A ladle liquid level control system, an automatic casting system and a method

Abstract

The present invention discloses a ladle liquid level control system, an automatic casting system and a method. The ladle liquid level control system includes: a liquid level detection mechanism, which is arranged directly above the ladle and is used for detecting the liquid level of the ladle; a holding furnace, which is provided with a liquid outlet, and a runner is arranged between the liquid outlet and the liquid inlet end of the ladle; a holding driving mechanism, which is connected to the holding furnace and is used for driving the holding furnace to swing so as to control the amount of liquid discharged from the liquid outlet; and a control system module, which is used for receiving the detection information of the liquid level detection mechanism and controlling the running state of the holding driving mechanism based on the detection information. The present invention controls the swing angle of the holding furnace, thereby controlling the amount of liquid input into the ladle, stabilizing the liquid level in the ladle within a certain range, and reducing the influence of the liquid level fluctuation in the ladle on the liquid level of the casting pool. The present invention realizes the automatic and high-precision control of the heights of the ladle and the casting pool liquid levels, and improves the casting quality.

Description

Technical Field

[0001] The present invention relates to the technical field of copper liquid casting control systems, and particularly relates to a ladle liquid level control system, an automatic casting system and a method. Background Art

[0002] Casting is a common and important production method. In the current copper casting process, most of the raw materials are melted in a furnace and then transferred to a ladle and cast into a mold. The casting process of copper parts needs to be realized by using a related copper liquid casting system. The existing copper liquid casting system is provided with components such as a servo motor, a stopper rod, a camera, a casting ladle and a casting pool. By controlling the servo motor to move the position of the stopper rod, the height of the copper liquid in the casting pool is adjusted.

[0003] The existing casting system only identifies the liquid level height of the casting pool through a visible light camera, and controls the servo motor to move the stopper rod up and down by using the deviation between the monitored actual liquid level height and the preset reference line, so as to control the flow rate of the copper liquid flowing out of the casting ladle. However, during the casting process, the existing casting system does not control the liquid level inside the ladle. The liquid level height inside the ladle itself will also fluctuate, and the liquid level height inside the ladle will affect the copper liquid flow rate, will affect the copper liquid level in the casting pool, and further will affect the casting quality. Therefore, only controlling the stopper rod cannot achieve precise control of the casting copper liquid flow rate and casting quality. Summary of the Invention

[0004] Therefore, the technical problem to be solved by the present invention is to overcome the defect that in the casting process, the existing casting system does not control the liquid level inside the ladle, and thus cannot achieve precise control of the casting copper liquid flow rate and casting quality, so as to provide a ladle liquid level control system, an automatic casting system and a method.

[0005] To achieve the above object, the technical solution adopted by the present invention is as follows:

[0006] A ladle liquid level control system, comprising:

[0007] A liquid level detection mechanism, which is arranged directly above the ladle, and is used for detecting the liquid level of the ladle;

[0008] A holding furnace, which is provided with a liquid outlet, and a flow channel is arranged between the liquid outlet and the liquid inlet end of the ladle;

[0009] A holding driving mechanism, which is connected to the holding furnace, and is used for driving the holding furnace to swing to control the amount of liquid discharged from the liquid outlet;

[0010] The control system module is used to receive the detection information of the liquid level detection mechanism and control the operating state of the heat preservation driving mechanism based on the detection information.

[0011] Further optimize the technical solution. The heat preservation driving mechanism includes:

[0012] The heat preservation furnace positioning seat, on which the heat preservation furnace is positioned;

[0013] At least two rotating rollers, which support the heat preservation furnace positioning seat, and the rotating rollers are in rolling contact with the heat preservation furnace positioning seat;

[0014] The heat preservation furnace connecting arm, which is connected to the side wall of the heat preservation furnace and is arranged on the opposite sides of the heat preservation furnace with the liquid outlet;

[0015] The connecting arm driving part, which has a telescopic end, and the telescopic end of the connecting arm driving part is hinged to the heat preservation furnace connecting arm and drives the heat preservation furnace connecting arm to move.

[0016] Further optimize the technical solution. The connecting arm driving part is a hydraulic cylinder; the hydraulic cylinder is connected to the servo hydraulic system and is controlled by the servo hydraulic system, and the controlled end of the servo hydraulic system is connected to the output end of the control system module.

[0017] Further optimize the technical solution. The bottom of the heat preservation furnace positioning seat is an arc surface, the bottom of the heat preservation furnace positioning seat is in rolling contact with the rotating roller, and the heat preservation furnace positioning seat rotates around its center; the heat preservation furnace is eccentrically arranged on the heat preservation furnace positioning seat.

[0018] An automatic casting system includes:

[0019] The ladle, which has a liquid inlet end and a liquid outlet end;

[0020] The casting pool, which is arranged below the ladle and corresponds to the liquid outlet end of the ladle;

[0021] The stopper rod, which is inserted into the ladle and controls the liquid outlet state of the liquid outlet end of the ladle;

[0022] The stopper rod actuator, which is connected to the stopper rod and controls the action of the stopper rod;

[0023] The ladle liquid level control system, in which the launder in the ladle liquid level control system corresponds to the liquid inlet end of the ladle; the controlled end of the stopper rod actuator is connected to the output end of the control system module in the ladle liquid level control system.

[0024] Further optimize the technical solution. The automatic casting system further includes:

[0025] A camera, which is set in an air-conditioned constant-temperature room above the casting pit, is used to monitor the liquid level of the casting pit; the output end of the camera is connected to the input end of the control system module, and the control system module is used to obtain the video stream captured by the camera, obtain the edge contour of the liquid in the casting pit through binary processing, and then calculate the percentage of the liquid surface area of the casting pit through a vision algorithm to judge the liquid level in the casting pit.

[0026] An automatic casting method, which is based on the above-mentioned automatic casting system, includes the following steps:

[0027] Use the liquid level detection mechanism to detect the liquid level in the ladle;

[0028] Compare the detection value of the liquid level detection mechanism with the set value through the control system module; when the detection value of the liquid level detection mechanism deviates from the set value, control the adjustment amplitude of the stopper rod and / or control the inclination angle of the holding furnace according to the deviation amplitude of the ladle liquid level.

[0029] Further optimize the technical solution. When the detection value of the liquid level detection mechanism deviates from the set value, control the adjustment amplitude of the stopper rod according to the deviation amplitude of the ladle liquid level, including the steps:

[0030] Set the reference value of the ladle liquid level height percentage as P%;

[0031] When the ladle liquid level height percentage deviates from the set value of P%, B = α·(P% - A); where: B—the servo hydraulic control point of the holding furnace, α—the servo hydraulic adjustment coefficient of the holding furnace, A—the ladle liquid level height percentage.

[0032] Further optimize the technical solution. When the detection value of the liquid level detection mechanism deviates from the set value, control the adjustment amplitude of the stopper rod according to the deviation amplitude of the ladle liquid level, including the steps:

[0033] Set the reference value of the ladle liquid level height percentage as P%;

[0034] Before the ladle liquid level fluctuation intervention control, the stopper rod height is set as m = k·(P% - h); after the ladle (1) liquid level fluctuation intervention control, the stopper rod height is set as m = k·x·(P% - h); where: m—the stopper rod height percentage, k—the stopper rod adjustment coefficient, h—the monitored casting pit liquid level height percentage, x—the ladle liquid level height correction coefficient, , A—the ladle liquid level height percentage.

[0035] Further optimize the technical solution, and further include the following steps:

[0036] Monitor the casting pool area through a camera, collect the video stream in a micro time period, obtain the liquid edge contour through binary processing, and then calculate the percentage of the liquid surface area through a vision algorithm as the criterion for judging the liquid height.

[0037] When the percentage of the actually monitored liquid surface area deviates from the set value, the control system module drives the stopper rod actuator to adjust the up and down height of the stopper rod to control the liquid casting speed.

[0038] The technical solution of the present invention has the following advantages:

[0039] 1. A ladle liquid level control system provided by the present invention monitors the liquid level in the ladle in real time through a liquid level detection mechanism. The control system module compares the real-time liquid level information in the ladle with the set liquid level information, controls the heat preservation drive mechanism, and then controls the swing angle of the holding furnace, thereby controlling the amount of liquid input into the ladle, stabilizing the liquid level in the ladle within a certain range, and reducing the influence of the liquid level fluctuation in the ladle on the liquid level in the casting pool. The present invention realizes the automatic and high-precision control of the heights of the ladle and the casting pool liquid levels, improving the casting quality.

[0040] 2. An automatic casting system provided by the present invention controls the liquid level in the ladle in real time through a ladle liquid level control system, and at the same time adjusts and corrects the adjustment range of the stopper rod based on the liquid level state in the ladle. The two cooperate with each other to jointly realize the automatic and high-precision control of the height of the casting pool liquid level, improving the casting quality.

[0041] 3. An automatic casting method provided by the present invention realizes the real-time adjustment of the liquid level in the ladle by controlling the adjustment range of the stopper rod and / or controlling the inclination angle of the holding furnace, and sets the height of the stopper rod based on the liquid level state in the ladle, enabling the stopper rod to adjust the liquid surface in the casting pool more precisely.

[0042] 4. An automatic casting method provided by the present invention abandons the method of judging the liquid level height by a reference line and adopts the method of monitoring the percentage of the copper liquid surface area in the monitoring area, which can judge the height of the copper liquid level with higher precision. Continuously monitor the height of the casting pool liquid level and continuously automatically adjust the height of the stopper rod to realize the closed-loop control of the height of the casting pool liquid level. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following will briefly introduce the drawings required for use in the description of the specific embodiments or the prior art. Obviously, the drawings in the following description are some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0044] Figure 1 Structural schematic diagram of the ladle liquid level control system provided by the present invention;

[0045] Figure 2 Structural schematic diagram of the automatic casting system provided by the present invention;

[0046] Figure 3 Video image of the casting pool processed by the binary method of the present invention.

[0047] Reference numerals:

[0048] 1. Ladle, 2. Camera, 3. Stopper rod, 4. Stopper rod actuator, 5. Servo motor system, 6. Runner, 7. Holding furnace, 71. Liquid outlet, 72. Holding furnace connecting arm, 8. Servo hydraulic system, 9. Casting pool, 10. Control system module, 11. Radar liquid level gauge, 12. Holding furnace positioning seat, 13. Rotating roller. Detailed implementation manners

[0049] The exemplary embodiments of the present disclosure will be described in more detail below with reference to the drawings. Although the exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided so that the present disclosure can be more thoroughly understood and the scope of the present disclosure can be fully conveyed to those skilled in the art.

[0050] It should be understood that the terms used herein are for the purpose of describing specific exemplary embodiments only and are not intended to be limiting. Unless otherwise clearly indicated in the context, the singular forms "a" and "an" as used herein may also include the plural forms. The terms "comprising", "including" and "having" are inclusive and thus specify the presence of the stated features, elements and / or components, but do not preclude the presence or addition of one or more other features, elements, components and / or combinations thereof.

[0051] Although terms such as first and second may be used in the text to describe multiple elements, components, regions, layers, and / or sections, these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or section from another region, layer, or section. Unless clearly indicated in the context, terms such as "first" and "second" and other numerical terms do not imply an order or sequence when used in the text. Additionally, in the description of the present invention, unless otherwise clearly specified and defined, the terms "arranged" and "connected" should be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or an integral connection; it may be directly connected or indirectly connected through an intermediate medium. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0052] For ease of description, spatial relative relationship terms may be used in the text to describe the relationship of one element or feature shown in the figure with respect to another element or feature. These relative relationship terms are, for example, "front", "rear", "middle", "inner", "longitudinal", "lateral", "side", "vertical", "outer", etc. Such spatial relative relationship terms are intended to include different orientations of the mechanism during use or operation other than the orientations depicted in the figure. For example, if the mechanism in the figure is flipped, an element described as "below other elements or features" or "beneath other elements or features" will then be oriented as "above other elements or features" or "over other elements or features". Therefore, the example term "below" can include both upper and lower orientations. The mechanism can be otherwise oriented (rotated 90 degrees or in other directions) and the spatial relative relationship descriptors used in the text are interpreted accordingly.

[0053] The existing casting system only identifies the liquid level height of the casting pool through a visible light camera, and controls the up and down movement of the stopper rod by the servo motor using the deviation between the monitored actual liquid level height and the preset reference line, thereby controlling the flow rate of the molten copper flowing out of the casting ladle. However, during the casting process, the existing casting system does not control the liquid level inside the ladle itself. The liquid level height inside the ladle itself will also fluctuate, and the liquid level inside the ladle will affect the molten copper flow rate, will affect the liquid level of the molten copper in the casting pool, and thus will affect the casting quality.

[0054] The existing casting system only focuses on the influence of the stopper rod on the flow rate of the molten copper for casting, but does not pay attention to the influence of the liquid level height inside the ladle itself on the flow rate of the molten copper for casting, which has certain limitations. Whether the liquid level in the casting pool is too high or too low has a fatal impact on the casting quality. Therefore, the existing casting system cannot achieve precise control of the flow rate of the molten copper for casting and the casting quality.

[0055] Based on this, the present invention provides an automatic casting system. By adding a radar to detect the liquid level height in the ladle and controlling the deflection angle change of the holding furnace, the liquid level height of the ladle is stabilized within a small range. The liquid level height of the ladle is obtained in real time, and the adjustment range of the stopper rod is corrected to achieve more accurate control of the copper liquid casting flow rate.

[0056] Embodiment 1

[0057] The specific embodiments of the present invention will be elaborated in detail below in combination with the ladle liquid level control system of the first aspect of the present invention.

[0058] It should be noted that the ladle liquid level control system of the first aspect of the present invention is only a preferred embodiment of the present invention. The ladle liquid level control system of the present invention can either adopt the ladle liquid level control system of the first aspect of the present invention or adopt other structures. For the convenience of elaboration, the following will be elaborated through the ladle liquid level control system of the first aspect of the present invention.

[0059] Combined with Figure 1 As shown, this embodiment discloses a ladle liquid level control system, including a liquid level detection mechanism, a holding furnace 7, a holding drive mechanism, and a control system module 10.

[0060] The liquid level detection mechanism is arranged directly above the ladle 1, and the liquid level detection mechanism is used to detect the liquid level of the ladle. More specifically, the liquid level detection mechanism is a radar level gauge 11, and other structures can also be adopted.

[0061] The holding furnace 7 is provided with a liquid outlet 71, and a flow channel 6 is arranged between the liquid outlet 71 and the liquid inlet end of the ladle 1. The flow channel 6 is used to transfer the liquid output from the holding furnace 7 into the ladle 1.

[0062] The holding drive mechanism is connected to the holding furnace 7, and the holding drive mechanism is used to drive the holding furnace 7 to swing to control the amount of liquid discharged from the liquid outlet 71.

[0063] The output end of the liquid level detection mechanism is connected to the input end of the control system module 10, and the controlled end of the holding drive mechanism is connected to the output end of the control system module 10. The control system module 10 is used to receive the detection information of the liquid level detection mechanism and control the operating state of the holding drive mechanism based on the detection information.

[0064] The above ladle liquid level control system monitors the liquid level in the ladle 1 in real time through the liquid level detection mechanism. The control system module 10 compares the real-time liquid level information in the ladle 1 with the set liquid level information, controls the heat preservation driving mechanism, and further controls the swing angle of the holding furnace 7, so as to control the amount of liquid input into the ladle 1, stabilize the liquid level in the ladle 1 within a certain range, and reduce the influence of the liquid level fluctuation in the ladle 1 on the liquid level of the casting pool 9. This embodiment realizes the automatic and high-precision control of the liquid levels of the ladle 1 and the casting pool 9, and improves the casting quality.

[0065] It should be noted that the liquid in this embodiment refers to molten metal, and the liquid is determined based on the material of the casting. When the casting is a copper part, the liquid is molten copper.

[0066] In some embodiments, the heat preservation driving mechanism includes a holding furnace positioning seat 12, a rotating roller 13, a holding furnace connecting arm 72, and a connecting arm driving member. At least two rotating rollers 13 are provided. The rotating rollers 13 support the holding furnace positioning seat 12, and the rotating rollers 13 are in rolling contact with the holding furnace positioning seat 12. Thus, the holding furnace positioning seat 12 can rotate in the circumferential direction. The holding furnace 7 is positioned on the holding furnace positioning seat 12, and when the holding furnace 7 rotates, it can drive the holding furnace positioning seat 12 to rotate. The holding furnace connecting arm 72 is connected to the side wall of the holding furnace 7 and is arranged on the opposite sides of the liquid outlet 71 of the holding furnace 7. The connecting arm driving member has a telescopic end. The telescopic end of the connecting arm driving member is hinged to the holding furnace connecting arm 72 and drives the holding furnace connecting arm 72 to move.

[0067] In this embodiment, when the connecting arm driving member performs telescopic movement, it can drive the holding furnace 7 and the holding furnace positioning seat 12 to swing through the holding furnace connecting arm 72, so as to control the liquid output of the liquid outlet 71 on the holding furnace 7. When the inclination angle of the holding furnace 7 becomes larger, the liquid output of the liquid outlet 71 on the holding furnace 7 will increase; when the inclination angle of the holding furnace 7 becomes smaller, the liquid output of the liquid outlet 71 on the holding furnace 7 will decrease.

[0068] In some embodiments, the connecting arm driving member is a hydraulic cylinder. The hydraulic cylinder is connected to the servo hydraulic system 8 and is controlled by the servo hydraulic system 8. The controlled end of the servo hydraulic system 8 is connected to the output end of the control system module 10. This embodiment only gives one structural form of the connecting arm driving member. In addition to being a hydraulic cylinder, the connecting arm driving member can also be other structures, such as a pneumatic cylinder, etc. The specific structure of the connecting arm driving member is not limited here.

[0069] In some embodiments, the bottom of the holding furnace positioning seat 12 is an arc surface, which is in rolling contact with the rotating roller 13, and the holding furnace positioning seat 12 rotates around its center. The holding furnace 7 is eccentrically arranged on the holding furnace positioning seat 12. Thus, when the connecting arm driving member drives the holding furnace 7, the holding furnace 7 will swing. In this embodiment, the liquid outlet 71 of the holding furnace 7 is eccentric. By controlling the deflection angle of the holding furnace 7 through the servo hydraulic system 8, the flow rate of the copper liquid flowing from the holding furnace 7 into the ladle 1 can be controlled.

[0070] Embodiment 2

[0071] The specific embodiments of the present invention will be elaborated in detail below in combination with the automatic casting system of the second aspect of the present invention.

[0072] It should be noted that the automatic casting system of the second aspect of the present invention is only a preferred embodiment of the present invention. The automatic casting system of the present invention can either adopt the automatic casting system of the second aspect of the present invention or adopt other structures. For the convenience of elaboration, the following will be elaborated through the automatic casting system of the second aspect of the present invention.

[0073] Combined with Figure 2 As shown, this embodiment discloses an automatic casting system, including a ladle 1, a casting pool 9, a stopper rod 3, a stopper rod actuator 4, and the ladle liquid level control system of Embodiment 1.

[0074] The ladle 1 has an inlet end and an outlet end. The top end of the ladle 1 is the inlet end, and the bottom end of the ladle 1 is the outlet end.

[0075] The casting pool 9 is arranged below the ladle 1 and corresponds to the outlet end of the ladle 1, and the liquid flows from the ladle 1 to the casting pool 9.

[0076] The stopper rod 3 is inserted into the ladle 1 to control the liquid outlet state of the outlet end of the ladle. When the stopper rod 3 moves upward, the opening of the outlet end of the ladle becomes larger, so that more liquid flows from the ladle 1 to the casting pool 9; when the stopper rod 3 moves downward, the opening of the outlet end of the ladle becomes smaller, thereby reducing the flow rate of the liquid flowing from the ladle 1 to the casting pool 9.

[0077] The stopper rod actuator 4 is connected to the stopper rod 3 and controls the movement of the stopper rod 3. The stopper rod actuator 4 includes a connecting rod connected to the stopper rod 3 and a servo motor system 5 connected to the connecting rod. The servo motor system 5 can control the movement of the connecting rod, and thus drive the movement of the stopper rod 3. The role of the stopper rod is equivalent to a valve. Its position affects the opening of the valve and the flow rate of the copper liquid casting. In this embodiment, the high-precision control of the stopper rod position is realized by the motor action of the servo motor system through the stopper rod execution mechanical structure (connecting rod).

[0078] The launder 6 in the ladle liquid level control system corresponds to the liquid inlet end of the ladle 1; the controlled end of the stopper rod actuator 4 is connected to the output end of the control system module 10 in the ladle liquid level control system.

[0079] In the above automatic casting system, the liquid level in the ladle 1 is controlled in real time through the ladle liquid level control system, and at the same time, the adjustment amplitude of the stopper rod 3 is adjusted and corrected based on the liquid level state in the ladle 1. The two cooperate with each other to jointly achieve the automatic and high-precision control of the liquid level height of the casting pool 9, improving the casting quality.

[0080] In some embodiments, the automatic casting system further includes a camera 2. The camera 2 is arranged above the casting pool 9, and the camera 2 is used to monitor the liquid level of the casting pool 9. The camera is located above the control room beside the casting machine. In an air-conditioned and temperature-controlled room, the casting pool 9 area is monitored through focusing, effectively avoiding the damage to the camera 2 caused by the too high temperature around the casting pool 9.

[0081] The output end of the camera 2 is connected to the input end of the control system module 10. The control system module 10 is used to obtain the video stream captured by the camera 2, obtain the liquid edge contour of the casting pool 9 through binary processing, and then calculate the percentage of the liquid surface area of the casting pool 9 through a vision algorithm to judge the liquid level of the liquid in the casting pool 9.

[0082] Embodiment 3

[0083] The specific embodiments of the present invention will be elaborated in detail below in combination with the automatic casting method of the third aspect of the present invention.

[0084] It should be noted that the automatic casting method of the third aspect of the present invention is only a preferred embodiment of the present invention. The automatic casting method of the present invention can be carried out by using the automatic casting method of the third aspect of the present invention, or can also be carried out by using other methods. For the convenience of elaboration, the following will be elaborated through the automatic casting method of the third aspect of the present invention.

[0085] This embodiment discloses an automatic casting method, which is based on the automatic casting system and includes the following steps:

[0086] S1. Detect the liquid level in the ladle 1 by using a liquid level detection mechanism.

[0087] S2. Compare the detection value of the liquid level detection mechanism with the set value through the control system module 10; when the detection value of the liquid level detection mechanism deviates from the set value, control the adjustment amplitude of the stopper rod and / or control the inclination angle of the holding furnace 7 according to the deviation amplitude of the ladle liquid level.

[0088] The above automatic casting method realizes the real-time adjustment of the liquid level in the ladle 1 by controlling the adjustment range of the stopper rod and / or the inclination angle of the holding furnace 7, and sets the height of the stopper rod 3 based on the liquid level state in the ladle 1, so that the stopper rod 3 can adjust the liquid level of the casting pool 9 more precisely.

[0089] In some embodiments, when the detected value of the liquid level detection mechanism deviates from the set value, the adjustment range of the stopper rod is controlled according to the deviation amplitude of the ladle liquid level, including the steps:

[0090] Set the reference value of the ladle 1 liquid level height percentage as P%.

[0091] Taking P% as 50% as an example, before the ladle 1 liquid level fluctuation intervenes in the control, the stopper rod height is set as m = k·(50% - h); after the ladle 1 liquid level fluctuation intervenes in the control, the stopper rod height is set as m = k·x·(50% - h); where: m - the stopper rod height percentage (0% - 100%), k - the stopper rod adjustment coefficient, h - the detected casting pool liquid level height percentage (0% - 100%), x - the ladle liquid level height correction coefficient, , A - the ladle liquid level height percentage (0% - 100%).

[0092] In this embodiment, the inside of the ladle 1 is a hollow cavity. During normal production, the lower part of the cavity is filled with molten copper, and the upper part is air. A radar level gauge 11 is added to the top of the ladle 1 to detect the liquid level height in the ladle 1. When the detected liquid level of the ladle 1 deviates from the set value, the adjustment range of the stopper rod 3 is multiplied by a correction coefficient according to the deviation amplitude of the ladle 1 liquid level. For example, when the ladle liquid level is 10% higher, the stopper rod adjustment range is reduced by 10%.

[0093] In some embodiments, in order to reduce the influence of the ladle liquid level fluctuation on the casting flow rate, when the detected value of the liquid level detection mechanism deviates from the set value, that is, when the detected liquid level of the ladle 1 deviates from the set value, the inclination angle of the holding furnace 7 is adjusted by controlling the holding drive mechanism according to the deviation amplitude of the ladle 1 liquid level to control the liquid level flowing into the ladle 1, including the steps:

[0094] Set the reference value of the ladle 1 liquid level height percentage as P%.

[0095] Taking P% as 50% as an example, when the ladle 1 liquid level height percentage deviates from the set value of 50%, B = α·(50% - A); where: B - the holding furnace servo hydraulic control point, α - the holding furnace servo hydraulic adjustment coefficient, A - the ladle liquid level height percentage.

[0096] In this embodiment, the positions of the servo hydraulic control points of the holding furnace are different, and the inclination angles of the holding furnace 7 are different, so as to control the inclination angle of the holding furnace 7. For example, when the radar level gauge 11 detects that the liquid level in the ladle 1 is low, the holding furnace 7 needs to increase the inclination angle to pour out more molten copper into the ladle 1; when the radar level gauge 11 detects that the liquid level in the ladle 1 is high, the holding furnace 7 needs to decrease the inclination angle to pour out less molten copper into the ladle 1.

[0097] In some embodiments, the automatic casting method further includes the following steps: monitoring the casting pool 9 area through the camera 2, collecting the video stream in a micro time period, obtaining the liquid edge contour through binary processing, and then calculating the percentage of the liquid surface area through a vision algorithm as the evaluation criterion for the liquid height. Since the molten copper in the casting pool 9 is continuously poured down, the upper surface of the molten copper is in a continuously fluctuating state, and the height values obtained by real-time acquisition fluctuate greatly, but the actual average liquid level height fluctuates not much, that is, the change in the upper area of the observed molten copper is not large. By monitoring the video stream in a micro time period through the camera and calculating the surface area obtained, the evaluation of the liquid level height is more accurate.

[0098] In this embodiment, the set reference surface area percentage value during debugging is set to 50%. When the percentage of the actually monitored liquid surface area deviates from 50%, the control system module 10 drives the stopper rod actuator 4 to adjust the up and down height of the stopper rod 3 to achieve the control of the liquid casting speed. In this embodiment, the liquid level height of the casting pool 9 is continuously monitored, and the height of the stopper rod 3 is continuously adjusted automatically to achieve the closed-loop control of the liquid level height of the casting pool 9.

[0099] Combined Figure 3 as shown Figure 3 is the video image of the casting pool processed by the binary method. When setting the liquid level height of 50% during debugging, several closed contours connected by pixel points can be set as shown Figure 3 The area of this closed contour is the liquid level height of the casting pool corresponding to the percentage of 50%. In this embodiment, the method of judging the liquid level height by the reference line is abandoned, and the method of monitoring the percentage of the molten copper surface area in the monitoring area is adopted, which can judge the molten copper liquid level height with higher precision.

[0100] Obviously, the above embodiments are only examples clearly described and not limitations on the implementation manners. For those of ordinary skill in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to enumerate all the implementation manners here. And the obvious changes or modifications derived therefrom are still within the protection scope of the present invention.

Claims

1. An automatic casting system, characterized in that, Comprising: A ladle (1), the ladle (1) having a liquid inlet end and a liquid outlet end; A casting pit (9), the casting pit (9) being arranged below the ladle (1) and corresponding to the liquid outlet end of the ladle (1); A stopper rod (3), the stopper rod (3) being inserted into the ladle (1) to control the liquid outlet state of the liquid outlet end of the ladle; A stopper rod actuator (4), the stopper rod actuator (4) being connected to the stopper rod (3) to control the movement of the stopper rod (3); A ladle liquid level control system, a launder (6) in the ladle liquid level control system corresponding to the liquid inlet end of the ladle (1); the controlled end of the stopper rod actuator (4) being connected to the output end of a control system module (10) in the ladle liquid level control system; The ladle liquid level control system includes: A liquid level detection mechanism, the liquid level detection mechanism being arranged directly above the ladle (1) for detecting the liquid level of the ladle; A holding furnace (7), the holding furnace (7) being provided with a liquid outlet (71), a launder (6) being arranged between the liquid outlet (71) and the liquid inlet end of the ladle (1); A holding drive mechanism, the holding drive mechanism being connected to the holding furnace (7) for driving the holding furnace (7) to swing to control the amount of liquid discharged from the liquid outlet (71); A control system module (10), the control system module (10) being configured to receive the detection information of the liquid level detection mechanism and control the operating state of the holding drive mechanism based on the detection information; An automatic casting method based on the automatic casting system described above, comprising the following steps: Using the liquid level detection mechanism to detect the liquid level in the ladle (1); Comparing the detection value of the liquid level detection mechanism with a set value through the control system module (10); when the detection value of the liquid level detection mechanism deviates from the set value, controlling the adjustment amplitude of the stopper rod and / or controlling the inclination angle of the holding furnace (7) according to the deviation amplitude of the ladle liquid level; When the detection value of the liquid level detection mechanism deviates from the set value, controlling the adjustment amplitude of the stopper rod according to the deviation amplitude of the ladle liquid level, including the steps of: Setting a reference value of the ladle (1) liquid level height percentage as P%; Before the intervention control of the ladle (1) liquid level fluctuation, the stopper rod height is set to m = k·(P% - h); after the intervention control of the ladle (1) liquid level fluctuation, the stopper rod height is set to m = k·x·(P% - h); where: m - the percentage of the stopper rod height, k - the stopper rod adjustment coefficient, h - the percentage of the monitored casting pool liquid level height, x - the ladle liquid level height correction coefficient, A - the percentage of the ladle liquid level height.

2. The automatic casting system according to claim 1, characterized in that, The holding drive mechanism includes: A holding furnace positioning seat (12), the holding furnace (7) being positioned on the holding furnace positioning seat (12); At least two rotating rollers (13), the rotating rollers (13) supporting the holding furnace positioning seat (12) and being in rolling contact with the holding furnace positioning seat (12); A holding furnace connecting arm (72), the holding furnace connecting arm (72) being connected to the side wall of the holding furnace (7) and being arranged on opposite sides of the holding furnace (7) with the liquid outlet (71); A connecting arm driving member, the connecting arm driving member having a telescopic end, the telescopic end of the connecting arm driving member being hinged to the holding furnace connecting arm (72) to drive the holding furnace connecting arm (72) to move.

3. The automatic casting system according to claim 2, characterized in that, The connecting arm driving member is a hydraulic cylinder; the hydraulic cylinder is connected to a servo hydraulic system (8) and controlled by the servo hydraulic system (8), the controlled end of the servo hydraulic system (8) being connected to the output end of the control system module (10).

4. The automatic casting system according to claim 2, wherein The bottom of the holding furnace positioning seat (12) is an arc surface. The bottom of the holding furnace positioning seat (12) is in rolling contact with the rotating roller (13), and the holding furnace positioning seat (12) rotates around its center; the holding furnace (7) is eccentrically arranged on the holding furnace positioning seat (12).

5. The automatic casting system according to claim 4, characterized in that, The automatic casting system further includes: A camera (2), the camera (2) is arranged in an air-conditioned constant temperature room above the casting pool (9), and the camera (2) is used to monitor the liquid level of the casting pool (9); the output end of the camera (2) is connected to the input end of the control system module (10), and the control system module (10) is used to obtain the video stream captured by the camera (2), obtain the liquid edge contour of the casting pool (9) through binary processing, and then calculate the percentage of the liquid surface area of the casting pool (9) through a vision algorithm to judge the liquid level in the casting pool (9).

6. The automatic casting system according to claim 1, characterized in that, When the detection value of the liquid level detection mechanism deviates from the set value, according to the deviation amplitude of the ladle liquid level, the inclination angle of the holding furnace (7) is adjusted by controlling the holding drive mechanism through the PID algorithm, including the steps of: Setting the reference value of the ladle (1) liquid level height percentage to P%; When the ladle (1) liquid level height percentage deviates from the set value of P%, B = α·(P% - A); where: B - the holding furnace servo hydraulic control point, α - the holding furnace servo hydraulic adjustment coefficient, A - the ladle liquid level height percentage.

7. The automatic casting system according to claim 1, characterized in that, It also includes the following steps: Monitoring the casting pool (9) area through the camera (2), collecting the video stream in a micro time period, obtaining the liquid edge contour through binary processing, and then calculating the percentage of the liquid surface area through a vision algorithm as the judgment standard for the liquid height; When the percentage of the actually monitored liquid surface area deviates from the set value, the control system module (10) drives the stopper rod actuator (4) to adjust the up and down height of the stopper rod (3) to control the liquid casting speed.

Images