A contact centrifugal atomization online monitoring system and method

Abstract

The present invention relates to the technical field of atomization powder making, and discloses a contact centrifugal atomization online monitoring system and method, the system comprises a tank body, the tank body is divided into a smelting chamber and an atomization chamber by a partition, the smelting chamber and the atomization chamber are respectively connected to a vacuum pump group; the atomization system comprises a tundish and an atomization unit, the tundish is fixedly connected to the top of the partition, the atomization unit is fixedly connected in the atomization chamber, the bottom end of the tundish penetrates the partition for conveying the smelting liquid in the smelting chamber to the atomization unit, and the atomization unit atomizes the smelting liquid; the monitoring system comprises a sampler and a detection unit, the sampler is arranged on the tank body and is connected to the atomization chamber, the detection unit is arranged at the output end of the sampler, and the detection unit is used to detect the powder index after atomization. The present invention automatically samples and analyzes the powder online through the detection unit, and uses the control atomization system to quickly adjust the powder atomization parameters, thereby dynamically adjusting the fine powder yield, reducing the experimental cost and improving the production efficiency.

Description

Technical Field

[0001] The invention relates to the technical field of atomization powder making, and in particular to a contact type centrifugal atomization online monitoring system and method. Background Art

[0002] In the traditional gas atomization powder making process, the liquid is broken into droplets of different sizes by the airflow. Under the action of turbulence and vortex, large and small particle droplets are prone to multiple collisions and adhesion to form satellite powders. Satellite powders will cause the powder fluidity to deteriorate and produce pore defects in additive manufacturing. Therefore, it is necessary to find a production process that avoids the generation of satellite powders. The nitrogen in the atomization chamber of the subsequent turntable atomization powder making is relatively stable. During the production process, the molten steel is atomized into droplets at the edge of the turntable and flies out along the tangent direction of the turntable and continues to disperse in the atomization chamber. The droplets are not easy to collide and agglomerate during the flight, avoiding the appearance of satellite powders. In the turntable atomization powder making, a sedimentation layer is easily formed near the edge of the turntable, and large-sized steel shots are easily formed due to insufficient flow of the molten steel, which affects the fine powder recovery rate.

[0003] At present, the atomization powder making equipment cannot perform real-time detection of the produced powder. The experimenters or production personnel cannot know the powder parameters during the experiment and can only take out the powder for testing after the experiment. In addition, in the same furnace experiment or production, if the experimental conditions such as rotation speed, air pressure, oscillation frequency are adjusted, the powders under different conditions will be mixed together, and the corresponding relationship between different conditions and powder parameters cannot be clearly determined. This means that if you want to change the experimental conditions, you need to conduct multiple experiments, so the experimental cycle and experimental costs will increase accordingly. Summary of the invention

[0004] The purpose of the present invention is to provide a contact type centrifugal atomization online monitoring system and method to solve the problems existing in the above-mentioned prior art.

[0005] To achieve the above object, the present invention provides the following solution: The present invention provides a contact centrifugal atomization online monitoring system, comprising a tank body,

[0006] The tank body is divided into a smelting chamber and an atomizing chamber by a partition, the smelting chamber is located above the atomizing chamber, and the smelting chamber and the atomizing chamber are respectively connected to a vacuum pump group;

[0007] An atomization system, comprising a tundish and an atomization unit, wherein the tundish is fixedly connected to the top of the partition, the atomization unit is fixedly connected to the atomization chamber, the bottom end of the tundish penetrates the partition to transport the smelting liquid in the smelting chamber to the atomization unit, and the atomization unit atomizes the smelting liquid;

[0008] The monitoring system comprises a sampler and a detection unit. The sampler is arranged on the tank body and communicated with the atomization chamber. The detection unit is arranged at the output end of the sampler and is used to detect the atomized powder.

[0009] Preferably, the atomization unit includes a bracket fixedly connected in the atomization chamber, a support plate fixedly connected to the top of the bracket, a centrifugal turntable rotatably connected to the support plate via a rotating shaft, a first ultrasonic transducer, an ultrasonic concentrator and a high-speed motor fixedly connected to the bottom end of the support plate in sequence from top to bottom, and an output shaft of the high-speed motor fixedly connected to the bottom end of the rotating shaft.

[0010] Preferably, the detection unit includes a detection box fixedly connected to the output end of the sampler, a second ultrasonic transducer and a detection trough are fixedly connected on both sides of the detection box, one end of a vibration trough is fixedly connected to the second ultrasonic transducer, a detection channel is provided in the detection trough, the other end of the vibration trough is located directly above the detection channel, a detection component is provided in the detection channel, the detection component is used to detect powder, and a first powder collecting tank is fixedly connected to the bottom end of the detection box, and the first powder collecting tank is communicated with the detection channel.

[0011] Preferably, the detection component includes a camera and a pulse light source, and the camera and the pulse light source are respectively located on two opposite inner side walls of the detection channel.

[0012] Preferably, the sampler includes a sampling chamber, which is connected to the atomization chamber through a sampling pipe, and the bottom of the sampling chamber is connected to the detection box. The sampling chamber is provided with a sampling airflow valve, a first fan and an exhaust port, and a flow meter is installed on the sampling pipe.

[0013] Preferably, the intermediate ladle includes an insulation layer fixedly connected to the top of the partition, a heating element is arranged inside the insulation layer, a crucible is arranged inside the heating element, one end of a guide nozzle is fixedly connected to the bottom end of the crucible, the other end of the guide nozzle passes through the partition and is located directly above the centrifugal turntable, and a guide nozzle heater is fixedly connected to the outside of the guide nozzle.

[0014] Preferably, the smelting chamber and the atomizing chamber are both connected with an inflation pipe, and the inflation pipe is provided with a servo proportional valve and a pressure transmitter.

[0015] Preferably, the bottom end of the tank body is connected to a powder collector via a powder conveying pipeline, the top end of the powder collector is connected to a second fan via an exhaust pipeline, and the bottom end of the powder collector is fixedly connected to a second powder collecting tank.

[0016] Preferably, the camera is a high-speed CCD camera, and an automatic zoom telecentric lens is provided on the high-speed CCD camera.

[0017] A contact type high-speed rotating centrifugal atomization method comprises the following steps:

[0018] Putting metal raw materials into a melting chamber to prepare a melt;

[0019] The prepared solution is transported to the atomization unit through the tundish for atomization;

[0020] The atomized powder is transported to the detection unit through the sampler for detection, and the atomization parameters are adjusted according to the detection data;

[0021] Repeat the above preparation, atomization and testing process until the test data is qualified and carry out continuous production.

[0022] Compared with the prior art, the present invention has the following advantages and technical effects:

[0023] The present invention provides a contact centrifugal atomization online monitoring system and method. The tank body is divided into a smelting chamber and an atomization chamber. The smelting chamber is used to smelt metal to prepare a molten liquid. The prepared molten liquid is transported to the atomization unit through the tundish for atomization treatment. The powder in the atomization process is collected by a sampler and transported online to the detection unit for detection. The various atomization process parameters are adjusted online according to the detection results until the set product indicators are reached, thereby performing continuous production. The present application can further refine the atomization process of molten steel through the dual effects of centrifugation and ultrasonic oscillation, automatically sample and analyze the powder online through the detection unit, and quickly adjust the powder atomization parameters by controlling the atomization system, thereby dynamically adjusting the fine powder yield, reducing experimental costs and improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative labor:

[0025] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0026] Figure 2 It is a schematic diagram of the structure of the monitoring system of the present invention;

[0027] Figure 3 It is a schematic diagram of the structure of the atomization system of the present invention;

[0028] Among them, 1. tank body; 2. partition; 3. smelting chamber; 4. atomization chamber; 5. tundish; 51. insulation layer; 52. heating element; 53. crucible; 54. guide nozzle; 55. guide nozzle heater; 56. thermocouple; 6. atomization unit; 61. bracket; 62. support plate; 63. rotating shaft; 64. centrifugal turntable; 65. first ultrasonic transducer; 66. ultrasonic concentrator; 67. high-speed motor; 7. feeding bin; 8. sampler; 81. sampling bin; 82. sampling pipeline; 83. sampling air flow valve; 84. first fan; 85. exhaust mouth; 86, flow meter; 9, detection unit; 91, detection box; 92, second ultrasonic transducer; 93, detection tank; 94, vibration trough; 95, detection channel; 96, camera; 97, pulse light source; 98, first powder collecting tank; 99, automatic zoom telecentric lens; 10, vacuum pump group; 11, charging pipe; 12, servo proportional valve; 13, pressure transmitter; 14, powder conveying pipeline; 15, powder collector; 16, exhaust duct; 17, second fan; 18, second powder collecting tank; 19, smelting vessel; 20, thermometer; 21, baffle. DETAILED DESCRIPTION

[0029] 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.

[0030] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0031] Reference Figure 1-Figure 3 The present invention provides a contact centrifugal atomization online monitoring system, comprising a tank body 1,

[0032] The tank body 1 is divided into a smelting chamber 3 and an atomizing chamber 4 by a partition 2. The smelting chamber 3 is located above the atomizing chamber 4. The smelting chamber 3 and the atomizing chamber 4 are respectively connected to a vacuum pump group 10.

[0033] The atomization system includes a tundish 5 and an atomization unit 6. The tundish 5 is fixedly connected to the top of the partition 2. The atomization unit 6 is fixedly connected to the atomization chamber 4. The bottom end of the tundish 5 penetrates the partition 2 to transport the molten liquid in the smelting chamber 3 to the atomization unit 6. The atomization unit 6 atomizes the molten liquid.

[0034] The monitoring system includes a sampler 8 and a detection unit 9. The sampler 8 is arranged on the tank body 1 and is connected to the atomization chamber 4. The detection unit 9 is arranged at the output end of the sampler 8 and is used to detect the atomized powder.

[0035] A further optimized solution is that the atomization unit 6 includes a bracket 61 fixedly connected to the atomization chamber 4, a support plate 62 is fixedly connected to the top of the bracket 61, a centrifugal turntable 64 is rotatably connected to the support plate 62 via a rotating shaft 63, and a first ultrasonic transducer 65, an ultrasonic concentrator 66 and a high-speed motor 67 are fixedly connected to the bottom end of the support plate 62 from top to bottom in sequence, and the output shaft of the high-speed motor 67 is fixedly connected to the bottom end of the rotating shaft 63.

[0036] Reference Figure 3 The first ultrasonic transducer 65 and the ultrasonic concentrator 66 are sequentially installed on the support plate 62, and the front flange of the high-speed motor 67 is connected to the ultrasonic concentrator 66. The first ultrasonic transducer 65 converts high-frequency oscillation electrical energy into high-frequency vibration, and the high-frequency vibration is concentrated on the flange of the high-speed motor 67 through the ultrasonic concentrator 66. The high-speed motor 67 transmits the high-frequency vibration to the centrifugal turntable 64 and drives the centrifugal turntable 64 to rotate at a high speed, thereby realizing atomization by the combined action of rotation and vibration. The first ultrasonic transducer 65 and the high-speed motor 67 can be controlled by controlling the frequency.

[0037] A further optimized solution is that the detection unit 9 includes a detection box 91 fixedly connected to the output end of the sampler 8, and a second ultrasonic transducer 92 and a detection trough 93 are fixedly connected on both sides of the detection box 91. One end of a vibration trough 94 is fixedly connected to the second ultrasonic transducer 92. A detection channel 95 is provided in the detection trough 93, and the other end of the vibration trough 94 is located directly above the detection channel 95. A detection component is provided in the detection channel 95, and the detection component is used to detect powder. A first powder collecting tank 98 is fixedly connected to the bottom end of the detection box 91, and the first powder collecting tank 98 is connected to the detection channel 95.

[0038] Reference Figure 2 The vibration trough 94 is installed on the second ultrasonic transducer 92. The sampled powder falls on one end of the vibration trough 94 and falls into the detection channel 95 along with the vibration trough 94. The speed of the vibration trough 94 can be controlled by controlling the frequency. The baffle 21 can be added and the gap between the baffle and the detection channel 95 can be controlled to control the falling speed of the sampled powder.

[0039] According to a further optimized solution, the detection component includes a camera 96 ​​and a pulse light source 97 , and the camera 96 ​​and the pulse light source 97 are respectively located on two opposite inner side walls of the detection channel 95 .

[0040] Reference Figure 2The camera 96 ​​is installed on one side of the detection channel 95, and the pulse light source 97 is installed on the other side of the detection channel 95. The camera 96 ​​performs image recognition on the powder falling into the detection channel 95. The image signal tracks and detects the sampled powder through the particle edge image recognition technology, and can output the original image, particle size, sphericity, aspect ratio and other particle parameter information of the sampled powder, and can calculate the statistical distribution of these parameter information based on the sampled powder, such as circularity distribution, particle size distribution, aspect ratio distribution, etc.

[0041] To further optimize the solution, the sampler 8 includes a sampling chamber 81, which is connected to the atomization chamber 4 through a sampling pipe 82, and the bottom of the sampling chamber 81 is connected to the detection box 91. The sampling chamber 81 is provided with a sampling airflow valve 83, a first fan 84 and an exhaust port 85, and the sampling pipe 82 is installed with a flow meter 86.

[0042] Reference Figure 2 The powder generated in the atomization chamber 4 is sucked by the first fan 84 and enters the sampling bin 81 along the sampling pipe 82 with the air flow. In this process, the air flow is discharged from the exhaust port 85 through the sampling air flow valve 83 and the first fan 84 due to its relatively light mass. The powder slides along the inner wall of the sampling bin 81 to the vibrating trough 94 under the influence of gravity.

[0043] A further optimized solution is that the intermediate ladle 5 includes an insulating layer 51 fixedly connected to the top of the partition 2, a heating element 52 is arranged inside the insulating layer 51, a crucible 53 is arranged inside the heating element 52, one end of a guide nozzle 54 is fixedly connected to the bottom end of the crucible 53, the other end of the guide nozzle 54 passes through the partition 2 and is located directly above the centrifugal turntable 64, and a guide nozzle heater 55 is fixedly connected to the outside of the guide nozzle 54.

[0044] Specifically, a thermocouple 56 is also provided on the crucible 53 .

[0045] According to a further optimized solution, both the smelting chamber 3 and the atomizing chamber 4 are connected with an air charging pipe 11 , and a servo proportional valve 12 and a pressure transmitter 13 are provided on the air charging pipe 11 .

[0046] According to a further optimization scheme, the bottom end of the tank body 1 is connected to a powder collector 15 through a powder conveying pipeline 14 , the top end of the powder collector 15 is connected to a second fan 17 through an exhaust pipeline 16 , and the bottom end of the powder collector 15 is fixedly connected to a second powder collecting tank 18 .

[0047] According to a further optimization scheme, the camera 96 ​​is a high-speed CCD camera, and an automatic zoom telecentric lens 99 is provided on the high-speed CCD camera.

[0048] A contact type high-speed rotating centrifugal atomization method comprises the following steps:

[0049] Putting metal raw materials into the smelting chamber 3 to prepare a melt;

[0050] According to the alloy composition ratio, the metal raw materials are loaded into the smelting vessel 19 in the smelting chamber 3 along the charging bin 7 and the furnace cover is closed. The vacuum pump group 10 is started to evacuate the vacuum. When the vacuum degree is displayed as 6.7*10-1Pa, the heating power supply of the tundish 5 is started and the power is adjusted to 20kw to start preheating the tundish 5. The preheating time is 20min.

[0051] When the vacuum degree shows 6.7*10-3Pa, adjust the power of the heating power supply of the tundish 5 to 45kw. When the temperature reaches 1300℃, start insulation. At the same time, start the smelting power supply, adjust the power to 50kw, preheat for 20min. When the surface of the metal raw material emits a faint red light, adjust the power to 90kw, heat for 30min. When the metal raw material begins to melt and splash, introduce argon protective gas to 0.05Pa, and adjust the power to 150kw at the same time. Heat for 45min. When all the metal raw materials are melted, adjust the power to 160kw, refine for 10min, and complete the preparation of the alloy melt.

[0052] Specifically, a temperature measuring instrument 20 is provided on the tank body 1 for monitoring the temperature.

[0053] The prepared solution is transported to the atomization unit 6 through the tundish 5 for atomization;

[0054] The molten liquid in the smelting vessel 19 is poured into the crucible 53 of the tundish 5. After the molten liquid drips, the gas charging pipe 11 is opened to adjust the initial atomization pressure to 2 MPa, and the high-speed motor 67 is turned on at the same time to perform atomization powder collection.

[0055] The atomized powder is transported to the detection unit 9 through the sampler 8 for detection, and the atomization parameters are adjusted according to the detection data;

[0056] The sampling air flow valve 83 is opened to collect the first batch of alloy powder after atomization, and the powder is transported to the detection tank 93 through the detection tank 93 for detection by the camera 96 ​​and the pulse light source 97.

[0057] Repeat the above preparation, atomization and testing process until the test data is qualified and carry out continuous production.

[0058] The powder test results are fed back to the intelligent control system (not shown in the figure). When the sphericity is less than 90% and D50 is greater than 53um, the system will adjust the atomization process parameters according to the following formula:

[0059] (ε is the atomization coefficient).

[0060] In the intelligent control system, intelligent identification is performed to predict the droplet size by considering the influence of liquid flow rate, liquid viscosity and ultrasonic amplitude:

[0061]

[0062] We represents the Weber number; Oh represents the Ohnesorg number that affects viscosity; In represents the intensity number; σ represents the surface tension coefficient of the liquid; P represents the density of the liquid alloy (kg / m 3 ); f represents the ultrasonic frequency.

[0063] At the same time, the atomization air intake pressure, rotation speed, amplitude and other parameters are automatically adjusted to adjust the powder making process online to repeat the powder collection, transportation and online detection steps. When the test results meet the sphericity>90%, D50<53um, the system will automatically solidify the process for continuous preparation.

[0064] In the description of the present invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside" and "outside" etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0065] The embodiments described above are only descriptions of the preferred modes of the present invention, and are not intended to limit the scope of the present invention. Without departing from the design spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by ordinary technicians in this field should all fall within the protection scope determined by the claims of the present invention.

Claims

1. A contact centrifugal atomization online monitoring system, comprising a tank (1), characterized in that: The tank body (1) is divided into a smelting chamber (3) and an atomizing chamber (4) by a partition (2); the smelting chamber (3) is located above the atomizing chamber (4); and the smelting chamber (3) and the atomizing chamber (4) are respectively connected to a vacuum pump group (10); An atomization system, comprising a tundish (5) and an atomization unit (6), wherein the tundish (5) is fixedly connected to the top of the partition (2), and the atomization unit (6) is fixedly connected to the inside of the atomization chamber (4); the bottom end of the tundish (5) penetrates the partition (2) and is used to transport the molten liquid in the smelting chamber (3) to the atomization unit (6), and the atomization unit (6) atomizes the molten liquid; A monitoring system, comprising a sampler (8) and a detection unit (9), wherein the sampler (8) is arranged on the tank body (1) and is connected to the atomization chamber (4), and the detection unit (9) is arranged at the output end of the sampler (8), and the detection unit (9) is used to detect the atomized powder; The detection unit (9) comprises a detection box (91) fixedly connected to the output end of the sampler (8), a second ultrasonic transducer (92) and a detection trough (93) are fixedly connected to the two sides of the detection box (91), one end of a vibration trough (94) is fixedly connected to the second ultrasonic transducer (92), a detection channel (95) is provided in the detection trough (93), the other end of the vibration trough (94) is located directly above the detection channel (95), a detection component is provided in the detection channel (95), and the detection component is used to detect powder, and a first powder collecting tank (98) is fixedly connected to the bottom end of the detection box (91), and the first powder collecting tank (98) is communicated with the detection channel (95).

2. A contact centrifugal atomization online monitoring system according to claim 1, characterized in that: The atomization unit (6) comprises a bracket (61) fixedly connected to the atomization chamber (4); a support plate (62) is fixedly connected to the top of the bracket (61); a centrifugal turntable (64) is rotatably connected to the support plate (62) via a rotating shaft (63); a first ultrasonic transducer (65), an ultrasonic concentrator (66) and a high-speed motor (67) are fixedly connected to the bottom of the support plate (62) in sequence from top to bottom; and an output shaft of the high-speed motor (67) is fixedly connected to the bottom of the rotating shaft (63).

3. The contact centrifugal atomization online monitoring system according to claim 1, characterized in that: The detection component comprises a camera (96) and a pulse light source (97), and the camera (96) and the pulse light source (97) are respectively located on two opposite inner side walls of the detection channel (95).

4. The contact centrifugal atomization online monitoring system according to claim 1, characterized in that: The sampler (8) comprises a sampling chamber (81), the sampling chamber (81) is connected to the atomization chamber (4) through a sampling pipe (82), the bottom end of the sampling chamber (81) is connected to the detection box (91), the sampling chamber (81) is provided with a sampling air flow valve (83), a first fan (84) and an exhaust port (85), and the sampling pipe (82) is installed with a flow meter (86).

5. The contact centrifugal atomization online monitoring system according to claim 2, characterized in that: The tundish (5) comprises a heat-insulating layer (51) fixedly connected to the top of the partition (2), a heating element (52) is arranged inside the heat-insulating layer (51), a crucible (53) is arranged inside the heating element (52), one end of a guide nozzle (54) is fixedly connected to the bottom end of the crucible (53), the other end of the guide nozzle (54) passes through the partition (2) and is located directly above the centrifugal turntable (64), and a guide nozzle heater (55) is fixedly connected to the outside of the guide nozzle (54).

6. The contact centrifugal atomization online monitoring system according to claim 1, characterized in that: The smelting chamber (3) and the atomizing chamber (4) are both connected to an air charging pipe (11), and the air charging pipe (11) is provided with a servo proportional valve (12) and a pressure transmitter (13).

7. The contact centrifugal atomization online monitoring system according to claim 1, characterized in that: The bottom end of the tank body (1) is connected to a powder collector (15) via a powder conveying pipeline (14); the top end of the powder collector (15) is connected to a second fan (17) via an exhaust pipeline (16); and the bottom end of the powder collector (15) is fixedly connected to a second powder collecting tank (18).

8. The contact centrifugal atomization online monitoring system according to claim 3, characterized in that: The camera (96) is a high-speed CCD camera, and an automatic zoom telecentric lens (99) is provided on the high-speed CCD camera.

9. A contact type high speed rotating centrifugal atomization method, applicable to a contact type centrifugal atomization online monitoring system as claimed in claim 1, characterized in that: The following steps are involved: Putting metal raw materials into a smelting chamber (3) to prepare a melt; The prepared solution is transported to the atomization unit (6) through the intermediate package (5) for atomization; The atomized powder is transported to a detection unit (9) through a sampler (8) for detection, and atomization parameters are adjusted according to the detection data; Repeat the above preparation, atomization and testing process until the test data is qualified and carry out continuous production.

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