Tel：86-510-86281566
86-510-80620298
Fax：86-510-80629077

Case Study | Breaking Through the Monitoring Blind Spot of Ultra-High Temperatures: A Demonstrative Integration of the Steel Industry and Intelligent Sensing

2025-07-09

1. Project Background

A certain special steel enterprise is a major domestic production base for high-standard, high-performance specialty steels. Its ladle degassing refining process is the primary method of secondary metallurgy, which involves gas stirring to enhance mixing and promote chemical reactions, while Control of gas intensity It exerts a significant influence throughout the entire process; however, the industry currently lacks an appropriate real-time gas-flow-intensity monitoring solution. In actual operating conditions, the inside of the ladle typically maintains temperatures exceeding 1,500°C, and the molten steel remains in a “black-box” state, making it impossible to capture the evolution of the flow regime in real time. Relying solely on manual expertise for assessment results in substantial error rates and significant time lags. No quantitative basis This directly results in the inability to precisely control the quality of the molten steel.

2. Our Company’s Advantages

According to technical exchanges between the two parties, gas stirring within the steelmaking furnace generates internal vortices in the molten steel, which in turn causes ladle vibration. There is a certain correlation between the measured gas intensity and the magnitude of the vibration. Multiple trials have demonstrated that vibration signals are an effective means of characterizing gas intensity. Leveraging our company’s more than 40 years of technological expertise in the sensor field and extensive experience in data analysis, we have established a team led by Dr. Cheng. Technical Task Force , jointly explore with the client and build Ladle Degassing and Refining Process with Vibration Characteristics A related data model uses quantitative data to directly characterize gas intensity during the process.

This project achieves its objectives by integrating vibration acceleration sensors, signal acquisition units, industrial control units, and other equipment. Effective Online Monitoring of Gas Concentration Symmetrically installed vibration sensors, coupled with a signal acquisition and analysis module and an information early-warning display module, are used to analyze and extract characteristic values from the vibration signals. By employing a sliding-window approach, the differences in vibration amplitude and dispersion across various vibration sensors and measurement directions within each window period are analyzed to define the ladle response value (LRV) based on vibration signals. Establish a data model relating vibration magnitude to gas intensity. , describe the operational conditions for gas stirring during the refining process to avoid the common issues of insufficient or excessive stirring that often arise with conventional empirical stirring methods, Improve mixing efficiency 。

This application belongs to A Milestone-Defining Cross-Industry Innovation , reflecting the deep integration of technological innovation and industrial innovation, and also marking a shift from “experience-driven” to “ Data-driven the cognitive revolution. We not only provide hardware products with high sensitivity, high reliability, and high stability, but also develop dedicated software to meet users’ Data Cleaning and Data Modeling . Our company has already submitted multiple applications for the theoretical and product innovations resulting from this cross-industry collaboration. Invention Application 。

3. Solution

Product Name	Product Model
Stainless Steel Protective Enclosure
Vibration Signal Collector	XDG6275E
Three-axis accelerometer	XDG1283
Signal Acquisition and Display Software

4. Customer Reviews

Without disrupting production, technical personnel provided on-site support throughout the entire project, resulting in its successful acceptance. The project’s high-quality R&D and innovation capabilities, coupled with its status as an industry-first application, have not only earned rave reviews from the client but also widespread acclaim within the industry.

Our company will also continue to deepen our expertise in this field, driving the process industry from “black-box operations” toward “ Transparent Factory a historic leap.