Abstract
A new system to predict and prevent sticking type breakout in slab continuous casting is presented. It uses novel logic judgment model for sticker prediction. The elaborate model has four important characteristics: (1) arranging more rows of thermocouples in high density; (2) using temperature change rate and the time lag of abnormal changes for neighbouring thermocouple temperatures; (3) abandoning frequently used temperature inversion; and (4) vertical detection and horizontal detection to accurately recognise sticker propagation. The results of example simulations and field application indicate that the present model can detect sticking type breakout completely and in time keep false alarm ratios to a minimum and so achieve better performance for breakout prediction and prevention. Also, the mould breakout prevention system (MBPS) uses online thermal map of the mould for process visualisation and assisting breakout prediction. A novel method called ‘contour region filling method’ is proposed for drawing the colour maps, which includes discrete data gridding, contour line generation and contour polygon filling. Simulation experiments demonstrate that the method is feasible and effective for drawing online thermal maps. Meanwhile, field application results indicate that the present thermal map could well reflect the characteristics of temperature field of mould in normal and abnormal conditions, and is satisfactory for the process of practical operation.
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