System and method for automatically transferring molten aluminum into furnace

Abstract

The invention discloses a system and method for automatically transferring molten aluminum into a furnace, and particularly relates to the technical field of aluminum smelting automation. Initial information of the molten aluminum is collected through a sensor installed on a transfer trolley, and conveying safety analysis is carried out, so that it is ensured that the initial state of a molten aluminum ladle meets the safety conveying standard; in the transfer process, the system carries out swing analysis in real time, the speed and acceleration of the transfer trolley are dynamically adjusted based on the analysis result, and the liquid level fluctuation risk is reduced; after transferring is completed, the state of the molten aluminum in the smelting furnace and the state of the molten aluminum ladle on the transferring trolley are subjected to danger analysis, the danger index is generated by integrating the temperature difference, the liquid level fluctuation and the pressure difference, the dumping strategy is adaptively optimized based on the analysis result, and it is ensured that the molten aluminum is stably and safely poured into the smelting furnace; according to the method, the transportation strategy can be dynamically adjusted, the transportation safety of the molten aluminum in the high-temperature and complex environment is ensured, the requirement for manual intervention is reduced, and potential safety hazards caused by high temperature and splashing are reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of aluminum smelting automation, and more specifically, to a system and method for automatically transferring molten aluminum into a furnace. Background Art

[0002] Aluminum smelting is an important field in the modern metal processing industry. The production of aluminum mainly relies on electrolytic aluminum technology, which electrolyzes aluminum oxide into aluminum liquid at high temperature. In this process, the high temperature characteristics of aluminum liquid and its fluidity bring many technical challenges, especially in the process of transferring aluminum liquid from the electrolytic cell to large smelting furnaces or other processing units. How to effectively control liquid level fluctuations, temperature differences and transportation safety has become an important issue.

[0003] Traditional aluminum liquid transfer methods mostly rely on manual or semi-automatic equipment to transfer aluminum liquid from the smelting furnace to the transfer trolley, and then use the trolley to deliver the aluminum liquid to the predetermined location. However, due to the extremely high temperature and strong fluidity of aluminum liquid, there are the following problems in its transportation and dumping process: the temperature of the aluminum liquid in the smelting furnace may be greatly different from the temperature of the transfer trolley or other containers. The temperature difference may cause the rapid flow of the liquid to be unstable, and even produce local splashes or bubbles, making the dumping process a safety hazard. In addition, the temperature difference will cause the density of the aluminum liquid to change, resulting in inconsistent liquid flow state.

[0004] During the transportation of aluminum liquid, especially when the trolley is accelerating, decelerating or turning, the liquid level will fluctuate violently. This fluctuation will cause the liquid to be unstable, prone to splashing, overflowing and other dangerous situations, increase the difficulty of aluminum liquid transportation, and may threaten the operating environment and personnel safety. Traditional transportation equipment often lacks the ability of real-time monitoring and dynamic adjustment, and cannot effectively control fluctuations.

[0005] In the process of transferring and dumping aluminum liquid, traditional equipment usually requires a lot of manual monitoring and lacks automation and intelligent control methods. Such systems are prone to low efficiency and high workload when handling large amounts of aluminum liquid, and there is a risk of operational errors. In addition, traditional systems are often unable to adjust transportation parameters according to actual conditions, resulting in waste of resources and reduced production efficiency.

[0006] These problems not only reduce production efficiency and increase safety hazards, but also affect the consistency of aluminum liquid quality. In order to solve the above problems, a system and method for automatically transferring aluminum liquid into a furnace is proposed to ensure the safety, stability and efficiency of aluminum liquid during transportation and dumping. Summary of the invention

[0007] To achieve the above object, the present invention provides the following technical solutions:

[0008] The method for automatically transferring molten aluminum into a furnace comprises the following steps:

[0009] The sensors installed on the transfer cart collect the initial information of the aluminum liquid and conduct a preset transportation safety analysis to ensure that the initial state of the aluminum ladle formed by the aluminum liquid on the transfer cart meets the standards for safe transportation;

[0010] The transfer operation is carried out by a transfer vehicle, and swing analysis is performed in real time during the transfer operation. The transfer strategy is dynamically adjusted based on the swing analysis results;

[0011] After the transfer operation is completed, a risk analysis is performed based on the state of the molten aluminum in the smelting furnace and the current state of the molten aluminum ladle on the transfer cart. Based on the risk analysis results, the dumping strategy is adaptively optimized and adjusted, and the optimized dumping strategy is executed.

[0012] In a preferred embodiment, the initial information of the aluminum liquid includes the temperature, weight and real-time center of gravity position of the aluminum ladle formed by the aluminum liquid.

[0013] In a preferred embodiment, when the aluminum liquid is completely transferred to the transfer cart, multiple sampling is performed within a preset safe transportation judgment period, the temperature and weight of the aluminum ladle are determined based on the results of the multiple samplings, and the real-time center of gravity position corresponding to each sampling time point is recorded.

[0014] In a preferred embodiment, the transportation safety analysis refers to:

[0015] The temperature and weight of the aluminum ladle are compared with the preset temperature safety range and weight safety range. If the temperature and weight fall into the preset temperature safety range and weight safety range, a safety signal is generated, otherwise an abnormal signal is generated;

[0016] Based on the real-time center of gravity position corresponding to each sampling time point, a standard center of gravity position is preset, and the Euclidean distance between the real-time center of gravity position and the preset standard center of gravity position is calculated, and then the average value and standard deviation of all Euclidean distances are respectively obtained, and the average value and standard deviation of the Euclidean distance are respectively compared with the preset standard threshold value 1 and the standard threshold value 2. If the average value of the Euclidean distance is less than or equal to the preset standard threshold value 1 and the standard deviation is less than or equal to the preset standard threshold value 2, a safety signal is generated, otherwise an abnormal signal is generated;

[0017] When all the results of the transportation safety analysis are safety signals, it is judged that the initial state of the aluminum water bag formed by the aluminum liquid on the transfer car meets the standards for safe transportation.

[0018] The transfer operation of the transfer vehicle is divided into three stages, namely, the acceleration stage, the constant speed stage, and the deceleration stage, and it meets the following requirements: the distance length of the acceleration stage is less than or equal to the distance length of the deceleration stage.

[0019] In a preferred embodiment, swing analysis refers to:

[0020] The liquid level sensor installed on the transfer trolley collects real-time data of aluminum liquid level fluctuation, including fluctuation height, fluctuation frequency and liquid level inclination angle. The sampling period is set to T. The liquid level data collected in each period include fluctuation height, fluctuation frequency and liquid level inclination angle.

[0021] Then use the formula to calculate the swing index: ; Indicates the fluctuation height of the aluminum liquid level at time t, represents the frequency of liquid level fluctuation, It represents the inclination angle of the liquid surface fluctuation and the angle with the horizontal direction, which is used to evaluate the influence of the fluctuation direction. k is the weight coefficient of the fluctuation acceleration, which is used to adjust the influence of the liquid surface acceleration in the sway index. represents the acceleration of the liquid surface fluctuation, It is expressed as the second-order derivative of the change in liquid level, specifically: ; The sway index is used to evaluate the stability of the aluminum liquid level during transportation.

[0022] In a preferred embodiment, dynamically adjusting the transport strategy based on the swing analysis results refers to:

[0023] During the acceleration and deceleration phases, the acceleration is adjusted, and during the uniform speed phase, the uniform speed is adjusted to meet the following conditions:

[0024] ; is the preset sway index safety threshold, is the preset maximum value of the permissible swing index. is the acceleration or uniform velocity before adjustment, is the adjusted acceleration or uniform velocity.

[0025] In a preferred embodiment, performing risk analysis based on the state of molten aluminum in the smelting furnace and the current state of the molten aluminum ladle on the transfer vehicle refers to:

[0026] The following parameters are collected by sensors installed on the melting furnace and transfer trolley:

[0027] Current aluminum liquid temperature in the smelting furnace , Temperature of aluminum water bag in transfer car , the maximum height of the liquid level fluctuation of the aluminum ladle , Aluminum water ladle liquid level fluctuation frequency , the total weight of aluminum water bag ;

[0028] Calculate the temperature difference coefficient between the smelting furnace and the aluminum ladle of the transfer car :

[0029] ; is the thermal expansion coefficient of aluminum, The temperature of aluminum water bag in the transfer car The density of aluminum liquid under the temperature curve can be expressed as:

[0030] ; is the reference temperature The density of aluminum liquid is is the preset density temperature coefficient of aluminum;

[0031] Calculation of the Fluctuation Coefficient of the Liquid Level of the Aluminum Ladle in the Transfer Car :

[0032] ; is the acceleration due to gravity, is the liquid height of the aluminum water bag in the transfer trolley, is the mass of the liquid surface in the aluminum ladle, ;

[0033] Calculate the difference coefficient of liquid pressure between the smelting furnace and the aluminum ladle on the transfer trolley :

[0034] ; is the temperature of aluminum liquid in the melting furnace The density of aluminum liquid under is the liquid height of aluminum liquid in the smelting furnace;

[0035] Calculate the danger level WX:

[0036] ; It is a preset constant reference value used for normalization.

[0037] In a preferred embodiment, the system for automatically transferring molten aluminum into a furnace comprises:

[0038] The data acquisition module collects the initial information of the aluminum liquid through sensors installed on the transfer cart;

[0039] The transportation safety analysis module performs preset transportation safety analysis to ensure that the initial state of the aluminum ladle formed by the aluminum liquid on the transfer trolley meets the standards for safe transportation;

[0040] The transfer module performs transfer operations through a transfer cart, performs swing analysis in real time during the transfer operation, and dynamically adjusts the transfer strategy based on the swing analysis results;

[0041] The hazard analysis module performs hazard analysis based on the state of the molten aluminum in the smelting furnace and the current state of the molten aluminum ladle on the transfer cart before dumping;

[0042] Adaptive optimization module, which performs adaptive optimization and adjustment of dumping strategies based on hazard analysis results;

[0043] The execution module converts the optimized and adjusted dumping strategy into a parameter combination recognized by the transfer vehicle, so that the transfer vehicle executes the optimized and adjusted dumping strategy.

[0044] Technical effects and advantages of the present invention:

[0045] The present invention can effectively reduce the risk of overturning, splashing and overflowing during the transportation of molten aluminum by installing sensors on the transfer cart to monitor key parameters such as the temperature, liquid level fluctuation and pressure of the molten aluminum in real time. Through comprehensive analysis of the temperature difference coefficient, liquid level fluctuation coefficient and pressure difference coefficient, the system can dynamically adjust the transportation strategy to ensure the transportation safety of molten aluminum in high temperature and complex environments. Before the molten aluminum is dumped, the system performs a hazard analysis based on real-time data, evaluates the temperature difference, liquid level fluctuation and pressure of the molten aluminum, and generates a hazard index. On this basis, the system dynamically adjusts the dumping speed, angle and flow rate through an adaptive optimization module, making the molten aluminum dumping process smoother, reducing splashing caused by uneven flow, and ensuring the stability of the dumping operation.

[0046] The present invention adopts adaptive optimization control, which can automatically adjust the dumping strategy of the transfer cart according to real-time monitoring data without manual intervention, significantly reducing the dependence on operators. This automated control not only improves production efficiency, but also reduces the risk of manual misoperation, which helps to reduce production costs. The present invention dynamically adjusts the acceleration, uniform speed and dumping speed, so that the transfer cart can complete the transportation and dumping of molten aluminum with high efficiency within a safe range. The system can adaptively adjust the speed according to the fluctuation of the liquid level, avoid excessive deceleration or frequent adjustments, and improve transportation efficiency. In addition, the system reduces the loss of molten aluminum and waste of resources by accurately controlling the flow rate and speed during the dumping process, thereby improving resource utilization.

[0047] The present invention comprehensively considers multiple factors such as temperature difference, liquid level fluctuation and pressure difference, and converts them into a parameter combination that can be recognized by the system, so that the transfer vehicle can automatically adapt and adjust under different working conditions, which is conducive to achieving safe and stable transportation and dumping operations, and improving the adaptability and reliability of the system. Since the present invention reduces the need for manual intervention and significantly reduces the risk of aluminum liquid splashing during the dumping process, it can improve the working environment of on-site operators and reduce the safety hazards caused by high temperature and splashing. This improvement not only helps to ensure personnel safety, but also meets the requirements of environmental protection and safe production. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] In order to facilitate understanding by those skilled in the art, the present invention is further described below in conjunction with the accompanying drawings;

[0049] Figure 1 It is a schematic diagram of the automatic aluminum liquid transfer method into the furnace in the present invention.

[0050] Figure 2 It is a schematic diagram of the automatic aluminum liquid transport system into the furnace in the present invention.

[0051] Figure 3 It is a schematic diagram of the structure of the dumping device in the present invention. DETAILED DESCRIPTION

[0052] 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.

[0053] Reference Figure 1 - Figure 3 The following examples are obtained:

[0054] Example 1

[0055] Reference Figure 1 The method for automatically transferring molten aluminum into a furnace comprises the following steps:

[0056] The sensors installed on the transfer cart collect the initial information of the aluminum liquid and conduct a preset transportation safety analysis to ensure that the initial state of the aluminum ladle formed by the aluminum liquid on the transfer cart meets the standards for safe transportation; before the transfer cart is started, confirm that the initial state of the aluminum liquid meets the standards for safe transportation. By collecting the temperature, weight and center of gravity position information of the aluminum liquid through sensors and conducting a transportation safety analysis, it can be ensured that the aluminum ladle is in a safe condition at the beginning stage to avoid potential dangerous situations. For example, if the temperature of the aluminum liquid is too high, the weight exceeds the safe load, or the center of gravity deviates from the standard position, it may cause overturning or fluctuation instability during transportation. Through the initial safety analysis, these risks can be identified and eliminated in a timely manner to ensure the stability and safety of the transportation process.

[0057] The transfer operation is carried out by a transfer cart, and a real-time swing analysis is performed during the transfer operation. The transfer strategy is dynamically adjusted based on the swing analysis results. When the transfer cart is moving, the stability of the aluminum liquid during the transfer process needs to be guaranteed. Due to acceleration, deceleration and road inequality, the aluminum liquid surface will shake (sway), which may cause liquid overflow or the cart to tip over. The liquid level sensor installed on the cart monitors the fluctuation height, fluctuation frequency and tilt angle of the aluminum liquid surface in real time, and the swing index can be calculated to evaluate the shaking situation in real time. The speed and acceleration of the cart are dynamically adjusted based on the swing analysis results to ensure that the swing amplitude is within a safe range. This step reduces the risk of liquid surface shaking by dynamically adjusting the strategy to ensure the safety and stability of the transportation process.

[0058] After the transfer operation is completed, a hazard analysis is performed based on the state of the molten aluminum in the smelting furnace and the current state of the molten aluminum ladle on the transfer trolley. Based on the results of the hazard analysis, the dumping strategy is adaptively optimized and adjusted, and the optimized dumping strategy is executed. After the transfer operation is completed, a hazard analysis is performed on the current state of the molten aluminum ladle in the smelting furnace and the transfer trolley. The purpose is to conduct a risk assessment before dumping the molten aluminum to ensure the safety of the dumping operation. In this step, the system analyzes factors such as the temperature difference between the smelting furnace and the trolley, the liquid level fluctuation, and the liquid level pressure difference, and generates a hazard level value. This analysis helps to determine whether splashing, pressure fluctuations, or other potential hazards will occur during the pouring of molten aluminum into the smelting furnace. Through hazard analysis, risk information during the dumping of molten aluminum can be obtained, providing a basis for optimizing the dumping strategy. In order to implement the safest and most stable strategy during the dumping process, based on the results of the hazard analysis, the system will adaptively adjust the preset parameters such as the dumping speed, angle, and flow rate. Adaptive optimization ensures the safety of the pouring process: if the temperature difference is large, the liquid level fluctuation is high, or the pressure difference is large, the system will automatically reduce the pouring speed, adjust the angle, or delay the pouring process to avoid aluminum splashing or other unstable situations. The optimized pouring strategy ensures that the aluminum liquid can be poured smoothly into the melting furnace, avoiding accidents and improving the safety of the entire transfer process.

[0059] It should be noted that the adaptive algorithm can automatically adjust the preset operating parameters such as dumping speed, angle, flow rate, etc. according to the real-time hazard analysis results (hazard level value) to ensure that the process of pouring into the smelting furnace is smoother and safer. In this application scenario, the core function of the adaptive algorithm is to continuously adjust the system parameters according to the real-time feedback (such as the hazard level value) to keep the dumping operation safe under changing conditions. Typical adaptive algorithm implementations may include: Adaptive adjustment based on PID control: By adjusting the gain (proportional, integral, differential) of the dumping speed or angle, the system remains stable based on the real-time hazard level feedback. Fuzzy logic adaptive control: According to the level of the hazard level value, the dumping strategy is divided into different rule sets, and fuzzy logic control is used to adjust the dumping parameters. This method is particularly suitable for continuous changes in the hazard level value. Adaptive model based on machine learning: Use machine learning models (such as neural networks) to learn from historical data, predict the optimal dumping parameters under certain dangerous conditions, and adaptively adjust the dumping strategy according to real-time conditions. Adaptive algorithms are widely used technologies in control engineering and automation systems. They are considered as prior art in this invention and will not be repeated, and the specific choice of adaptive algorithm depends on the user.

[0060] The initial information of the aluminum liquid includes the temperature, weight and real-time center of gravity position of the aluminum ladle into which the aluminum liquid is gathered. The temperature of the aluminum liquid directly affects its physical properties (such as fluidity and density) and safety. Excessive temperature may cause thermal damage to the transfer trolley or peripheral equipment, and increase the risk of aluminum liquid splashing, especially in the case of large temperature differences. When the aluminum liquid is poured into the melting furnace, if the temperature difference is too large, splashing or sputtering may occur due to thermal stress. Temperature information is also used to ensure that the state of the aluminum liquid is within a safe range. If the temperature exceeds the preset safety range, it may need to be cooled or adjusted before transportation to reduce the danger during transportation.

[0061] The weight of the aluminum ladle is the core load of the transfer trolley. The load capacity of the transfer trolley is limited. If the weight of the aluminum ladle exceeds the load range of the trolley, it will increase the risk of mechanical failure and even cause the trolley to tip over. During the transfer operation, weight information can help the system determine the acceleration and speed to prevent unsafe situations caused by excessive inertia. Weight also affects the acceleration and deceleration characteristics of the trolley. Too much weight may require additional measures to reduce shaking.

[0062] The center of gravity of the aluminum ladle affects its stability during transportation. The aluminum liquid in the aluminum ladle is fluid. If the center of gravity is offset, especially when turning, accelerating or decelerating, it may cause the aluminum liquid to tilt, shake or overflow during transportation, affecting the balance of the transfer trolley. By monitoring the real-time center of gravity position, the distribution state of the aluminum liquid can be evaluated to ensure its stability.

[0063] When the aluminum liquid is completely transferred to the transfer vehicle, multiple sampling is performed within the preset safe transportation judgment period, and the temperature and weight of the aluminum ladle are determined based on the results of multiple sampling, and the real-time center of gravity position corresponding to each sampling time point is recorded. Transportation safety analysis refers to: comparing the temperature and weight of the aluminum ladle with the preset temperature safety range and weight safety range respectively. If the temperature and weight fall into the preset temperature safety range and weight safety range respectively, a safety signal is generated, otherwise an abnormal signal is generated;

[0064] Based on the real-time center of gravity position corresponding to each sampling time point, a standard center of gravity position is preset, and the Euclidean distance between the real-time center of gravity position and the preset standard center of gravity position is calculated, and then the average value and standard deviation of all Euclidean distances are respectively obtained, and the average value and standard deviation of the Euclidean distance are respectively compared with the preset standard threshold value 1 and the standard threshold value 2. If the average value of the Euclidean distance is less than or equal to the preset standard threshold value 1 and the standard deviation is less than or equal to the preset standard threshold value 2, a safety signal is generated, otherwise an abnormal signal is generated;

[0065] When all the results of the transportation safety analysis are safety signals, it is judged that the initial state of the aluminum water bag formed by the aluminum liquid on the transfer car meets the standards for safe transportation.

[0066] The aluminum liquid is fluid during the transfer process and will be affected by factors such as ambient temperature and vibration. A single sampling may not accurately reflect the true state of the aluminum ladle, but multiple sampling can capture the changing trend of the aluminum liquid state within a certain period of time.

[0067] By sampling temperature, weight and center of gravity multiple times, the system can obtain more stable and accurate data, making transportation safety analysis more reliable and avoiding misjudgments due to abnormal instantaneous conditions.

[0068] Temperature and weight directly affect the carrying capacity of the transfer trolley and the safety of the aluminum liquid. Too high temperature or too much weight will increase the risk of transfer, so by comparing the temperature and weight (the average of multiple samplings) with the preset safety range, it is possible to promptly identify whether there is a situation that exceeds the safety range. If the temperature or weight exceeds the safety range, the system will generate an abnormal signal to prompt the operator or system to take cooling, weight reduction or other safety measures to avoid dangerous situations.

[0069] The center of gravity of aluminum liquid directly affects its stability during transportation. The fluidity of aluminum liquid can cause the center of gravity to shift, thus affecting the balance of the trolley. If the center of gravity deviates too much from the preset standard position, it may shake or tilt during transportation, increasing the risk of aluminum liquid overflowing or the trolley tipping over. Euclidean distance is used to measure the degree of deviation of the center of gravity of each sampling from the standard position. By taking the average and standard deviation of multiple sampling results, the stability of the center of gravity position can be more comprehensively evaluated. These statistical data are compared with the preset thresholds. If the conditions are met, the center of gravity position is considered stable and a safety signal is generated; otherwise, an abnormal signal is generated. This analysis method avoids misjudgment caused by abnormal single sampling data and improves the reliability and accuracy of the judgment.

[0070] Generate safety signal: When all sampling data of temperature, weight and center of gravity are within the safe range, the system generates a safety signal. This means that the initial state of the aluminum ladle is stable and meets the standards for safe transportation, and subsequent transportation operations can be carried out.

[0071] Generate abnormal signal: If any data exceeds the safety range, an abnormal signal will be generated. The abnormal signal prompts the system or operator to adjust the state of the aluminum liquid (such as cooling, reducing the load or adjusting the center of gravity) to ensure that transportation is started only when safety conditions are met.

[0072] The transfer operation of the transfer trolley is divided into three stages, namely the acceleration stage, the uniform speed stage, and the deceleration stage, and the following conditions are met: the distance of the acceleration stage is less than or equal to the distance of the deceleration stage. During the aluminum liquid transfer process, the acceleration and deceleration stages are stages with greater shaking and instability. The aluminum liquid is fluid on the trolley, and any sudden acceleration or deceleration will cause the liquid surface to shake, thereby increasing the risk of liquid splashing or the trolley tilting. If the acceleration or deceleration is too fast, a greater inertial force will be generated on the aluminum liquid, causing the liquid surface to fluctuate violently, leading to danger. Constraining the distance of the acceleration stage and the deceleration stage, especially making the distance of the acceleration stage less than or equal to the distance of the deceleration stage, can effectively reduce the shaking amplitude of the liquid on the trolley and maintain the relative stability of the liquid surface.

[0073] Due to the fluidity of molten aluminum, the trolley needs enough distance to decelerate smoothly during the deceleration stage. If the deceleration stage is shorter, the trolley will have to decelerate quickly in a shorter distance, which will cause the center of gravity of the molten aluminum to tilt forward, increasing the risk of tipping or liquid spillage. Ensure that the length of the deceleration stage is greater than or equal to the length of the acceleration stage, so that the trolley gradually decelerates over a longer distance, and the speed can be smoothly reduced to zero, thereby reducing the impact on the molten aluminum and preventing the liquid level from fluctuating more. This arrangement helps the trolley to stop smoothly and keep the molten aluminum stable at the end of the transportation.

[0074] In the mechanical system, sudden acceleration and deceleration will have a great impact on the motor, brake system and suspension system of the trolley. Excessive acceleration and deceleration will increase the wear of the system and reduce the service life of the equipment. By controlling the distance of the acceleration and deceleration stages, the acceleration and deceleration process of the trolley can be eased, so that the trolley can start and stop under more gentle conditions, reduce damage to the mechanical system, and improve the reliability and service life of the system.

[0075] Setting the distance of the acceleration phase to be less than or equal to the distance of the deceleration phase ensures that the vehicle can start and stop in a stable state, avoiding safety hazards caused by sudden acceleration or deceleration. At the same time, this operation makes the transportation process more controllable and improves the efficiency of transportation. Users can reasonably arrange the ratio of acceleration, constant speed and deceleration distance to maximize the transportation speed and efficiency while ensuring safety.

[0076] Swing analysis refers to:

[0077] The liquid level sensor installed on the transfer trolley collects real-time data of aluminum liquid level fluctuation, including fluctuation height, fluctuation frequency and liquid level inclination angle. The sampling period is set to T. The liquid level data collected in each period include fluctuation height, fluctuation frequency and liquid level inclination angle.

[0078] Then use the formula to calculate the swing index:

[0079] ; Indicates the fluctuation height of the aluminum liquid level at time t, represents the frequency of liquid level fluctuation, It represents the inclination angle of the liquid surface fluctuation and the angle with the horizontal direction, which is used to evaluate the influence of the fluctuation direction. k is the weight coefficient of the fluctuation acceleration, which is used to adjust the influence of the liquid surface acceleration in the sway index. represents the acceleration of the liquid surface fluctuation, It is expressed as the second-order derivative of the change in liquid level, specifically:

[0080] ; The sway index is used to evaluate the stability of the aluminum liquid surface during transportation. The formula includes multiple factors such as fluctuation height, fluctuation frequency, fluctuation inclination angle, and fluctuation acceleration. These factors work together to determine the fluctuation of the aluminum liquid surface, so they need to be considered comprehensively. It has an important influence on the stability of the liquid surface. As a correction factor, the influence of the fluctuation direction on stability can be adjusted according to the directionality of the liquid surface inclination, which is more accurate for evaluating the actual impact of the fluctuation.

[0081] An acceleration term is introduced into the formula It is the second derivative of the fluctuation height, which is used to indicate the rate of change of the fluctuation of the liquid level. The greater the acceleration, the more rapid the change of the speed of the liquid level fluctuation, thus increasing the risk. The influence of acceleration on the overall sway index can be adjusted by the weighting coefficient k.

[0082] The swing index YB can comprehensively evaluate the severity of liquid level fluctuations through parameters such as fluctuation height, frequency, angle and acceleration. The higher the index, the more severe the liquid level fluctuations, and more stringent control measures need to be taken. During transportation, the swing index can provide real-time feedback on the shaking of the liquid surface, helping the system to dynamically adjust the acceleration or speed to reduce liquid level fluctuations and ensure the stability of the transportation process.

[0083] Excessive fluctuations in the aluminum liquid level can cause liquid splashing or the trolley to overturn. The introduction of the swing index can provide early warning of potential risks. According to the changes in the swing index, the system can make timely adjustments to avoid the risks of liquid leakage and overturning.

[0084] The larger the swing index YB is, the more violent the liquid level fluctuation is, which is specifically reflected in the following aspects: Large fluctuation amplitude: that is, the liquid level changes greatly, and the liquid may produce an unstable tilt in the trolley, increasing the risk of liquid splashing. High fluctuation frequency: The increase in the fluctuation frequency of the liquid level means that the liquid shakes frequently in a short period of time, which may cause the trolley to be unstable and increase the risk of transportation. Large deviation in the fluctuation direction: The increase in the tilt angle means that the direction of the liquid level fluctuation is far away from the horizontal, and the liquid may tilt more in the trolley. Such fluctuations will affect the balance of the trolley. Large fluctuation acceleration: The greater the acceleration, the faster the liquid level changes and the more violent the shaking, further increasing the instability of transportation.

[0085] Dynamically adjusting the transport strategy based on the swing analysis results means:

[0086] During the acceleration and deceleration phases, the acceleration is adjusted, and during the uniform speed phase, the uniform speed is adjusted to meet the following conditions:

[0087] ; It is the preset sway index safety threshold, indicating the safe range of aluminum liquid shaking during transportation. The preset maximum value of the permissible sway index. Exceeding this value indicates that the sway is extremely severe and there is a great danger. is the acceleration or uniform velocity before adjustment, is the adjusted acceleration or uniform speed. The liquid surface of aluminum liquid may shake violently due to acceleration, deceleration and other external interference during transportation. By dynamically adjusting the acceleration and uniform speed according to the swing index YB, the speed can be slowed down or adjusted in time when the liquid surface is unstable to avoid liquid splashing or overturning. By setting the safety threshold and the maximum allowable value, the system can make advance adjustments when the swing index exceeds the safety range but has not yet reached a dangerous state. This preventive adjustment strategy can ensure that the trolley gradually reduces its speed when the swing amplitude increases, instead of suddenly reducing the speed, avoiding further impact on the liquid caused by drastic speed changes.

[0088] Adjustment factors in formulas It is a linear decreasing coefficient. When the swing index YB approaches Imax, the adjusted acceleration or speed tj will gradually approach zero. This design ensures that when the shaking approaches the dangerous value, the speed will be significantly reduced, thereby reducing the impact of the shaking. When the swing index YB is low, the adjustment coefficient is close to 1, indicating that the current acceleration or speed adjustment is small, and the transfer vehicle can continue to run at a faster speed to ensure efficiency. Only when the swing index YB exceeds the safety threshold Isafe will the system begin to significantly reduce the speed to prevent excessive deceleration from affecting transportation efficiency. By dynamically calculating the swing index YB and adjusting the acceleration and uniform speed, the system can make adjustments based on real-time data, showing strong adaptability and flexibility, adapting to different transportation conditions and external interference, and while ensuring safety, avoiding excessive deceleration and frequent adjustments, balancing efficiency and safety, so that the transfer vehicle can maintain a higher speed as much as possible within a safe range.

[0089] The hazard analysis based on the state of the molten aluminum in the smelting furnace and the current state of the molten aluminum ladle on the transfer car refers to:

[0090] The following parameters are collected by sensors installed on the melting furnace and transfer trolley:

[0091] Current aluminum liquid temperature in the smelting furnace , Temperature of aluminum water bag in transfer car , the maximum height of the liquid level fluctuation of the aluminum ladle , Aluminum water ladle liquid level fluctuation frequency , the total weight of aluminum water bag ;

[0092] Calculate the temperature difference coefficient between the smelting furnace and the aluminum ladle of the transfer car :

[0093] ; is the thermal expansion coefficient of aluminum, which is used to describe the effect of temperature change on the volume expansion of aluminum liquid. The temperature of aluminum water bag in the transfer car The density of aluminum liquid under the temperature condition, considering the influence of temperature change on density, can be expressed as:

[0094] ; is the reference temperature The density of aluminum liquid is It is the preset density temperature coefficient of aluminum. The temperature difference coefficient reflects the temperature difference between the melting furnace and the transfer trolley. Too large a temperature difference may cause splashing of aluminum liquid or thermal stress problems during pouring.

[0095] Calculation of the Fluctuation Coefficient of the Liquid Level of the Aluminum Ladle in the Transfer Car :

[0096] ; is the acceleration due to gravity, is the liquid height of the aluminum water bag in the transfer trolley, is the mass of the liquid surface in the aluminum ladle, The liquid level fluctuation coefficient indicates the degree of shaking of the aluminum liquid in the transfer trolley. Excessive fluctuation may cause liquid overflow or the trolley to tip over, so this parameter is used to assess the risk of fluctuation.

[0097] Calculate the difference coefficient of liquid pressure between the smelting furnace and the aluminum ladle on the transfer trolley :

[0098] ; is the temperature of aluminum liquid in the melting furnace The density of aluminum liquid under The liquid height of the aluminum liquid in the melting furnace; the liquid surface pressure difference coefficient is used to measure the liquid surface pressure difference between the melting furnace and the aluminum ladle. Too large a pressure difference will cause liquid instability during pouring, increasing the risk of splashing or overflowing.

[0099] Calculate the danger level WX:

[0100] ; is the preset constant reference value for normalization. The influence of temperature difference and liquid level fluctuation is combined by the square root method to ensure that the influence of each factor is taken into account; and the liquid level pressure difference is expressed by an exponential term, so that when the pressure difference increases, the danger level value WX will increase significantly. This nonlinear design reflects the different degrees of influence of various factors on safety. The calculated WX can be used to determine whether the dumping process needs to be adjusted. When WX exceeds the preset danger threshold, the system can take measures such as reducing the dumping speed or adjusting the angle to ensure safety. When WX does not exceed the preset danger threshold, the system can follow the preset dumping strategy set to reduce the adjustment computing power, such as the dumping angle of 60 degrees, the dumping speed of 0.5 m / s and other standard dumping parameters under preset safety conditions. By analyzing the temperature difference, fluctuation amplitude and pressure difference, potential risks can be discovered and handled in advance before dumping, avoiding unsafe situations during the aluminum liquid dumping process and improving the stability of the entire system. When WX is small, it means that the temperature difference, fluctuation and pressure difference are all within the safe range, and the dumping process can proceed normally. When WX increases, it indicates that one or more factors of temperature difference, fluctuation or pressure difference are close to or beyond the safe range, and the risk of the dumping process increases. At this time, the system may need to make adjustments, such as reducing the dumping speed, changing the dumping angle, or even suspending the operation.

[0101] Example 2

[0102] Reference Figure 2 , automatic aluminum liquid transfer into the furnace system, including:

[0103] The data acquisition module collects the initial information of the aluminum liquid through sensors installed on the transfer cart;

[0104] The transportation safety analysis module performs preset transportation safety analysis to ensure that the initial state of the aluminum ladle formed by the aluminum liquid on the transfer trolley meets the standards for safe transportation;

[0105] The transfer module performs transfer operations through a transfer cart, performs swing analysis in real time during the transfer operation, and dynamically adjusts the transfer strategy based on the swing analysis results;

[0106] The hazard analysis module performs hazard analysis based on the state of the molten aluminum in the smelting furnace and the current state of the molten aluminum ladle on the transfer cart before dumping;

[0107] Adaptive optimization module, which performs adaptive optimization and adjustment of dumping strategies based on hazard analysis results;

[0108] The execution module converts the optimized and adjusted dumping strategy into a parameter combination recognized by the transfer vehicle, so that the transfer vehicle executes the optimized and adjusted dumping strategy.

[0109] With the support of the hazard analysis module and the adaptive optimization module, the system optimizes and adjusts various parameters during the dumping process. These adjustments are calculated based on real-time monitoring data (such as temperature difference, liquid level fluctuation, and pressure difference) to ensure the safety and stability of the aluminum liquid dumping process. The core task of the execution module is to convert these optimized dumping strategies into specific parameter combinations that can be executed by the transfer cart. These parameters are the basis for the trolley to perform dumping operations, ensuring that it can be poured into the smelting furnace safely and stably under different environmental conditions. Once the optimized parameter combination is generated, the execution module will automatically send these parameters to the control system of the transfer cart, so that the trolley follows the optimized strategy when dumping without manual intervention.

[0110] The parameter combination for dumping strategy transformation usually includes:

[0111] Pour speed: The pour speed determines the flow rate of aluminum liquid into the melting furnace. Too fast a pour speed may cause liquid splashing, while too slow a pour speed will affect efficiency. The optimized pour speed is determined based on data such as swing index, temperature difference and liquid surface pressure difference to ensure that the speed is within a safe range while meeting production efficiency requirements.

[0112] Pour angle: The pour angle determines the tilt direction of the aluminum liquid outflow, and has a direct impact on the flow path and stability of the liquid. Through optimization, the system can set a suitable pour angle so that the aluminum liquid can be poured smoothly into the melting furnace without side splashing.

[0113] Tipping acceleration: Tipping acceleration controls the initial acceleration and deceleration of the tipping process to ensure smooth flow of molten aluminum and avoid shaking caused by sudden acceleration or deceleration. The optimized tipping acceleration parameters can help the trolley to complete the action smoothly in different tipping stages (starting, acceleration, constant speed, deceleration).

[0114] Dumping flow rate: Adjust the flow rate of aluminum liquid poured into the melting furnace per unit time to meet production needs. According to the current state of the melting furnace (such as temperature and liquid level) and the results of the hazard analysis, the system can set the appropriate flow rate to prevent the risk of overflow caused by pouring the liquid too quickly.

[0115] Pour start and end time: Through precise pour start and end time control, the duration of aluminum liquid pouring into the melting furnace can be determined. Combined with parameters such as temperature and liquid level fluctuation, the system can set the best pouring time period to ensure the appropriate pouring amount and avoid liquid level fluctuation affecting the stability of the pouring process.

[0116] Reference Figure 3 , 2 is an AGV trolley, 1 is a base placed on the AGV trolley 2, i.e., the transfer trolley, 3 is a flip bracket, 4 is a power mechanism for driving the flip bracket 3 to rotate, and the power mechanism can be a commonly used oil cylinder or other component that can drive the flip bracket 3 to rotate, so that the aluminum water bag on the flip bracket 3 can be dumped into the smelting furnace. The present invention sets a dumping device composed of a base 1, a flip bracket 3, a power mechanism 4 and an AGV trolley 2, i.e., a transfer trolley. In the description of the present invention, the use principle of the transfer trolley is assumed to be a description of its integrated dumping device. The aluminum water in the aluminum water bag is poured into the smelting furnace, and the aluminum water bag is placed on the flip bracket 3 of the dumping device through a lifting mechanism, and a transfer trolley is added to achieve the purpose of automatic transportation. The dumping device is pre-set with a load capacity of: being able to dump 30 tons of molten aluminum. Through the automatic aluminum liquid transfer system of the present invention, the trolley can perform the transfer operation after taking the aluminum liquid bag from the warehouse, and pour the molten aluminum next to the furnace. Moreover, multiple smelting furnaces can be used together with one dumping device without manual intervention, thus freeing up manpower and improving the safety and reliability of the overall automatic aluminum liquid transfer into the furnace.

[0117] The above formulas are all dimensionless and numerical calculations. The formula is a formula for the most recent real situation obtained by collecting a large amount of data and performing software simulation. The preset parameters in the formula are set by technicians in this field according to actual conditions.

[0118] It should be understood that in the various embodiments of the present application, the size of the serial numbers of the above-mentioned processes does not mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present application.

[0119] Those of ordinary skill in the art will appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professional and technical personnel can use different methods to implement the described functions for each specific application, but such implementation should not be considered to be beyond the scope of this application.

[0120] Those skilled in the art can clearly understand that, for the convenience and brevity of description, the specific working processes of the systems, devices and units described above can refer to the corresponding processes in the aforementioned method embodiments and will not be repeated here.

[0121] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art who is familiar with the present technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

Claims

1. A method for automatically transferring molten aluminum into a furnace, characterized in that: The following steps are involved: The sensors installed on the transfer cart collect the initial information of the aluminum liquid and conduct a preset transportation safety analysis to ensure that the initial state of the aluminum ladle formed by the aluminum liquid on the transfer cart meets the standards for safe transportation; The transfer operation is carried out by a transfer vehicle, and swing analysis is performed in real time during the transfer operation. The transfer strategy is dynamically adjusted based on the swing analysis results; After the transfer operation is completed, a risk analysis is performed based on the state of the molten aluminum in the smelting furnace and the current state of the molten aluminum ladle on the transfer cart. Based on the risk analysis results, the dumping strategy is adaptively optimized and adjusted, and the optimized dumping strategy is executed.

2. The method for automatically transporting molten aluminum into a furnace according to claim 1, characterized in that: The initial information of the aluminum liquid includes the temperature, weight and real-time center of gravity position of the aluminum ladle formed by the aluminum liquid.

3. The method for automatically transporting molten aluminum into a furnace according to claim 2, characterized in that: When the aluminum liquid is completely transferred to the transfer cart, multiple sampling is carried out within the preset safe transportation judgment period, the temperature and weight of the aluminum ladle are determined based on the results of multiple sampling, and the real-time center of gravity position corresponding to each sampling time point is recorded.

4. The method for automatically transporting molten aluminum into a furnace according to claim 3, characterized in that: Transportation safety analysis refers to: The temperature and weight of the aluminum ladle are compared with the preset temperature safety range and weight safety range. If the temperature and weight fall into the preset temperature safety range and weight safety range, a safety signal is generated, otherwise an abnormal signal is generated; Based on the real-time center of gravity position corresponding to each sampling time point, a standard center of gravity position is preset, and the Euclidean distance between the real-time center of gravity position and the preset standard center of gravity position is calculated, and then the average value and standard deviation of all Euclidean distances are respectively obtained, and the average value and standard deviation of the Euclidean distance are respectively compared with the preset standard threshold value 1 and the standard threshold value 2. If the average value of the Euclidean distance is less than or equal to the preset standard threshold value 1 and the standard deviation is less than or equal to the preset standard threshold value 2, a safety signal is generated, otherwise an abnormal signal is generated; When all the results of the transportation safety analysis are safety signals, it is judged that the initial state of the aluminum water bag formed by the aluminum liquid on the transfer car meets the standards for safe transportation.

5. The method for automatically transporting molten aluminum into a furnace according to claim 4, characterized in that: The transfer operation of the transfer vehicle is divided into three stages, namely, the acceleration stage, the constant speed stage, and the deceleration stage, and it meets the following requirements: the distance length of the acceleration stage is less than or equal to the distance length of the deceleration stage.

6. The method for automatically transporting molten aluminum into a furnace according to claim 5, characterized in that: Swing analysis refers to: The liquid level sensor installed on the transfer trolley collects real-time data of aluminum liquid level fluctuation, including fluctuation height, fluctuation frequency and liquid level inclination angle. The sampling period is set to T. The liquid level data collected in each period include fluctuation height, fluctuation frequency and liquid level inclination angle. Then use the formula to calculate the swing index: ; Indicates the fluctuation height of the aluminum liquid level at time t, represents the frequency of liquid level fluctuation, It represents the inclination angle of the liquid surface fluctuation and the angle with the horizontal direction, which is used to evaluate the influence of the fluctuation direction. k is the weight coefficient of the fluctuation acceleration, which is used to adjust the influence of the liquid surface acceleration in the sway index. represents the acceleration of the liquid surface fluctuation, It is expressed as the second-order derivative of the change in liquid level, specifically: ; The sway index is used to evaluate the stability of the aluminum liquid level during transportation.

7. The method for automatically transporting molten aluminum into a furnace according to claim 6, characterized in that: Dynamically adjusting the transport strategy based on the swing analysis results means: During the acceleration and deceleration phases, the acceleration is adjusted, and during the uniform speed phase, the uniform speed is adjusted to meet the following conditions: ; is the preset sway index safety threshold, is the preset maximum value of the permissible swing index. is the acceleration or uniform velocity before adjustment, is the adjusted acceleration or uniform velocity.

8. The method for automatically transporting molten aluminum into a furnace according to claim 7, characterized in that: The hazard analysis based on the state of the molten aluminum in the smelting furnace and the current state of the molten aluminum ladle on the transfer car refers to: The following parameters are collected by sensors installed on the melting furnace and transfer trolley: Current aluminum liquid temperature in the smelting furnace , Temperature of aluminum water bag in transfer car , the maximum height of the liquid level fluctuation of the aluminum ladle , Aluminum water ladle liquid level fluctuation frequency , the total weight of aluminum water bag ; Calculate the temperature difference coefficient between the smelting furnace and the aluminum ladle of the transfer car : ; is the thermal expansion coefficient of aluminum, The temperature of aluminum water bag in the transfer car The density of aluminum liquid under the temperature curve can be expressed as: ; is the reference temperature The density of aluminum liquid is is the preset density temperature coefficient of aluminum; Calculation of the Fluctuation Coefficient of the Liquid Level of the Aluminum Ladle in the Transfer Car : ; is the acceleration due to gravity, is the liquid height of the aluminum water bag in the transfer trolley, is the mass of the liquid surface in the aluminum ladle, ; Calculate the difference coefficient of liquid pressure between the smelting furnace and the aluminum ladle on the transfer trolley : ; is the temperature of aluminum liquid in the melting furnace The density of aluminum liquid under is the liquid height of aluminum liquid in the smelting furnace; Calculate the danger level WX: ; It is a preset constant reference value used for normalization.

9. A system for automatically transporting molten aluminum into a furnace, which is implemented based on the method for automatically transporting molten aluminum into a furnace according to any one of claims 1 to 8, characterized in that: include: The data acquisition module collects the initial information of the aluminum liquid through sensors installed on the transfer cart; The transportation safety analysis module performs preset transportation safety analysis to ensure that the initial state of the aluminum ladle formed by the aluminum liquid on the transfer trolley meets the standards for safe transportation; The transfer module performs transfer operations through a transfer cart, performs swing analysis in real time during the transfer operation, and dynamically adjusts the transfer strategy based on the swing analysis results; The hazard analysis module performs hazard analysis based on the state of the molten aluminum in the smelting furnace and the current state of the molten aluminum ladle on the transfer cart before dumping; Adaptive optimization module, which performs adaptive optimization and adjustment of dumping strategies based on hazard analysis results; The execution module converts the optimized and adjusted dumping strategy into a parameter combination recognized by the transfer vehicle, so that the transfer vehicle executes the optimized and adjusted dumping strategy.

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