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Overview: The BPS-K600 continuous casting mould breakout prediction system is developed by Wuhan CenterRise M&C Measuring Co., Ltd. It adopts artificial neural network and combines with traditional artificial intelligence and information processing technology to overcome the defects of traditional logic-based prediction models. It has the functions of self-adaptation, self-organization and real-time learning. The breakout prediction system has an optimized industrial network structure. According to the distribution and change rules of the temperature field of the mold, it can track and respond to the breakout process in real time. It can learn and judge by itself, and provide early warning information for on-site operations. It can effectively prevent the occurrence of breakout accidents, greatly reducing the cost and improving the safety factor of continuous casting. The system is suitable for all kinds of continuous casting machines such as square billet, round billet, rectangular billet and slab. Block Diagram of Breakout Prediction System The composition of the system Thermocouple: according to the on-site conditions of the mold, water tank, bolts and mold frame to desgin Front-end acquisition system: Multi-module acquisition chain, industrial Ethernet interface, high-speed embedded processing module Working platform: Real-time display of mold temperature field status, online analysis and prediction of mold breakout Server: Data exchange and storage management, reporting and printing system, with data analysis and self-learning functions The Main technical parameters Data sampling: the sampling frequency of K-type/T-type thermocouple can up to 10HZ Accuracy of temperature measurement: ±0.25℃ Support communication protocol: Industrial Ethernet (TCP/IP)，PROFIBUS-DP，CANopen Executive standard: DE0411 Standard Class III/1EC584/IEC1515 Transmission speed: 100M/bps The composition of the software Online monitoring software for breakout prediction Offline query software for breakout prediction Data recovery and self-learning software packages Data acquisition and monitoring software The software package of mold thermal status display The functions of the system Real-time data acquisition, data analysis and judgment Automatic selection of steel grade’s alarm parameters Real-time dynamic picture monitoring Prediction alarm and information display of breakout signs Automatic deceleration after alarm Historical data storage and historical trend graph display Automatic report generation and printing Alarm prediction and pattern recognition of unknown steel grades by neural network Dynamic real-time temperature profile prediction Mould heat flow field display FIG 1：Typical process of mold breakout prediction The features of the system 1. Reasonable design of temperature measurement point and professional protection front-end acquisition system, and complete installation and calibration tool components. 2. The system has strong adaptability and can meet the transformation of various structural continuous casting machines. 3. High-speed data communication, using industrial network to form an independent local area network for each workstation and server. It can realize high-speed data transmission of alarm files, alarm parameters, and other databases. 4. The combination of artificial neural network and intelligent forecasting model improves the alarm accuracy of breakout forecasting. 5. Historical data storage and historical trend graph display, historical reports, historical alarm legend printing, real-time alarm data printing. 6. Provide a local area network interface, which can realize the storage and forwarding of alarm files, and the input and output of offline alarm data. 7. Remote Web browsing can be achieved according to customer needs. 8. Can be seamlessly connected with MES-C220 mould expert system.

Overview The automatic control for the molten steel level of the mold is one of the key technologies of continuous casting production. It is very important to reduce the labor intensity of workers, improve production efficiency, improve the quality and output of casting billet, reduce overflow and breakout of steel and improve the 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, if the level will fluctuate too much, and slag will be involved, forming surface slag inclusion on the surface of the casting billet, affecting the quality of the billet. The test points out that the relationship between the level fluctuation and the depth of casting billet surface slag inclusion is as follows: The experience has shown that surface slag inclusions can be eliminated when the level fluctuation is within ±10mm. At the same time, if the level fluctuation is more than 10mm, the rate of longitudinal cracks on the casting billet surface is 30%. It means that the level fluctuation directly affects the surface quality of the casting billet. The principle of the system The eddy current type molten steel level gauge is the key to the system. The system 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 the level change of the mold and does not detect the mold flux or 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 tundish car or on the platform. The sensor is cooled by compressed air during use. The principle is shown in the figure A high-frequency exciting winding is installed above the molten steel surface of the mold. The high-frequency magnetic field generated by the high-frequency exciting winding induces eddy currents on the molten steel surface to form a magnetic field. The magnetic field generated by the induced eddy current is 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 the winding material and structure, steel grade, temperature remain unchanged, the coil impedance change only has a single-value function relationship with the height of the molten steel level. As long as the impedance change of the high-frequency winding is detected, the change of the molten steel level in the 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 is ① eddy 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 of ② mold 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 the ③ control computer to complete data processing and system control functions. We can also control the actuator manually and automatically through the ④on-site operation display control panel, and the opening of the stopper is controlled by the ⑤ actuator 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, the mold level 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. The level control is the main loop, and there is a proportional gain of the main loop controller. According to the self-adaptive correction of the mold width change and feedforward compensation of casting speed, so as to further reduce and eliminate liquid level fluctuations caused by mold width adjustment and casting speed 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 fluctuates lightly. And the system will choose a shorter intergrating time when molten steel level fluctuates greatly. 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 level gauge, an appropriate filtering link is added and the vibration frequency synchronous filter is used for filtering processing, which can overcome the interference of mold vibration frequency and amplitude variation.

Overview: LGK-S107 analog heat source instrument (heating tool) is independently developed and designed by Wuhan CenterRise M&C CO., Ltd. This instrument is a heating and testing equipment used to test the performance of the thermocouples installed in the mold in continuous casting machine. After the installation of the mold breakout prediction thermocouples completed, the analog heat source instrument is used to test these thermocouples before they go online. After the thermocouple is connected to the mold thermocouple detector, the current temperature of each thermocouple point will be displayed. By using our heating device to heat the copper plate point of each thermocouple at a fixed point, the thermocouple will have a synchronous temperature rise and then we can observe the temperature rise curve of the same column of temperature points to see whether the temperature measurement consistency of the column of thermocouples is consistent, so as to judge the overall status of thermocouples installed in the mold. If an abnormal point occurs, it needs to be repaired and replaced, so as to ensure the stable operation of the mold breakout prediction system. The working principle: The heating tool generates high heat by 220v alternating current and the electric heating element. The heat is transmitted to the copper plate of the mold through the copper head to simulate the heat source of molten steel, so that the thermocouples of the mold can sense the temperature change to achieve the purpose of calibrating the temperature measurement system. The composition: Walking trolley mechanism Preloader Pure copper heating contacts PID thermostat High power heating tube high power driver The parameters: Power supply: AC220V 50Hz Total power: 2200W Single point power: 300W Temperature control accuracy: 1°C Temperature control range: 0°C-500°C Common temperature range: 25°C-300°C Heating points: 3 (points can be customized) Heating method: heating tube heating Heating contact material: copper

Overview The infrared converter slag detection system uses a far-infrared thermal imager to monitor the situation of converter tapping in real time, and is connected to the main control computer in the electrical room through the conversion and transmission of video signals. The radiation intensity in the infrared wavelength range of 7-14um is different to distinguish molten steel and slag. In the later stage of the converter tapping, the molten steel gradually decreases, and the steelmaking slag is involved in the molten steel and flows out of the tapping hole. After the thermal imager recognizes the steelmaking slag in the imaging temperature measurement, it will give an alarm according to the slag content ratio threshold set by the software. The thermal imager will start the slide plate to close the tapping hole, so as to realize the control of the slag in the converter tapping, and ensure the maximum yield of molten steel and the minimum control of the steelmaking slag content. The effect of slag detection in converter tapping is of great significance to the control effect of the slag amount. The converter slag detection and control system developed by our company conducts non-contact monitoring of the tapping steel flow through the far-infrared detector thermal imager. It can detect the slag condition in real time and output an alarm signal and control system, which can replace manual visual inspection and provide accurate, efficient and stable slag detection effect. When the system finds the slag, the intelligent control unit quickly makes a judgment of lifting the furnace and blocking the slag and outputs an alarm signal. As shown in Figure 1, the system includes thermal imager, front purge protection box, front electrical box, power distribution cabinet, main control monitor, monitor of rocking furnace chamber, sound and light alarm, infrared converter slag monitoring software system, etc. The features of thermal imager 1. The temperature measurement range is 200°C ~ 2000°C, high temperature measurement accuracy, and multiple temperature measurement intervals can be set. 2. High-resolution thermal imaging system, the imaging picture is clear, and the imaging color can be freely marked according to the set temperature. 3. With hot zone alarm function, the alarm zone and temperature range can be set arbitrarily. 4. With hot zone tracking function 5. Equipped with special 7~14um infrared filter lens The technical parameters 1. Temperature measurement range: 200°C ~ 2000°C 2. Temperature measurement accuracy: 2% 3. Detection accuracy and alarm accuracy: ≥98% 4. Resolution: ≥ 0.5℃ 5. Pixels: 640x240PT 6. Band: 7~14um 7. Field of view: 7.5°×5.5° 8. Frame rate: ≥ 25 frames/sec 9. Equipment service life: ≥5 years 10. The normal operation rate of the automatic control system: ≥99%

Overview MAC-G320 automatic mold flux feeding system is a new generation product of automatic adding mold flux, which is independently developed by Wuhan CenterRise M&C Engineering Co., Ltd. According to different steel grades, casting speed, vibration and other process parameters, then the system can analyze and calculate the accurate mold flux addition amount through intelligent software. Then the system sends out signals to control the mold flux addition process and mold flux addition amount, and designs appropriate nozzles and propellers according to the fluidity of molten steel in the mold and the ductility of mold flux. After the system setting is completed, there is no manual intervention is required. It completely replaces the whole process of manual addition of mold flux, and realizes the automation of mold flux addition. The features of the system 1. The system automatically controls the amount, process and time of adding mold flux according to the process requirements of automatic mold flux addition, so as to maintain the physical state of the mold flux and prevent it from being broken. 2. The user can match different parameters according to actual needs, so as to change the length of the mold flux feeding time and the amount of mold flux, which can suit for the use of different segments and different casting speeds. 3. The casting speed signal is used and the amount of adding mold flux can be automatically adjusted according to the casting speed. The mold flux can be added timely and evenly, which can improve the quality of the billet and reduce labor intensity. 4. The time is controlled by PLC, no manual intervention is required. The adjustment is very convenient. It has manual, automatic, local and remote control modes. 5. The system has reliable performance and simple structure, and can be adapted to powder and granular mold flux. 6. It has a special anti-blocking nozzle and backflushing design to overcome the phenomenon of pipeline blockage. 7. Strong operability, simple and convenient maintenance, and low maintenance cost. 8. It can maintain the even distribution of the flux layer in the mold. The composition of the system The system consists of feeding trolley, feeding bucket, swing arm and feeder motor, swing arm transmission device, PLC and control equipment. 1. The feeding trolley is the support and walking equipment of the mold flux feeder. The basic equipment of the adding mold flux machine is installed on the feeding trolley. At the same time, the trolley can easily make the mold flux feeder walk to the working position or the parking position. 2. The feeding bucket is a device for holding mold flux. The mold flux is pre-filled in the feeding bucket and is evenly output through the feeder. The feeding bucket is provided with alarm contact of mold flux level limit.. 3. The swing arm and the feeder motor form a feeding and conveying device. The mold flux is evenly transmitted to the feed opening at the front end of the swing arm through the screw distributing device controlled by the motor. Then the mold flux can be used for mold distribution. 4. PLC and control equipment adjust and control the mold flux feeding speed, operation mode and control mode of the mold flux feeding machine, and realize various control modes and rates. 5. The swing arm transmission device controls the reciprocating motion of the swing arm according to the size of different molds, so that the mold flux is evenly distributed in the mold. The technical parameter Mold width: 500-2000mm Mold thickness: 100-500mm Type: screw conveying type mold flux feeding machine Heating method: stirring electric heating Arrangement location: on the pouring platform (with its own wheels to move) Adding capacity: 0.5～7.5L/min, continuously adjustable feeding tube Molding flux storage tank: 300 L, with material level detection and alarm Control mode: local/remote control, automatic /manual mode Molding flux type: granular flux or powder flux flux adding method: spiral swing adding flux Casting speed interlock: yes Mould size setting: yes Signal transmission: DP/Industrial Ethernet

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Overview In order to ensure the quality of the slab, it is necessary to strictly control the performance and various parameters of the CCM’s guide roll within a certain error range. Due to the continuous casting machine (CCM) is large and in a harsh production environment, it is difficult to measure the performance of the continuous casting machine manually, and many parameters are difficult to measure. Therefore, it is very important to have a set of equipment that can simulate drawing of steel billet to realize the measurement of CCM’s various parameters and performance. The multifunctional strand condition monitor uses various sensors to realize the measurement of CCM’s roll gap value, the arc value of continuous casting section, the rotation quality of the rolls, and the water spray pressure under the condition of simulating drawing of steel billet. Therefore, the CCM’s quality can be controlled in real time, and it is convenient for the maintenance personnel to analyze the CCM’s measurement results. The problem areas of the casting machine equipment can also be found. If these problems doesn’t be found in time, it will cause the bad quality of CCM’s products, the steel breakout in pouring process, surface and internal cracks and centerline deviation. The measurement of the strand condition monitor Roll gap value： By measuring the distance between a series of inner arc guide rolls and outer arc guide rolls on the CCM’s roller bed. It can be used to set the correct roll gap spacing for each pair of guide rolls in the slab caster. Arc condition of guide roller ： Measuring the position between the position of the CCM’s outer arc guide roll and the two adjacent guide rolls and then measuring the deviation compared with the origical position of CCM’s guide roll, we can obtain the arc condition of the outer arc guided roller. Guided roller rotation： It is possible to know whether each guided roller can rotate freely by measuring. Water spray pressure： The operation of the water spray cooling system can be judged by measuring the situation of secondary cooling water spray at different positions of CCM's width direction. Then we can accurately locate whether the water spray at a certain point is normal. The main components of the strand condition monitor 1. The main body of the strand condition monitor used to measure the continuous casting sector 2. The connecting chain between strand condition monitor and dummy bar 3. The storage rack chain of strand condition monitor 4. Battery charger: 24V 5A 5. Calibration equipment 6. Remote control 7. Laptop 8. Printer 9. Data communication cable The technical parameter 1. The measurement range of roll gap: 210mm, 230mm (can be customized according to requirements) 2. The measurement accuracy of roll gap: 0.01mm 3. The arc measurement range: ±80° 4. The arc measurement accuracy: 0.01° 5. The spray measurement range: 0-10 6. The spray measurement accuracy: ±1 7. The battery usage times: 3 times

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