device, the image recognition technology is used to determine the specific position of the sample on the sampling and separating device, and the generated sample position information is sent to the transfer trolley.

S303, driving a first electric gripper to grip a sample from the sampling and separating device to a pneumatic sample feeding inlet by a second mechanical arm on the transfer trolley; the pneumatic sample conveying channel conveys the sample to the pneumatic sample conveying outlet, and the transfer trolley returns to the zero position.

S4, executing a test instruction by the third robot station, grabbing a sample from the outlet of the pneumatic sample conveying pipeline, polishing the sample, and performing test analysis;

s401, driving a second electric gripper to an outlet of the pneumatic sample conveying pipeline to grip a sample to a sampling machine from a zero position by a third mechanical arm;

s402, polishing the sample by the sampling machine, and removing the surface oxidation layer and the attachments so as to avoid the oxidation layer and the attachments from influencing the subsequent inspection result.

And S403, driving a second electric gripper to grab the polished sample to an analysis device by a third mechanical arm for inspection and analysis.

And S404, returning the third mechanical arm to the zero position.

Since the embodiment of the method portion corresponds to the embodiment of the system portion, for the embodiment of the method portion, reference is specifically made to the description of the embodiment of the system portion, and details are not repeated here.

The foregoing embodiments are merely illustrative of the principles and utilities of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or change the above-mentioned embodiments without departing from the spirit and scope of the present invention. Accordingly, it is intended that all equivalent modifications or changes which can be made by those skilled in the art without departing from the spirit and technical spirit of the present invention be covered by the claims of the present invention.