Enhancing Steel Melting Shop Operations by Object Detection Using Template Matching Algorithm

Ladle monitoring systems are essential for optimizing steel melting operations. They improve material and equipment flow, reduce wait times, increase overall production, enable quick problem response, and ensure steel quality. Traditional ladle tracking methods utilizing sensors require a wide frequency band for data transmission. However, sensor technology has limitations such as high cost, limited range, signal interference, poor integration, wear, and tear. Thus, an additional layer of security is needed. To address these issues, a proposed solution suggests implementing a machine vision system for ladle tracking and management in steel factories. This vision-based system uses a live video captured by a camera as input to detect the ladle. The template matching algorithm is employed to compare the ladle template with the image’s covered window, allowing the system to identify the ladle’s ID and the zone where it is located. Various techniques for template matching are compared, and the most suitable one for the application is selected based on the results. The matched templates are stored in a database using Python SQLite3. The ladle tracking positions can be accessed through a web application, which also provides the capability to track individual ladles. The results demonstrate that implementing a vision-based tracking system for ladles in steel factories offers optimal outcomes with minimal hardware expenses.