Aluminum alloy smelting process and smelting equipment

Abstract

The invention relates to the technical field of stirring control, and specifically discloses a smelting process of aluminum alloy and smelting equipment thereof, comprising raw material preparation, charging into a furnace, heating and dissolving, detecting alloy components, purification treatment, adjusting components, casting and forming, and cooling and solidification; and in the heating and dissolving process, the molten alloy material is continuously stirred, and at the same time, the aluminum liquid is monitored during the stirring process, so as to control the stirring speed and the stirring route, and the specific method is: estimating the stirring speed during the stirring process; during the stirring process, the aluminum liquid is monitored, so as to control the stirring speed and the stirring route; the invention can timely discover and respond to the change of the aluminum liquid state by real-time monitoring aluminum liquid data, and calculating the adjusted stirring speed and selecting the adjusted stirring route according to the data, so as to achieve the ideal temperature distribution uniformity in a shorter time and with lower energy consumption, thereby improving the stirring efficiency and ensuring the stability of the stirring process and the product quality.

Description

Technical Field

[0001] The invention relates to the technical field of stirring control, and in particular to a smelting process and smelting equipment of an aluminum alloy. Background Art

[0002] In the melting process of aluminum alloy, the dissolution of metal elements is a key process, which directly affects the performance and quality of the alloy. Through stirring, strong convection can be formed in the aluminum liquid, thereby accelerating the mixing and diffusion of metal elements, making it easier to dissolve in the aluminum liquid. After stirring, the solubility of metal elements in the aluminum liquid is higher and the composition of the alloy is more uniform.

[0003] Stirring helps to achieve uniformity of alloy composition and temperature, and is a very important part of the alloy production process, because it is directly related to whether the alloy composition can be accurately controlled, which in turn affects the quality of the alloy product. By stirring, the chemical composition and temperature distribution of the alloy liquid in the furnace can be ensured to be more uniform, thereby improving the overall quality and performance of the alloy.

[0004] However, during the aluminum alloy smelting process, the state of the aluminum liquid will change due to a variety of factors. The traditional stirring control method lacks real-time monitoring and adjustment mechanisms, and it is difficult to cope with these changes. It is impossible to obtain the adjusted stirring speed and select the adjusted stirring route through real-time monitoring of the aluminum liquid data, and it is impossible to detect and respond to changes in the state of the aluminum liquid in time. Summary of the invention

[0005] The purpose of the present invention is to provide a smelting process and smelting equipment of aluminum alloy to solve the technical problems in the above background.

[0006] The purpose of the present invention can be achieved by the following technical solutions:

[0007] In a first aspect, the present invention provides a smelting process of an aluminum alloy, comprising:

[0008] Raw material preparation, loading into the furnace, heating and dissolving, alloy composition detection, purification, composition adjustment, casting and molding, cooling and solidification;

[0009] During the heating and dissolving process, the molten alloy material is continuously stirred. At the same time, the aluminum liquid is monitored during the stirring process to control the stirring speed and stirring route. The specific method is as follows:

[0010] Step 1: Estimate the stirring speed during the stirring process;

[0011] Step 2: During the stirring process, the aluminum liquid is monitored to control the stirring speed and stirring route;

[0012] The specific scheme for controlling the stirring speed in step 2 is:

[0013] B1: Monitor the stirring process and obtain the aluminum liquid data within the target period;

[0014] B2: Calculate the adjusted stirring speed based on the aluminum liquid data and the estimated stirring speed;

[0015] B3: Control the stirring speed during the stirring process according to the adjusted stirring speed, and change the stirring speed to the adjusted stirring speed until the next cycle;

[0016] The specific scheme for controlling the mixing route in step 2 is as follows:

[0017] D1: mark the aluminum liquid sub-regions in the same vertical direction as sub-region groups;

[0018] D2: Obtain the sub-region group deviation value of each sub-region respectively;

[0019] D3: preset the mixing route, obtain the pre-mixing route, calculate the mixing route parameter value according to the pre-mixing route, mark the pre-mixing route with the largest mixing route parameter value as the adjusted mixing route, and change the mixing route to the adjusted mixing route until the next cycle.

[0020] As a further solution of the present invention: the specific method for estimating the stirring speed during the stirring process is:

[0021] A1: Based on the historical data of the stirring process in the aluminum alloy smelting process, and modeling based on the historical data;

[0022] A2: Based on the established model, the stirring speed is estimated to obtain an estimated stirring speed value, and the estimated stirring speed value is marked as JY.

[0023] As a further solution of the present invention: the aluminum liquid data includes: an aluminum liquid temperature difference characterization value and a temperature deviation value.

[0024] As a further solution of the present invention: the method for acquiring aluminum liquid data is:

[0025] C1: Divide the aluminum liquid evenly into multiple sub-areas;

[0026] C2: During the stirring process, obtain the temperature of the aluminum liquid area within the target cycle;

[0027] C3: According to the temperature of the aluminum liquid sub-area, the aluminum liquid temperature difference characterization value and the temperature deviation value are calculated and the aluminum liquid temperature difference characterization value is marked as WB and the temperature deviation value is marked as WP.

[0028] As a further solution of the present invention: the specific calculation method of the aluminum liquid temperature difference characterization value is:

[0029] The temperatures of all aluminum liquid sub-areas are averaged to obtain the average aluminum liquid temperature;

[0030] The aluminum liquid temperature difference characterization value is calculated through the formula: aluminum liquid temperature difference characterization value = aluminum liquid temperature average value - aluminum liquid preset temperature.

[0031] As a further solution of the present invention: the specific calculation method of the temperature deviation value is:

[0032] The difference between the temperature of all aluminum liquid sub-areas and the average temperature of the aluminum liquid is calculated to obtain the sub-area temperature deviation value, and the absolute values ​​of the temperature deviation values ​​of all aluminum liquid sub-areas are summed to obtain the temperature deviation value.

[0033] As a further solution of the present invention: the method for obtaining the sub-region group deviation value is:

[0034] Based on the same sub-region group, the temperature deviation value of all aluminum liquid sub-regions in the same sub-region group is calculated, and the absolute values ​​of the temperature deviation values ​​of all aluminum liquid sub-regions in the same sub-region group are summed to obtain the sub-region group deviation value.

[0035] As a further solution of the present invention: the specific method for calculating the stirring route parameter value according to the stirring pre-route is:

[0036] All sub-region groups that the mixing route passes through are obtained, and the sub-region group deviation values ​​of all the sub-region groups are summed up and calculated to obtain the mixing route parameter value.

[0037] In a second aspect, the present invention provides an aluminum alloy smelting device used in any of the aluminum alloy smelting processes described above, the smelting device adopts a smelting furnace provided with a stirring device, the stirring device is provided with a stirring control system for detecting stirring, and the system comprises:

[0038] A stirring speed estimation module, wherein the stirring speed estimation module is used to estimate the stirring speed during the stirring process;

[0039] A stirring control module, wherein the stirring control module is used to monitor the aluminum liquid during the stirring process, thereby controlling the stirring speed and stirring route;

[0040] The specific scheme for controlling the stirring speed in step 2 is:

[0041] B1: Monitor the stirring process and obtain the aluminum liquid data within the target period;

[0042] B2: Calculate the adjusted stirring speed based on the aluminum liquid data and the estimated stirring speed;

[0043] B3: Control the stirring speed during the stirring process according to the adjusted stirring speed, and change the stirring speed to the adjusted stirring speed until the next cycle;

[0044] The specific scheme for controlling the mixing route in step 2 is as follows:

[0045] D1: mark the aluminum liquid sub-regions in the same vertical direction as sub-region groups;

[0046] D2: Obtain the sub-region group deviation value of each sub-region respectively;

[0047] D3: preset the mixing route, obtain the pre-mixing route, calculate the mixing route parameter value according to the pre-mixing route, mark the pre-mixing route with the largest mixing route parameter value as the adjusted mixing route, and change the mixing route to the adjusted mixing route until the next cycle.

[0048] Beneficial effects of the present invention:

[0049] The present invention monitors aluminum liquid data in real time, calculates the adjusted stirring speed and selects the adjusted stirring route according to the data, can timely discover and respond to changes in the state of aluminum liquid, achieve ideal temperature distribution uniformity in a shorter time and with lower energy consumption, thereby improving stirring efficiency and ensuring the stability of the stirring process and product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] The present invention will be further described below in conjunction with the accompanying drawings.

[0051] Figure 1 is a flow chart of the method of the present invention;

[0052] Figure 2 is a flow chart of the method for controlling stirring speed in the present invention;

[0053] Figure 3 It is a flow chart of the method for controlling the stirring route in the present invention;

[0054] Figure 4 It is a schematic diagram of the system of the present invention. DETAILED DESCRIPTION

[0055] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0056] Embodiment 1:

[0057] See also Figure 1As shown, a smelting process of an aluminum alloy according to an embodiment of the present invention comprises the following steps:

[0058] Raw materials preparation:

[0059] Prepare the raw materials according to the required aluminum alloy composition;

[0060] Among them, the mass proportion of each element in the aluminum alloy raw material is: silicon is 0.23%, copper is 0.18%, magnesium is 0.21%, Fe is 0.60%, Mn is 0.78%, and aluminum is 98%;

[0061] Charging into the furnace:

[0062] Loading the prepared aluminum alloy raw materials into a melting furnace;

[0063] Heat to dissolve:

[0064] The smelting furnace is turned on for heating, and the aluminum alloy raw materials are heated to the melting point and dissolved into liquid. During this process, the molten alloy materials need to be stirred continuously to ensure that they are evenly mixed;

[0065] Detection of alloy composition:

[0066] Through testing and analysis instruments, the composition and properties of the molten aluminum alloy are tested to ensure that the alloy quality meets the requirements;

[0067] Purification treatment:

[0068] The molten alloy is purified by gas oxidation smelting, carburizing, nitriding, etc. to remove impurities and oxides;

[0069] Adjusting ingredients:

[0070] Add or subtract elements from the alloy as needed to control the composition and properties of the alloy. When the element composition is too high, dilute it by adding aluminum ingots, and when the element composition is too low, increase its content by adding low-content elements. Test once when the furnace is half loaded and once when the furnace is full.

[0071] Casting:

[0072] The smelted alloy liquid passes through a hydraulic deep well aluminum block casting mechanism to form the required aluminum alloy products (rectangular aluminum blocks, weighing about 5 to 10 tons per block);

[0073] Cooling and solidification:

[0074] The cast aluminum alloy product is cooled and solidified to obtain the final product;

[0075] What needs to be solved is: during the heating and dissolving process, the molten alloy material needs to be stirred continuously, and at the same time, the aluminum liquid needs to be monitored during the stirring process to control the stirring speed and stirring route;

[0076] The idea of ​​the embodiment of the present invention is that stirring helps dissolving metal elements. In the melting process of aluminum alloy, the dissolution of metal elements is a key process, which directly affects the performance and quality of the alloy. By stirring, strong convection can be formed in the aluminum liquid, thereby accelerating the mixing and diffusion of metal elements, making it easier to dissolve in the aluminum liquid. After stirring, the solubility of metal elements in the aluminum liquid is higher, and the composition of the alloy is more uniform.

[0077] Stirring helps to achieve uniformity of alloy composition and temperature, and is a very important part of the alloy production process, because it is directly related to whether the alloy composition can be accurately controlled, which in turn affects the quality of the alloy product. By stirring, the chemical composition and temperature distribution of the alloy liquid in the furnace can be ensured to be more uniform, thereby improving the overall quality and performance of the alloy.

[0078] Embodiment 2:

[0079] Different from the first embodiment, in the smelting process of an aluminum alloy described in the embodiment of the present invention, the mass ratio of each element in the aluminum alloy raw material is:

[0080] Silicon is 0.24%, copper is 0.19%, magnesium is 0.19%, Fe is 0.55%, Mn is 0.73%, and aluminum is 98.1%.

[0081] Embodiment three:

[0082] Different from the first embodiment, in the smelting process of an aluminum alloy described in the embodiment of the present invention, the mass ratio of each element in the aluminum alloy raw material is:

[0083] Silicon is 0.21%, copper is 0.14%, magnesium is 0.23%, Fe is 0.65%, Mn is 0.83%, and aluminum is 97.94%.

[0084] Embodiment 4:

[0085] Based on Example 1, please refer to Figures 1 to 3 As shown, a smelting process of aluminum alloy according to an embodiment of the present invention includes monitoring the aluminum liquid during the stirring process, controlling the stirring speed and the stirring route, and the specific method is the following steps:

[0086] Step 1: Estimate the stirring speed during the stirring process;

[0087] Step 2: During the stirring process, the aluminum liquid is monitored to control the stirring speed and stirring route;

[0088] The specific implementation plan for estimating the stirring speed during the stirring process in step 1 is:

[0089] A1: Based on the historical data of the stirring process in the aluminum alloy smelting process, and modeling based on the historical data;

[0090] A2: Based on the established model, the stirring speed is estimated to obtain an estimated stirring speed value, and the estimated stirring speed value is marked as JY;

[0091] In some embodiments, the historical data includes: historical stirring data, historical stirring speed;

[0092] Furthermore, the stirring data include: alloy type and composition, melting temperature;

[0093] The specific implementation plan for monitoring the aluminum liquid in step 2 and controlling the stirring speed is as follows:

[0094] B1: Monitor the stirring process and obtain the aluminum liquid data within the target period;

[0095] Among them, the cycles include: 30 seconds, 60 seconds;

[0096] B2: Calculate the adjusted stirring speed based on the aluminum liquid data and the estimated stirring speed;

[0097] B3: Control the stirring speed during the stirring process according to the adjusted stirring speed, and change the stirring speed to the adjusted stirring speed until the next cycle;

[0098] In some embodiments, the aluminum liquid data includes: an aluminum liquid temperature difference characterization value and a temperature deviation value;

[0099] Furthermore, the method for obtaining aluminum liquid data is:

[0100] C1: Divide the aluminum liquid evenly into multiple sub-areas;

[0101] C2: During the stirring process, obtain the temperature of the aluminum liquid area within the target cycle;

[0102] C3: According to the temperature of the aluminum liquid sub-area, the aluminum liquid temperature difference characterization value and the temperature deviation value are calculated and the aluminum liquid temperature difference characterization value is marked as WB and the temperature deviation value is marked as WP;

[0103] Specifically, the calculation method of the aluminum liquid temperature difference characterization value is:

[0104] The temperatures of all aluminum liquid sub-areas are averaged to obtain the average aluminum liquid temperature;

[0105] The aluminum liquid temperature difference characterization value is calculated by the formula: aluminum liquid temperature difference characterization value = aluminum liquid temperature average value - aluminum liquid preset temperature;

[0106] Among them, the preset temperature of aluminum liquid is the aluminum liquid temperature under ideal conditions;

[0107] It should be explained that: when the aluminum liquid temperature difference representation value is less than 0, it means that the average aluminum liquid temperature is less than the aluminum liquid preset temperature. Because the excessive stirring speed will accelerate the loss of aluminum liquid temperature, it is necessary to reduce the stirring speed at this time so that the aluminum liquid temperature can reach the aluminum liquid preset temperature as soon as possible, thereby controlling the temperature of the aluminum liquid during the heating and dissolving process;

[0108] Specifically, the temperature deviation value is calculated as follows:

[0109] The temperature of all aluminum liquid sub-areas is calculated by difference with the average temperature of the aluminum liquid to obtain the temperature deviation value of the sub-area, and the absolute value of the temperature deviation value of all aluminum liquid sub-areas is calculated by summing up to obtain the temperature deviation value;

[0110] Furthermore, the specific method for calculating the adjusted stirring speed based on the aluminum liquid data and the stirring speed estimate is:

[0111] The aluminum liquid temperature difference characterization value WB and the temperature deviation value WP are processed;

[0112] By formula: , calculate the adjusted stirring speed TJ, where, , is the preset proportional factor, and both are greater than 0, n represents the nth cycle, n is a positive integer, and when n=1, = Estimated stirring speed JY;

[0113] The specific implementation plan for monitoring the aluminum liquid in step 2 and controlling the stirring route is as follows:

[0114] D1: mark the aluminum liquid sub-regions in the same vertical direction as sub-region groups;

[0115] D2: Obtain the sub-region group deviation value of each sub-region respectively;

[0116] D3: preset a mixing route, obtain a pre-mixing route, calculate a mixing route parameter value according to the pre-mixing route, mark a mixing route with the largest mixing route parameter value as an adjusted mixing route, and change the mixing route to the adjusted mixing route until the next cycle;

[0117] In some embodiments, the sub-region group deviation value is obtained by:

[0118] Based on the same sub-region group, the temperature deviation value of all aluminum liquid sub-regions in the same sub-region group is calculated, and the absolute value of the temperature deviation value of all aluminum liquid sub-regions in the same sub-region group is summed to obtain the sub-region group deviation value;

[0119] In some embodiments, the pre-set method of the stirring pre-route is:

[0120] Make circles of different diameters on the surface of the aluminum liquid, and each circle is a stirring pre-route;

[0121] In some embodiments, the specific method for calculating the stirring route parameter value according to the stirring pre-route is:

[0122] Obtain all sub-region groups that the mixing pre-route passes through, and sum up the sub-region group deviation values ​​of all sub-region groups to obtain the mixing route parameter value;

[0123] The concept of the embodiment of the present invention is as follows: During the aluminum alloy smelting process, the state of the aluminum liquid may change due to the influence of various factors. By real-time monitoring of the aluminum liquid data and calculating the adjusted stirring speed and selecting the adjusted stirring route based on the data, the changes in the state of the aluminum liquid can be discovered and responded to in time, and the ideal temperature distribution uniformity can be achieved in a shorter time and with lower energy consumption, thereby improving the stirring efficiency and ensuring the stability of the stirring process and the product quality.

[0124] Embodiment five:

[0125] Based on the first and fourth embodiments, please refer to Figure 4 As shown, an aluminum alloy smelting device according to an embodiment of the present invention adopts a smelting furnace provided with a stirring device (see the alloy smelting device disclosed in patent number CN205079604U for details, which is a prior art and will not be repeated here), and the stirring device is provided with a stirring control system for detecting stirring, and the system includes:

[0126] The stirring speed estimation module is used to estimate the stirring speed during the stirring process;

[0127] The stirring control module is used to monitor the aluminum liquid during the stirring process, so as to control the stirring speed and stirring route;

[0128] Wherein, the stirring control module includes: a stirring speed control unit and a stirring route control unit;

[0129] Specifically, the stirring speed control unit is used to control the stirring speed, and the specific scheme is:

[0130] B1: Monitor the stirring process and obtain the aluminum liquid data within the target period;

[0131] B2: Calculate the adjusted stirring speed based on the aluminum liquid data and the estimated stirring speed;

[0132] B3: Control the stirring speed during the stirring process according to the adjusted stirring speed, and change the stirring speed to the adjusted stirring speed until the next cycle;

[0133] Specifically, the stirring route control unit is used to control the stirring route, and the specific scheme is:

[0134] D1: mark the aluminum liquid sub-regions in the same vertical direction as sub-region groups;

[0135] D2: Obtain the sub-region group deviation value of each sub-region respectively;

[0136] D3: preset a mixing route, obtain a pre-mixing route, calculate a mixing route parameter value according to the pre-mixing route, mark a mixing route with the largest mixing route parameter value as an adjusted mixing route, and change the mixing route to the adjusted mixing route until the next cycle.

[0137] The above formulas are obtained by collecting a large amount of data and performing software simulation to select a formula close to the actual value. The factors in the formula are set by technicians in this field according to actual conditions; for example: Formula ; A technician in this field collects multiple sets of aluminum liquid data and sets a corresponding adjusted stirring speed for each set of aluminum liquid data; substitutes the set adjusted stirring speed and the collected aluminum liquid data into the formula, and any three formulas constitute a three-variable linear equation system. The calculated factors are screened and averaged to obtain , The values ​​of are 1.47 and 1.23 respectively;

[0138] The size of the factor is to quantify each parameter to obtain a specific value for subsequent comparison. The size of the factor depends on the amount of aluminum liquid data and the technical personnel in this field preliminarily set the corresponding adjusted stirring speed for each set of aluminum liquid data; as long as it does not affect the proportional relationship between the parameter and the quantified value, such as the adjusted stirring speed is proportional to the value of the temperature deviation value.

[0139] The above is a detailed description of an embodiment of the present invention, but the content is only a preferred embodiment of the present invention and cannot be considered to limit the scope of implementation of the present invention. All equivalent changes and improvements made within the scope of the present invention should still fall within the scope of the patent coverage of the present invention.

Claims

1. A smelting process for aluminum alloy, characterized in that: include: Raw material preparation, charging into furnace, heating and dissolving, alloy composition detection, purification, composition adjustment, casting and cooling and solidification; During the heating and dissolving process, the molten alloy material is continuously stirred. At the same time, the aluminum liquid is monitored during the stirring process to control the stirring speed and stirring route. The specific method is as follows: Step 1: Estimate the stirring speed during the stirring process; in step 1, the specific method for estimating the stirring speed during the stirring process is: A1: Based on the historical data of the stirring process in the aluminum alloy smelting process, and modeling based on the historical data; A2: Based on the established model, the stirring speed is estimated to obtain an estimated stirring speed value, and the estimated stirring speed value is marked as JY; Step 2: During the stirring process, the aluminum liquid is monitored to control the stirring speed and stirring route; In step 2, the specific scheme for controlling the stirring speed is: B1: Monitor the stirring process and obtain the aluminum liquid data within the target cycle; the aluminum liquid data includes: aluminum liquid temperature difference characterization value and temperature deviation value; B2: Calculate the adjusted stirring speed based on the aluminum liquid data and the estimated stirring speed; B3: Control the stirring speed during the stirring process according to the adjusted stirring speed, and change the stirring speed to the adjusted stirring speed until the next cycle; In step 2, the aluminum liquid data acquisition method is: C1: Divide the aluminum liquid evenly into multiple sub-areas; C2: During the stirring process, obtain the temperature of the aluminum liquid area within the target cycle; C3: According to the temperature of the aluminum liquid sub-area, the aluminum liquid temperature difference characterization value and the temperature deviation value are calculated and the aluminum liquid temperature difference characterization value is marked as WB and the temperature deviation value is marked as WP; The specific calculation method of the aluminum liquid temperature difference characterization value WB is: The temperatures of all aluminum liquid sub-areas are averaged to obtain the average aluminum liquid temperature; The aluminum liquid temperature difference characterization value WB is calculated by the formula: aluminum liquid temperature difference characterization value = aluminum liquid temperature average value - aluminum liquid preset temperature; The specific calculation method of the temperature deviation value WP is: The temperature of all aluminum liquid sub-areas is calculated by difference with the average temperature of aluminum liquid respectively to obtain the temperature deviation value of the sub-area, and the absolute value of the temperature deviation value of all aluminum liquid sub-areas is calculated by summing up to obtain the temperature deviation value WP; The aluminum liquid temperature difference characterization value WB and the temperature deviation value WP are processed; By formula: , calculate the adjusted stirring speed TJ, where, , is the preset proportional factor, and both are greater than 0, n represents the nth cycle, n is a positive integer, and when n=1, = Estimated stirring speed JY; In step 2, the specific scheme for controlling the mixing route is: D1: mark the aluminum liquid sub-regions in the same vertical direction as sub-region groups; D2: Obtain the sub-region group deviation value of each sub-region respectively; D3: Preset the stirring route and obtain the stirring pre-route. The method for presetting the stirring pre-route is as follows: make circles of different diameters on the surface of the aluminum liquid, each of which is a stirring pre-route, and calculate the stirring route parameter value according to the stirring pre-route, mark the stirring pre-route with the largest stirring route parameter value as the adjusted stirring route, and change the stirring route to the adjusted stirring route until the next cycle; The method for obtaining the sub-region group deviation value is: Based on the same sub-region group, the temperature deviation value of all aluminum liquid sub-regions in the same sub-region group is calculated, and the absolute value of the temperature deviation value of all aluminum liquid sub-regions in the same sub-region group is summed up to obtain the sub-region group deviation value; The specific method for calculating the mixing route parameter value according to the mixing pre-route is: All sub-region groups that the mixing route passes through are obtained, and the sub-region group deviation values ​​of all the sub-region groups are summed up and calculated to obtain the mixing route parameter value.

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