Project Background

The environment in the blast furnace area of the steel plant is extremely harsh, with multiple hazardous factors such as high temperature, loud noise, and accumulation of toxic and harmful gases, posing a threat to the safety of on-site workers. The traditional manual inspection method is inefficient, and inspection personnel find it difficult to comprehensively and accurately grasp the real-time situation of the blast furnace area, let alone respond to various abnormal situations in a timely manner. Not only does it increase the likelihood of accidents, but it also leads to an increase in operating costs for the enterprise. To address the above challenges, Zhiyi Era has launched a blast furnace tuyere inspection robot, which uses a laser systemSLAMNavigation technology, equipped with wheel autonomous movement and precise positioning capabilities, can perform automated inspection tasks on key parts such as blast furnace blow pipes and tuyere devices along preset paths,Significantly improve the safety and stability of blast furnace operation，It also provides key technical support for steel enterprises to achieve intelligent transformation.

construction objectives

1.Realize the blast furnace tuyere area2424-hour uninterrupted automated inspection, comprehensively improving inspection efficiency and data accuracy, timely identifying safety hazards and achieving rapid response, ensuring continuous and stable production operation;

2.Promote the unmanned operation of the blast furnace area/Reduced manpower intelligent operation and maintenance significantly reduces manual labor intensity and safety risks, freeing production and management personnel from repetitive, low value operations and shifting them towards more strategic functions such as analysis, decision-making, and optimization management;

3.By relying on real-time and multi-source data collection and intelligent analysis and diagnosis systems, early warning and predictive maintenance of equipment status can be achieved, minimizing economic losses caused by unplanned downtime and sudden failures, and extending the service life of equipment;

4.Build a real-time monitoring and intelligent decision support system based on cloud platform, achieve seamless integration and multi terminal collaboration of inspection data, provide comprehensive digital support for enterprise production control, operation and maintenance management, and security protection, and assist steel enterprises in intelligent transformation and upgrading.

System Composition

⭐ robot body

Robots integrate diverse sensing, intelligent navigation, and data processing capabilities with a highly integrated architecture to adapt to complex working conditions in blast furnaces. Equipped with infrared thermal imaging device, high-definition camera gimbal, and multiple types of gases/Noise sensors can comprehensively collect key data such as temperature, images, gas concentration, and noise; Relying on laser technologySLAMIntegrated with visual navigation, it can achieve high-precision positioning and dynamic obstacle avoidance in narrow spaces, independently complete full area inspection of air vents, and ensure complete and accurate data.

Specific functions:

Autonomous navigation and precise positioning: using laser technologySLAMIntegrating visual navigation technology to achieve centimeter level path planning within the narrow space of the blast furnace tuyere platform.

Intelligent obstacle avoidance: equipped with multi-dimensional ultrasonic sensors combined with laser sensors to achieve multi angle obstacle inspection, realizing autonomous obstacle avoidance in complex steel structure environments.

Multi dimensional state perception: integrated infrared thermal imaging device (monitoring the temperature field distribution on the surface of the air outlet), high-definition visible light camera gimbal (capturing visible defects such as water seepage and cracks), gas sensor (detecting)COLeakage and other multi-source sensors.

Real time data analysis and early warning: temperature anomaly threshold judgment and image defect recognition (based on deep learning model) are realized through edge computing equipment, and the processing results are transmitted to the central control system in real time.

Autonomous charging and long-lasting endurance: The robot can automatically detect the battery level and return to the charging station to charge according to the set charging level, meeting the needs of all-weather inspection.

⭐ Charging unit

The robot body is equipped with a wireless charging receiver, which is compatible with the transmitting end of the charging station, and can achieve automatic charging in a safe area. At the same time, it also supports manual emergency charging operations. When the robot meets the charging conditions, it can autonomously return to the charging position for wireless charging without manual intervention. After the battery is fully charged, it will automatically continue to perform inspection tasks.

⭐ software platform

The blast furnace tuyere inspection robot system platform supports high concurrency data access and millisecond level response, ensuring stable operation in complex high-temperature and high-pressure environments of the blast furnace. Based on the accumulated inspection data and trend analysis, the system can also achieve life prediction and predictive maintenance of tuyere equipment, helping enterprises build a safer, more efficient, and intelligent blast furnace operation and maintenance system.

cockpit

As the core control interface, the cockpit integrates monitoring and operation functions, providing users with an intuitive one-stop inspection and management experience. By visualizing the layout, real-time display of equipment status, visible light and infrared dual light image streams, and dynamic presentation of robot inspection status and environmental data; Users can remotely control the robot's movements, adjust sensor parameters, and view the progress and details of intelligent inspection tasks on the console; At the same time, the alarm recording module captures real-time events such as device deviation and temperature anomalies, while the inspection result module structurally archives historical data and image materials, ensuring that the status of the blast furnace tuyere can be traced throughout the process and responding quickly to anomalies, significantly improving the level of intelligent inspection and safety management efficiency.

Monitoring task query

Providing convenient query function, management personnel can quickly query detailed information such as inspection time, task name, and task type for specific inspection tasks according to their needs, facilitating systematic sorting and management of inspection work.

Historical data of monitoring points

Centralized display of infrared temperature measurement data and related images from various inspection points. By comparing and analyzing historical data, the trend of temperature changes in blast furnace tuyere can be discovered, and potential temperature anomalies can be identified in a timely manner, providing scientific basis for preventive maintenance of equipment.

Cruise management

In the cruise management module, detailed display of inspection plans, inspection tasks, and inspection point data. Management personnel can customize and adjust the inspection plan, arrange inspection tasks reasonably, and set relevant parameters for each inspection point to ensure the efficient and accurate implementation of inspection work.

Factory management

Display the code and name of the factory area, and support adding and modifying operations to facilitate unified management of different factory areas and adapt to the dynamic changes of the enterprise factory area.

Environmental monitoring factors

Centralize the presentation of all monitoring factors of the inspection robot, allowing management personnel to clearly understand the various environmental parameters that the robot can monitor, which helps to comprehensively plan and manage monitoring work.

System Administration

The system management module covers multiple aspects such as common code, running parameters, organizational structure, application management, module management, module resources, user roles, system roles, etc., achieving comprehensive management and configuration of the entire system. Ensure the stable operation of the system.

Actual application scenarios

At the blast furnace tuyere platform of the steel plant, inspection robots conduct close range and multi frequency inspections of key equipment such as blast furnace blow pipes, tuyere sleeves, and intermediate sleeves along a preset cruising route. Real time monitoring of the temperature distribution on the surface of the air outlet through an infrared thermal imaging device, and timely detection of local overheating caused by abnormal cooling; Using high-definition visible light video streams to identify visible defects such as bleeding, nodules, cracks, etc; Continuous detection combined with gas sensorsCOWait for the concentration of harmful gases to prevent the risk of leakage. systemplatformSupport automatic alarm for abnormal situations and generate inspection reports, providing decision-making basis for operation and maintenance personnel, significantly improving the reliability and safety of blast furnace operation.

The blast furnace tuyere inspection robot system effectively solves the pain points of low efficiency, high risk and discontinuous data faced by traditional manual inspection by integrating advanced technologies such as intelligent perception, autonomous navigation, edge computing and cloud edge collaboration, and provides strong technical support for safe and stable operation of blast furnace. This system not only realizes the automation, digitization, and intelligence of the inspection process, but also lays a solid foundation for building a smart operation and maintenance system for steel enterprises. In the future, with the continuous development of artificial intelligence and industrial Internet of Things technology, Zhiyi Era will continue to deepen the capabilities of robots in fault prediction, intelligent diagnosis, collaborative operation, and other aspects, helping the steel industry to continuously move towards green, efficient, and safe intelligent manufacturing.