圆坯连铸结晶器温度、热流实测数据分析及检测系统的建立
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摘要
连铸结晶器被称作是连铸机的“心脏”。它承担着钢液初始凝固和形成具有一定坯壳厚度的连铸坯的任务，传热现象是其内部发生的重要物理现象之一。由于结晶器的工作状况非常恶劣，是一个很难深知的黑匣，且传热的效率及均匀性与铸坯的缺陷和漏钢事故直接相关。因此结晶器传热监控的研究从理论到实践上都存在一定困难。
本文分为实测数据分析、离线分析软件的开发和温度在线检测系统的建立三个部分。
实测数据分析：对在线检测的大量圆坯连铸结晶器的温度和热流数据进行了离线研究。讨论了一些主要的工艺参数如拉速、弯月面高度、进口水温、出口水温、冷却水流量、电磁搅拌(以下简称EMS)电流、EMS频率、振频、结晶器安装状态及水套水垢状况对热流的影响规律，为热流作为重要监测参数，应用于连铸生产提供依据，对监测结果提供技术指导。
离线分析软件部分：该软件主要从数据的时序值、波动值、平均值三个方面来分析各工艺参数对结晶器内传热的影响及结晶器内的热流分布规律。分别介绍了软件的功能、设计和应用。
温度在线检测系统：在组态王软件基础上利用C语言进行二次开发，采用PCL818L-A／D板和PCLD-789D调理放大板和工控机等硬件，建立温度实时检测系统。该部分主要介绍了系统的硬件构成、软件设计及系统的温度检测实验。检测实验证明该系统在实验室可完成温度数据实时采集显示、存储等功能，为开发在生产现场使用的相应实用系统准备条件。
The mold have the name of "the heart of continuous caster", which takes up tasks of the beginning solidification of liquid steel and forming billet with some thickness, and heat transfer is one of the most important phenomenon happening in mold. The mold is working in hard condition, and the efficiency and uniformity of heat transfer is the most important for billet qualities and breakout. So investigation of the mold heat transfer monitoring has certain difficulty.
The paper has three main parts: data analysis, the off-line analysis software developed and temperature on-line measuring system built.
Data analysis: A great number of data of mold temperature and heat flux on-line measuring in continuous casting round billet has been off-line analyzed. The effect of some main parameters such as cast speed, meniscus height, import water temperature, export water temperature, cooling water flow, electromagnetic stirring (EMS) current, EMS frequency, mold oscillation frequency, the device status and boiler scale of mold on mold heat flux are discussed. It is the base for mold heat flux to be one of on-line monitoring parameters and provides monitoring result with technical director.
Off-line analysis software: This part analyzes the effect of all technical parameters on mold heat transfer and profile of heat flow from time sequence value, average value, fluctuation value. It introduces distinguishingly function, design, and applying of the software.
Temperature on-line measuring system: Based on the software KINGVIEW developed secondly by C programming language, temperature on-line measuring system is established, adopting PCL-818L A/D board, PCLD-789D amplifier board and industry computer. This part introduces mainly hardware composition, software design and measuring temperature experiment of system. It has been tested that the system can accomplish temperature real-time acquisition, display and save in laboratory, and enable corresponsive application system use in production site.
本文分为实测数据分析、离线分析软件的开发和温度在线检测系统的建立三个部分。
实测数据分析：对在线检测的大量圆坯连铸结晶器的温度和热流数据进行了离线研究。讨论了一些主要的工艺参数如拉速、弯月面高度、进口水温、出口水温、冷却水流量、电磁搅拌(以下简称EMS)电流、EMS频率、振频、结晶器安装状态及水套水垢状况对热流的影响规律，为热流作为重要监测参数，应用于连铸生产提供依据，对监测结果提供技术指导。
离线分析软件部分：该软件主要从数据的时序值、波动值、平均值三个方面来分析各工艺参数对结晶器内传热的影响及结晶器内的热流分布规律。分别介绍了软件的功能、设计和应用。
温度在线检测系统：在组态王软件基础上利用C语言进行二次开发，采用PCL818L-A／D板和PCLD-789D调理放大板和工控机等硬件，建立温度实时检测系统。该部分主要介绍了系统的硬件构成、软件设计及系统的温度检测实验。检测实验证明该系统在实验室可完成温度数据实时采集显示、存储等功能，为开发在生产现场使用的相应实用系统准备条件。
The mold have the name of "the heart of continuous caster", which takes up tasks of the beginning solidification of liquid steel and forming billet with some thickness, and heat transfer is one of the most important phenomenon happening in mold. The mold is working in hard condition, and the efficiency and uniformity of heat transfer is the most important for billet qualities and breakout. So investigation of the mold heat transfer monitoring has certain difficulty.
The paper has three main parts: data analysis, the off-line analysis software developed and temperature on-line measuring system built.
Data analysis: A great number of data of mold temperature and heat flux on-line measuring in continuous casting round billet has been off-line analyzed. The effect of some main parameters such as cast speed, meniscus height, import water temperature, export water temperature, cooling water flow, electromagnetic stirring (EMS) current, EMS frequency, mold oscillation frequency, the device status and boiler scale of mold on mold heat flux are discussed. It is the base for mold heat flux to be one of on-line monitoring parameters and provides monitoring result with technical director.
Off-line analysis software: This part analyzes the effect of all technical parameters on mold heat transfer and profile of heat flow from time sequence value, average value, fluctuation value. It introduces distinguishingly function, design, and applying of the software.
Temperature on-line measuring system: Based on the software KINGVIEW developed secondly by C programming language, temperature on-line measuring system is established, adopting PCL-818L A/D board, PCLD-789D amplifier board and industry computer. This part introduces mainly hardware composition, software design and measuring temperature experiment of system. It has been tested that the system can accomplish temperature real-time acquisition, display and save in laboratory, and enable corresponsive application system use in production site.
引文
1．M．Wolf，A．Stilli，连铸技术的最小发展，中国金属学会连续铸刚学会与首钢大学，1988
2．G．Holleis，连铸技术的十年回顾及十年展望，国外钢铁，1991，(2)，20—27
3．孙玮，我国连续铸钢技术的发展，钢铁，1987，22，(4)，60—66
4．杜波，硕士学位论文，连铸结晶器润滑与摩擦计算和实测数据分析，大连理工大学，2003
5．蔡开科，连续铸钢[M]，科学出版社，1991．
6．史寰兴．，实用连铸冶金技术[M]，冶金工业出版社，1998
7．李纯忠，雄毅刚编著，连铸设备[M]，东北大学出版社，1983
8．田乃媛主编，薄板坯连铸连轧[M]，冶金工业出版社，1998
9．蔡开科，程世富主编，连续铸钢原理与工艺[M]，冶金工业出版社，1994
10．蒲海清，依靠科技进步调整结构迎接中国钢铁工业新世界挑战，1999年中国钢铁年会论文集，1999，(34)，1-7
11．王晓齐，李忠娟，90年代以来若干关键共性技术对中国钢铁工业发展的影响于思考(二)，世界金属学报，2003．5．27
12．李世俊，中国的钢材市场与企业的市场定位，1999年中国钢铁年会论文集，1999，(34)，14-22
13．曹广畴，现代板坯连铸，冶金工业出版社，1994
14．蔡开科，铸坯质量(第一讲)凝固过程特点，连铸，1994，(1)，37-39
15．孙晓燕，小方坯连铸机拉速自动调节及二冷却水系统的优化，东北大学，2002
16. Rving W.R. On Line Quality Control for Continuously Cast Semis[J]. Ironmaking and Steelmaking, 1990, 17(3): 197-202
17. I.V.Samarasekera, S, Chandra, A.Z.Campbell, J.K.Brimacombe, Mould Shape, Heat Transfer and Mould-strand Interaction in the Continuous Casting of Steel Billets, Proc.Conf.on 'Continuous Casting of Steel in Developing Countries', Beijing, 1993, 189-199.
18．M．R．Ozgu，最新连铸检测仪表概述(一)，国外钢铁，1997，(9)33-39．
19．B．Mali RY．Etc．，结晶器的长期发展，第一届欧洲连铸会议论文集，佛罗伦萨，1991，134—141，中国金属学会连续铸刚学会
20. A.Tsuneoka, W.Ohashi, S.Ishitobi, etal., Measurement and Control System of Solification in Continuous Casting Mould, 1985, ISS Steelmaking conf.Proc., 3-10.
21．孔金满等，连铸结晶器检测控制技术的新发展，鞍钢技术，1997，(11)，1-15
22．大连理工大学，“宝钢圆坯连铸机结晶器温度和热流值在线监测系统研究”研究报告，2001，1
23．Emling，W．H：检测和控制拉漏的结晶器仪表，Steelmaking，Conference Proceedings，1991，P197～217
24．山上淳：铁钢，1986，S144
25．姚曼，王志道，方大成等，连铸，2001，No．1
26．1970，No．9，p．78
27．S．G．Thomton attack等，板坯连铸结晶器传热监控的应用，国外钢铁，1991，(9)，33-41
28. Emling W.H, Daoson S. Mold Instrumentation for Breakout Detection and Control[A]. ISS 71st Steelmaking Conference Proceedings[C]. Ontario, 1991. 197-217
29．胡志刚．连祷结晶器内粘结漏钢的形成机理及对策．炼钢．1998，6：23～27
30．张平．连铸结晶器中保护渣渣膜传热的研究现状．钢铁研究学报．1995，7(4)：74～82
31. C.A.M.Pinheiro. Mould heat transfer and continuously cast billet quality with mould flux lubrication Part1 Mould heat transfer. Ironmaking and Steelmaking, 2000, 27(1): 37-54
32. R.B.MAHAPATRA. Mold Behavior and Its Influence on Quality in the Continuous Casting of Steel Slabs: Part Ⅱ Mold Heat Transfer, Mold Flux Behavior, Formation of Oscillation Marks, Longitudinal Off-Comer Depressions, and Subsurface Cracks, Metallurgical Transactions B, 1991, 22B(12): 875-888
33．许志强．连铸坯在结晶器中表面热流分布规律的研究．重型机械．1997，5：16～20
34. B.G.THOMAS. Modeling of Transient Flow Phenomena in Continuous Casting of Steel.Canadian Metallurgical Quarterly, 1998, 37(3-4): 197-212
35. Herbert Steinruck. Modeling of Continuous Casting Processes. Nonlinear Analysis Theory Methods & Applications, 1997, 30(8): 4915-4925
36. X.R.Zhu. Calculation of the Free Surface Shape in the Electromagnetic Processing of Liquid Metals. Appl. Math. Modelling, 1997, 21: 207-214
37. T.ARAKI. Optimization of Mold Oscillation for High Speed Casting-New Criteria for Mold Oscillation. Canadian Metallurgical Quarterly, 1999, 38(5): 295-300
38．M．C．M．Cornelissen．不稳定的结晶器、偶然的扰动导致局部的产品缺陷．第一届欧洲连铸会议译文集．意大利．佛罗伦萨．1991：127-134
39．雷作胜．连铸结晶器弯月面区温度波动的模拟研究．上海大学学报(自然科学版)2002，8(4)：317—320
40．颜慧成．连铸结晶器弯月面区域传热模拟。钢铁，1999，34(1)：20-23
41. Tsutomu Takamoto. Initial solidification analysis in the vicinityof meniscus in continuous casting mold.Transaction ISIJ, 1986, 26(S 132): S 132
42．于功利，井上健，安中弘行．钢水流动对连铸坯初期凝固的影响．钢铁，1998，33(4)：13-16
43．程素森，马祥，杨天钧．冷却水水垢对冷却壁冷却能力影响的传热分析．钢铁，2002(7)，Vol．37，No．7：16—19．
44．斐郭国，阎立勇，刘晖．连铸圆坯表面裂纹及产生原因分析．第六届连续铸钢全国学术会议论文集，1999，乌鲁木齐，149-151．
45．亚林，Visual Basic 6.0中文版(基础篇)，人民交通出版社出版发行，2000
46．吴目诚，吴秉柔，精彩Visual Basic 6．0程序设计，科学出版社，2002
47．Clemens Miller，连铸工厂及其机组的集中监控系统，冶金设备和技术，1993，32—42
48. Coronado, A, A Practice Approach to the Conversion of a PC Into an Engineering Workstation. Proceedings of the Industrial Computing Conference, ICS/94, pp. 207-222A
49. Giovanni de Micheli, R.K. Gupta, Hardware/Software co-design, Proceedings of IEEE 85(3), 1997, 349-365
50. R.Emst, Codesign of embedded systems: status and trends, IEEE Design and Test of Computers April-June, 1998, 45-54
51. Mikio SUZUKI, Shinobu MIYAHARA, etc. Effect of mold oscillation curves on heat transfer and lubrication behavior in mold at high speed continuous casting of steel slabs, ISIJ, 1992, 113-120
52．PCL818L用户手册，台湾，研华公司．
53．PCL789D用户手册，台湾，研华公司．
54．北京亚控科技发展有限公司，组太王6.0手册，2001
55．游伯坤，詹宝玙．《温度测量仪表．》．机械工业出版社，北京，1982．
56．《镍铬-镍硅热电偶丝及分度表》，中华人民共和国国家标准，GB2614—81
2．G．Holleis，连铸技术的十年回顾及十年展望，国外钢铁，1991，(2)，20—27
3．孙玮，我国连续铸钢技术的发展，钢铁，1987，22，(4)，60—66
4．杜波，硕士学位论文，连铸结晶器润滑与摩擦计算和实测数据分析，大连理工大学，2003
5．蔡开科，连续铸钢[M]，科学出版社，1991．
6．史寰兴．，实用连铸冶金技术[M]，冶金工业出版社，1998
7．李纯忠，雄毅刚编著，连铸设备[M]，东北大学出版社，1983
8．田乃媛主编，薄板坯连铸连轧[M]，冶金工业出版社，1998
9．蔡开科，程世富主编，连续铸钢原理与工艺[M]，冶金工业出版社，1994
10．蒲海清，依靠科技进步调整结构迎接中国钢铁工业新世界挑战，1999年中国钢铁年会论文集，1999，(34)，1-7
11．王晓齐，李忠娟，90年代以来若干关键共性技术对中国钢铁工业发展的影响于思考(二)，世界金属学报，2003．5．27
12．李世俊，中国的钢材市场与企业的市场定位，1999年中国钢铁年会论文集，1999，(34)，14-22
13．曹广畴，现代板坯连铸，冶金工业出版社，1994
14．蔡开科，铸坯质量(第一讲)凝固过程特点，连铸，1994，(1)，37-39
15．孙晓燕，小方坯连铸机拉速自动调节及二冷却水系统的优化，东北大学，2002
16. Rving W.R. On Line Quality Control for Continuously Cast Semis[J]. Ironmaking and Steelmaking, 1990, 17(3): 197-202
17. I.V.Samarasekera, S, Chandra, A.Z.Campbell, J.K.Brimacombe, Mould Shape, Heat Transfer and Mould-strand Interaction in the Continuous Casting of Steel Billets, Proc.Conf.on 'Continuous Casting of Steel in Developing Countries', Beijing, 1993, 189-199.
18．M．R．Ozgu，最新连铸检测仪表概述(一)，国外钢铁，1997，(9)33-39．
19．B．Mali RY．Etc．，结晶器的长期发展，第一届欧洲连铸会议论文集，佛罗伦萨，1991，134—141，中国金属学会连续铸刚学会
20. A.Tsuneoka, W.Ohashi, S.Ishitobi, etal., Measurement and Control System of Solification in Continuous Casting Mould, 1985, ISS Steelmaking conf.Proc., 3-10.
21．孔金满等，连铸结晶器检测控制技术的新发展，鞍钢技术，1997，(11)，1-15
22．大连理工大学，“宝钢圆坯连铸机结晶器温度和热流值在线监测系统研究”研究报告，2001，1
23．Emling，W．H：检测和控制拉漏的结晶器仪表，Steelmaking，Conference Proceedings，1991，P197～217
24．山上淳：铁钢，1986，S144
25．姚曼，王志道，方大成等，连铸，2001，No．1
26．1970，No．9，p．78
27．S．G．Thomton attack等，板坯连铸结晶器传热监控的应用，国外钢铁，1991，(9)，33-41
28. Emling W.H, Daoson S. Mold Instrumentation for Breakout Detection and Control[A]. ISS 71st Steelmaking Conference Proceedings[C]. Ontario, 1991. 197-217
29．胡志刚．连祷结晶器内粘结漏钢的形成机理及对策．炼钢．1998，6：23～27
30．张平．连铸结晶器中保护渣渣膜传热的研究现状．钢铁研究学报．1995，7(4)：74～82
31. C.A.M.Pinheiro. Mould heat transfer and continuously cast billet quality with mould flux lubrication Part1 Mould heat transfer. Ironmaking and Steelmaking, 2000, 27(1): 37-54
32. R.B.MAHAPATRA. Mold Behavior and Its Influence on Quality in the Continuous Casting of Steel Slabs: Part Ⅱ Mold Heat Transfer, Mold Flux Behavior, Formation of Oscillation Marks, Longitudinal Off-Comer Depressions, and Subsurface Cracks, Metallurgical Transactions B, 1991, 22B(12): 875-888
33．许志强．连铸坯在结晶器中表面热流分布规律的研究．重型机械．1997，5：16～20
34. B.G.THOMAS. Modeling of Transient Flow Phenomena in Continuous Casting of Steel.Canadian Metallurgical Quarterly, 1998, 37(3-4): 197-212
35. Herbert Steinruck. Modeling of Continuous Casting Processes. Nonlinear Analysis Theory Methods & Applications, 1997, 30(8): 4915-4925
36. X.R.Zhu. Calculation of the Free Surface Shape in the Electromagnetic Processing of Liquid Metals. Appl. Math. Modelling, 1997, 21: 207-214
37. T.ARAKI. Optimization of Mold Oscillation for High Speed Casting-New Criteria for Mold Oscillation. Canadian Metallurgical Quarterly, 1999, 38(5): 295-300
38．M．C．M．Cornelissen．不稳定的结晶器、偶然的扰动导致局部的产品缺陷．第一届欧洲连铸会议译文集．意大利．佛罗伦萨．1991：127-134
39．雷作胜．连铸结晶器弯月面区温度波动的模拟研究．上海大学学报(自然科学版)2002，8(4)：317—320
40．颜慧成．连铸结晶器弯月面区域传热模拟。钢铁，1999，34(1)：20-23
41. Tsutomu Takamoto. Initial solidification analysis in the vicinityof meniscus in continuous casting mold.Transaction ISIJ, 1986, 26(S 132): S 132
42．于功利，井上健，安中弘行．钢水流动对连铸坯初期凝固的影响．钢铁，1998，33(4)：13-16
43．程素森，马祥，杨天钧．冷却水水垢对冷却壁冷却能力影响的传热分析．钢铁，2002(7)，Vol．37，No．7：16—19．
44．斐郭国，阎立勇，刘晖．连铸圆坯表面裂纹及产生原因分析．第六届连续铸钢全国学术会议论文集，1999，乌鲁木齐，149-151．
45．亚林，Visual Basic 6.0中文版(基础篇)，人民交通出版社出版发行，2000
46．吴目诚，吴秉柔，精彩Visual Basic 6．0程序设计，科学出版社，2002
47．Clemens Miller，连铸工厂及其机组的集中监控系统，冶金设备和技术，1993，32—42
48. Coronado, A, A Practice Approach to the Conversion of a PC Into an Engineering Workstation. Proceedings of the Industrial Computing Conference, ICS/94, pp. 207-222A
49. Giovanni de Micheli, R.K. Gupta, Hardware/Software co-design, Proceedings of IEEE 85(3), 1997, 349-365
50. R.Emst, Codesign of embedded systems: status and trends, IEEE Design and Test of Computers April-June, 1998, 45-54
51. Mikio SUZUKI, Shinobu MIYAHARA, etc. Effect of mold oscillation curves on heat transfer and lubrication behavior in mold at high speed continuous casting of steel slabs, ISIJ, 1992, 113-120
52．PCL818L用户手册，台湾，研华公司．
53．PCL789D用户手册，台湾，研华公司．
54．北京亚控科技发展有限公司，组太王6.0手册，2001
55．游伯坤，詹宝玙．《温度测量仪表．》．机械工业出版社，北京，1982．
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