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基于机器视觉+AI的连铸坯低倍数智化检测平台

Digital platform for macrostructure inspection in continuously cast slabs based on machine vision and artificial intelligence

  • 摘要: 连铸坯低倍组织检测是评价铸坯内部质量和指导连铸工艺优化的重要环节.针对传统人工目视评级存在主观性强、效率低和数据追溯困难等问题,研发了一套基于机器视觉的连铸坯低倍智能检测平台.该平台集成低倍图像采集、缺陷智能分割、自动评级和数据管理等功能,以改进U-Net模型为核心,实现中心偏析等低倍缺陷的像素级识别,并基于缺陷面积、长度、宽度、等效直径和最大连通域占比等指标,将传统图谱式评级经验转化为可计算、可追溯的数字化评级规则,并形成了采集、识别、评级、追溯和反馈的闭环流程.目前,该平台已在山钢集团莱芜钢铁公司现场落地实施并稳定运行一周年,现场应用结果表明,图像数据可用率达99.9%,综合自动评级准确率达98%,具有良好的工程应用价值和推广前景.

     

    Abstract: Macrostructure inspection of continuously cast slabs is an important procedure for evaluating the internal quality of slabs and guiding the optimization of continuous casting processes. To address the problems of strong subjectivity, low efficiency, and difficulty in data traceability associated with traditional manual visual rating, this study developed a machine-vision-based intelligent inspection platform for slab macrostructures. The platform integrates macrostructure image acquisition, intelligent defect segmentation, automatic rating, and data management. With an improved U-Net model as the core, the platform enables pixel-level recognition of macrostructure defects such as centerline segregation. Based on quantitative indicators including defect area, length, width, equivalent diameter, and the area ratio of the largest connected component, traditional atlas-based rating experience is transformed into computable and traceable digital rating rules. The system establishes a closed-loop workflow covering image acquisition, defect recognition, automatic rating, data traceability, and process feedback. At present, the platform has been implemented at the industrial site of Laiwu Steel Corporation, Shandong Iron and Steel Group, and has achieved stable operation for one year. Field application results show that the usability rate of image data reaches 99.9%, and the overall automatic rating accuracy reaches 98%, demonstrating good engineering application value and promising potential for further promotion.

     

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