Automatic aluminum liquid transfer into furnace system and method

Abstract

The present invention discloses an automatic aluminum liquid transfer and charging system and method, which specifically relates to the field of aluminum smelting automation technology. By collecting the initial information of the aluminum liquid through sensors installed on the transfer trolley and conducting a transportation safety analysis, it is ensured that the initial state of the aluminum ladle meets the safety transportation standards. During the transfer process, the system conducts a real-time swing analysis, dynamically adjusts the speed and acceleration of the transfer trolley based on the analysis results, and reduces the risk of liquid level fluctuations. After the transfer is completed, a hazard analysis is carried out on the state of the aluminum liquid in the smelting furnace and the state of the aluminum ladle on the transfer trolley. By comprehensively considering the temperature difference, liquid level fluctuations, and pressure difference, a hazard index is generated, and the pouring strategy is adaptively optimized based on the analysis results to ensure that the aluminum liquid is poured into the smelting furnace smoothly and safely. The present invention can dynamically adjust the transportation strategy, ensure the transportation safety of aluminum liquid in high-temperature and complex environments, reduce the need for manual intervention, and reduce the safety hazards caused by high temperature and splashing.

Description

Technical Field

[0001] The present invention relates to the technical field of aluminum smelting automation. More specifically, the present invention relates to an aluminum liquid automatic transfer and charging system and method. Background Art

[0002] Aluminum smelting is an important field in the modern metal processing industry. The production of aluminum mainly relies on the electrolytic aluminum technology, which electrolyzes alumina into aluminum liquid at high temperatures. During this process, the high-temperature characteristics and fluidity of the aluminum liquid bring many technical challenges. Especially during the process of transferring the aluminum liquid from the electrolytic cell to a large smelting furnace or other processing units, how to effectively control the liquid level fluctuation, temperature difference, and transportation safety has become an important issue.

[0003] Traditional aluminum liquid transfer methods mostly rely on manual or semi-automatic equipment to transfer the aluminum liquid from the smelting furnace to the transfer trolley, and then the trolley transports the aluminum liquid to the predetermined location. However, due to the extremely high temperature and strong fluidity of the aluminum liquid, there are the following problems during its transportation and pouring: There may be a large temperature difference between the aluminum liquid temperature in the smelting furnace and 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 cause local splashing or bubbling, making the pouring process have potential safety hazards. In addition, the temperature difference will cause the density change of the aluminum liquid, resulting in inconsistent liquid flow states.

[0004] During the transfer of the aluminum liquid, especially when the trolley accelerates, decelerates, or turns, the liquid level will fluctuate violently. This kind of fluctuation will cause the liquid to be unstable, and it is easy to appear dangerous situations such as splashing and overflowing, increasing the difficulty of aluminum liquid transfer and posing a threat to the operating environment and personnel safety. Traditional transportation equipment often lacks the ability of real-time monitoring and dynamic adjustment and cannot effectively control the fluctuation.

[0005] During the transfer and pouring of the aluminum liquid, traditional equipment usually requires a large amount of manual monitoring and lacks automated and intelligent control means. Such a system is prone to problems such as low efficiency and high workload when dealing with a large amount of aluminum liquid, and there is also a risk of operation errors. In addition, traditional systems often cannot adjust the transportation parameters according to the actual situation, resulting in waste of resources and reduced production efficiency.

[0006] These problems not only reduce the production efficiency, increase the potential safety hazards, but also affect the consistency of the aluminum liquid quality. To solve the above problems, an aluminum liquid automatic transfer and charging system and method are proposed here to ensure the safety, stability, and efficiency of the aluminum liquid during transportation and pouring. Summary of the Invention

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

[0008] Automatic aluminum liquid transfer into furnace method, comprising the following steps:

[0009] Collect the initial information of the aluminum liquid through the sensors installed on the transfer trolley and conduct a preset transportation safety analysis to ensure that the initial state of the ladle formed by the aluminum liquid on the transfer trolley meets the safety transportation standards;

[0010] Conduct a transfer operation through the transfer trolley, and conduct a swing analysis in real time during the transfer operation, and dynamically adjust the transfer strategy based on the swing analysis results;

[0011] After the transfer operation is completed, conduct a hazard analysis based on the state of the aluminum liquid in the melting furnace and the current state of the ladle on the transfer trolley, and adaptively optimize and adjust the pouring strategy based on the hazard analysis results and execute the optimized pouring strategy.

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

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

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

[0015] Compare the temperature and weight of the 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;

[0016] Based on the real-time centroid position corresponding to each sampling time point, there is a preset standard centroid position, calculate the Euclidean distance between the real-time centroid position and the preset standard centroid position, and then calculate the average value and standard deviation of all Euclidean distances respectively. Compare the average value and standard deviation of the Euclidean distance with the preset standard threshold one and standard threshold two respectively. If the average value of the Euclidean distance is less than or equal to the preset standard threshold one and the standard deviation is less than or equal to the preset standard threshold two, 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 ladle formed by the aluminum liquid on the transfer trolley meets the safety transportation standards.

[0018] When the transfer trolley conducts a transfer operation, it is divided into three stages, namely the acceleration stage, the constant speed stage, and the deceleration stage, and it satisfies that: 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, the swing analysis refers to:

[0020] Collecting real-time data on the fluctuation of the molten aluminum liquid level through a liquid level sensor installed on the transfer cart, including the fluctuation height, fluctuation frequency, and liquid level tilt angle. Assuming the sampling period is T, the liquid level data collected in each period includes the fluctuation height, fluctuation frequency, and liquid level tilt angle;

[0021] Then using the formula to calculate the swing index:

[0022] ; represents the fluctuation height of the molten aluminum liquid level at time t, represents the frequency of the liquid level fluctuation, represents the tilt angle of the liquid level fluctuation, the angle with the horizontal direction, used to evaluate the influence of the fluctuation direction, k is the weight coefficient of the fluctuation acceleration, used to adjust the influence of the liquid level acceleration on the swing index, represents the acceleration of the liquid level fluctuation, represents the second derivative of the change in the liquid level height, specifically:

[0023] ; is the swing index, and the swing index is used to evaluate the stability of the molten aluminum liquid level during the transfer process.

[0024] In a preferred embodiment, dynamically adjusting the transfer strategy based on the swing analysis result refers to:

[0025] During the acceleration phase and the deceleration phase, adjusting the acceleration, and during the constant speed phase, adjusting the constant speed, satisfying the following conditions:

[0026] ; is the preset swing index safety threshold, is the preset maximum allowable swing index, is the acceleration or constant speed before adjustment, is the acceleration or constant speed after adjustment.

[0027] In a preferred embodiment, performing a hazard analysis based on the state of the molten aluminum in the melting furnace and the current state of the ladle on the transfer cart refers to:

[0028] Collecting the following parameters through sensors installed in the melting furnace and on the transfer cart:

[0029] The current temperature of the molten aluminum in the melting furnace , the temperature of the ladle on the transfer cart , the maximum value of the liquid level fluctuation height of the ladle 、The liquid level fluctuation frequency of the molten aluminum ladle 、The total weight of the molten aluminum ladle ;

[0030] Calculate the temperature difference coefficient between the melting furnace and the molten aluminum ladle on the transfer trolley :

[0031] ; is the coefficient of thermal expansion of aluminum, is the temperature of the molten aluminum ladle on the transfer trolley The density of the molten aluminum at, based on the temperature curve, can be expressed as:

[0032] ; is the reference temperature The density of the molten aluminum at, is the preset density temperature coefficient of aluminum;

[0033] Calculate the liquid level fluctuation coefficient of the molten aluminum ladle on the transfer trolley :

[0034] ; is the acceleration due to gravity, is the liquid height of the molten aluminum ladle on the transfer trolley, is the mass of the liquid level in the molten aluminum ladle, ;

[0035] Calculate the liquid level pressure difference coefficient between the melting furnace and the molten aluminum ladle on the transfer trolley :

[0036] ; is the density of the molten aluminum in the melting furnace at The density of the molten aluminum at, is the liquid height of the molten aluminum in the melting furnace;

[0037] Calculate the danger level value WX:

[0038] ; is the preset constant reference value for normalization.

[0039] In a preferred embodiment, the automatic molten aluminum transfer into furnace system includes:

[0040] A data acquisition module that collects the initial information of the molten aluminum through sensors installed on the transfer trolley;

[0041] A transportation safety analysis module that performs a preset transportation safety analysis to ensure that the initial state of the molten aluminum ladle formed by the molten aluminum on the transfer trolley meets the standards of safe transportation;

[0042] Transfer module, which conducts transfer operations through a transfer trolley and performs swing analysis in real time during the transfer operation, and dynamically adjusts the transfer strategy based on the swing analysis results;

[0043] Hazard analysis module, which conducts hazard analysis based on the state of the molten aluminum in the smelting furnace and the current state of the ladle on the transfer trolley before pouring;

[0044] Adaptive optimization module, which adaptively optimizes and adjusts the pouring strategy based on the hazard analysis results;

[0045] Execution module, which converts the optimized and adjusted pouring strategy into a parameter combination recognizable by the transfer trolley, enabling the transfer trolley to execute the optimized and adjusted pouring strategy.

[0046] Technical effects and advantages of the present invention:

[0047] By installing sensors on the transfer trolley, the present invention can monitor key parameters such as the temperature, liquid level fluctuation, and pressure of the molten aluminum in real time, effectively reducing the risks of overturning, splashing, and overflowing during the transportation of molten aluminum. Through the 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 pouring the molten aluminum, the system conducts 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 pouring speed, angle, and flow rate through the adaptive optimization module, making the pouring process of the molten aluminum more stable, reducing the splashing phenomenon caused by uneven flow, and ensuring the stability of the pouring operation.

[0048] The present invention adopts adaptive optimization control, which can automatically adjust the pouring strategy of the transfer trolley 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 human error, helping to reduce production costs. By dynamically adjusting the acceleration, uniform speed, and pouring speed, the present invention enables the transfer trolley to complete the transportation and pouring of molten aluminum with high efficiency within a safe range. The system can adaptively adjust the speed according to the liquid level fluctuation, avoiding excessive deceleration or frequent adjustment, and improving the transportation efficiency. In addition, by precisely controlling the flow rate and speed during the pouring process, the system reduces the loss of molten aluminum and resource waste, improving the resource utilization rate.

[0049] The present invention comprehensively considers various factors such as temperature difference, liquid level fluctuation, and pressure difference, and converts them into a parameter combination that the system can recognize, enabling the transfer trolley to automatically adapt and adjust under different working conditions, facilitating the realization of safe and stable transportation and dumping operations, and enhancing the adaptability and reliability of the system. Since the present invention reduces the need for manual intervention and significantly reduces the risk of molten aluminum 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

[0050] For the convenience of those skilled in the art to understand, the present invention will be further described below in conjunction with the accompanying drawings;

[0051] Figure 1 is the schematic diagram of the principle of the method for automatically transferring molten aluminum into the furnace in the present invention.

[0052] Figure 2 is the schematic diagram of the principle of the system for automatically transferring molten aluminum into the furnace in the present invention.

[0053] Figure 3 is the schematic structural diagram of the dumping device in the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0054] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0055] Refer to Figure 1 - Figure 3 to obtain the following embodiments:

[0056] Embodiment 1

[0057] Refer to Figure 1 , the method for automatically transferring molten aluminum into the furnace includes the following steps:

[0058] 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.

[0059] 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.

[0060] 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 ladle on the transfer cart. Based on the results of the hazard analysis, the pouring strategy is adaptively optimized and the optimized pouring strategy is executed. After the transfer operation is completed, a hazard analysis is performed on the current states of the smelting furnace and the ladle on the transfer cart. The purpose is to conduct a risk assessment before pouring the molten aluminum to ensure the safety of the pouring operation. In this step, the system analyzes factors such as the temperature difference, liquid level fluctuation, and liquid level pressure difference between the smelting furnace and the cart, and generates a hazard level value. This analysis helps to determine whether splashing, pressure fluctuations, or other potential hazards will occur during the process of pouring the molten aluminum into the smelting furnace. Through the hazard analysis, risk information during the pouring of the molten aluminum can be obtained, providing a basis for optimizing the pouring strategy. To implement the safest and most stable strategy during the pouring process, based on the results of the hazard analysis, the system adaptively adjusts preset parameters such as the pouring speed, angle, and flow rate. The adaptive optimization ensures the safety of the pouring process: if the temperature difference is large, the liquid level fluctuation amplitude 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 splashing of the molten aluminum or other unstable situations. Execute the optimized pouring strategy to ensure that the molten aluminum can be poured smoothly into the smelting furnace, avoid accidents, and improve the safety of the entire transfer-into-furnace process.

[0061] It should be noted that: The adaptive algorithm can automatically adjust preset operation parameters such as the pouring speed, angle, and flow rate according to the real-time hazard analysis results (hazard level value) to ensure a smoother and safer process of pouring into the smelting furnace. In this application scenario, the core function of the adaptive algorithm is to continuously adjust the system parameters according to real-time feedback (such as the hazard level value) to keep the pouring operation safe under changing conditions. Typical adaptive algorithm implementations may include: Adaptive regulation based on PID control: By adjusting the gains (proportional, integral, derivative) of the pouring speed or angle, the system is kept stable based on the real-time hazard level value feedback. Fuzzy logic adaptive control: According to the levels of the hazard level value, the pouring strategy is divided into different rule sets, and fuzzy logic control is used to adjust the pouring parameters. This method is particularly suitable for continuous changes in the hazard level value. Adaptive model based on machine learning: Using a machine learning model (such as a neural network) to learn from historical data, predict the optimal pouring parameters under certain hazardous conditions, and adaptively adjust the pouring strategy according to the real-time situation. Adaptive algorithms are widely used technologies in control engineering and automation systems. In the present invention, they are regarded as prior art and will not be elaborated further, and the specific choice of adaptive algorithm depends on the user.

[0062] The initial information of the molten aluminum includes the temperature, weight, and real-time center of gravity position of the ladle formed by the molten aluminum. The temperature of the molten aluminum directly affects its physical properties (such as fluidity and density) and safety. Excessive temperature may cause thermal damage to the transfer trolley or surrounding equipment, and at the same time increase the risk of molten aluminum splashing, especially in the case of large temperature differences. When the molten aluminum is poured into the melting furnace, if the temperature difference is too large, splashing or sputtering may occur due to thermal stress. The temperature information is also used to ensure that the state of the molten aluminum is within the safe range. If the temperature exceeds the preset safe range, it may need to be cooled or adjusted before transportation to reduce the danger during transportation.

[0063] The weight of the ladle is the core load of the transfer trolley. The load capacity of the transfer trolley is limited. If the weight of the ladle exceeds the carrying range of the trolley, it will increase the risk of mechanical failure and even cause the trolley to tip over. During the transfer operation, the weight information can help the system determine the acceleration and speed to prevent unsafe situations caused by excessive inertia. The weight also affects the acceleration and deceleration characteristics of the trolley. Too large a weight may require additional measures to reduce the sway.

[0064] The center of gravity position of the ladle affects its stability during the transfer process. The molten aluminum in the ladle is fluid. If the center of gravity position shifts, especially during turning, accelerating, or decelerating, it may cause the molten aluminum to tilt, sway, or spill during transportation, affecting the balance of the transfer trolley. By monitoring the real-time center of gravity position, the distribution state of the molten aluminum can be evaluated to ensure its stability.

[0065] When the molten aluminum is completely transferred to the transfer trolley, multiple samples are taken within a preset safe transportation judgment period. Based on the results of multiple samples, the temperature and weight of the ladle are determined, and the real-time center of gravity position corresponding to each sampling time point is recorded. The conveying safety analysis refers to: comparing the temperature and weight of the 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.

[0066] Based on the real-time center of gravity position corresponding to each sampling time point, a standard center of gravity position is preset. Calculate the Euclidean distance between the real-time center of gravity position and the preset standard center of gravity position. Then, calculate the average value and standard deviation of all Euclidean distances respectively. Compare the average value and standard deviation of the Euclidean distances with the preset standard threshold one and standard threshold two respectively. If the average value of the Euclidean distance is less than or equal to the preset standard threshold one and the standard deviation is less than or equal to the preset standard threshold two, a safety signal is generated; otherwise, an abnormal signal is generated.

[0067] 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.

[0068] 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.

[0069] 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.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] 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.

[0074] When the transfer cart performs the transfer operation, it is divided into three stages: the acceleration stage, the constant speed stage, and the deceleration stage, and it satisfies that the distance length of the acceleration stage is less than or equal to the distance length of the deceleration stage. During the transfer of molten aluminum, the acceleration and deceleration stages are the stages with relatively large shaking and instability. Molten aluminum has fluidity on the cart, and any sudden acceleration or deceleration will cause the liquid surface to shake, thus increasing the risk of liquid splashing or the cart tipping. If the acceleration or deceleration is too fast, a greater inertial force will act on the molten aluminum, causing the liquid surface to fluctuate violently and leading to danger. Constraining the distance lengths of the acceleration stage and the deceleration stage, especially making the distance length of the acceleration stage less than or equal to the distance length of the deceleration stage, can effectively reduce the shaking amplitude of the liquid on the cart and maintain the relative stability of the liquid surface.

[0075] Due to the fluidity of the molten aluminum, the cart needs sufficient distance to decelerate smoothly during the deceleration stage. If the distance of the deceleration stage is short, the cart will have to decelerate quickly within a short distance, which will cause the center of gravity of the molten aluminum to tilt forward, increasing the risk of tipping over or liquid spilling. Ensuring that the distance length of the deceleration stage is greater than or equal to the distance length of the acceleration stage allows the cart to decelerate gradually over a longer distance, smoothly reducing the speed to zero, thereby reducing the impact on the molten aluminum and preventing the liquid surface from fluctuating violently. This arrangement helps the cart to stop smoothly and keeps the molten aluminum stable at the end of the transportation.

[0076] In a mechanical system, sudden acceleration and deceleration will have a greater impact on the motor, braking system, and suspension system of the cart. Too violent acceleration and deceleration will increase the wear of the system and reduce the service life of the equipment. By controlling the distances of the acceleration and deceleration stages, the acceleration and deceleration processes of the cart can be alleviated, enabling the cart to complete startup and stop under smoother conditions, reducing damage to the mechanical system, and improving the reliability and service life of the system.

[0077] Setting the distance length of the acceleration stage to be less than or equal to the distance length of the deceleration stage ensures that the cart can operate in a stable state during startup and stop, avoiding potential safety hazards caused by sudden acceleration or deceleration. At the same time, this operation makes the transportation process more controllable and improves the transportation efficiency. Users can, by reasonably arranging the ratios of the acceleration, constant speed, and deceleration distances, improve the transportation speed and efficiency as much as possible on the premise of ensuring safety.

[0078] The swing analysis refers to:

[0079] By means of the liquid surface sensor installed on the transfer cart, real-time data of the molten aluminum liquid surface fluctuation are collected, including the fluctuation height, fluctuation frequency, and liquid surface tilt angle. Let the sampling period be T, and the liquid surface data collected within each period include the fluctuation height, fluctuation frequency, and liquid surface tilt angle;

[0080] Then use the formula to calculate the swing index:

[0081] ; 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:

[0082] ; 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] When the swing index YB is larger, it indicates that the liquid surface fluctuates more violently, which is specifically reflected in the following aspects: Larger fluctuation amplitude: That is, the change in the liquid surface height is larger, and the liquid may cause unstable tilting in the trolley, increasing the risk of liquid splashing. Higher fluctuation frequency: The increase in the fluctuation frequency of the liquid surface means that the liquid sloshes frequently in a short period of time, which may cause the trolley to be unstable and increase the danger of transportation. Larger deviation of the fluctuation direction: The increase in the tilt angle indicates that the fluctuation direction of the liquid surface is far from horizontal, and the liquid may tilt more in the trolley. Such fluctuations will affect the balance of the trolley. Larger fluctuation acceleration: The larger the acceleration, the faster the change speed of the liquid surface height, and the more violent the sloshing, further increasing the instability of transportation.

[0087] Dynamically adjusting the transfer strategy based on the swing analysis results means:

[0088] During the acceleration stage and the deceleration stage, adjust the acceleration, and during the uniform speed stage, adjust the uniform speed, satisfying the following conditions:

[0089] ; is the preset swing index safety threshold, indicating the safe range of the sloshing of the molten aluminum during transportation, is the preset maximum allowable swing index. Exceeding this value indicates extremely violent sloshing and greater danger, is the acceleration or uniform speed before adjustment, is the acceleration or uniform speed after adjustment. During the transportation of the molten aluminum, due to acceleration, deceleration and other external interferences, the liquid surface may slosh violently. Dynamically adjusting the acceleration and uniform speed according to the swing index YB can slow down or adjust the speed in time when the liquid surface is found to be unstable, avoiding liquid splashing or overturning. By setting the safety threshold and the maximum allowable value, the system can make a premature adjustment when the swing index exceeds the safe range but has not reached the dangerous state. This preventive adjustment strategy can ensure that the trolley gradually reduces the speed when the swing amplitude increases, rather than suddenly reducing the speed, avoiding further impact on the liquid caused by violent speed changes.

[0090] The adjustment factor in the formula is a linearly decreasing coefficient. When the swing index YB approaches Imax, the adjusted acceleration or speed tj will gradually approach zero. This design can ensure that when the swaying approaches the dangerous value, the speed will be significantly reduced, thereby reducing the impact caused by the swaying. 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 trolley can continue to run at a relatively fast speed to ensure efficiency. Only when the swing index YB exceeds the safety threshold Isafe will the system start to significantly reduce the speed to prevent excessive deceleration from affecting the 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 self-adaptability and flexibility, adapting to different transportation conditions and external interferences, and while ensuring safety, avoiding excessive deceleration and frequent adjustments, balancing efficiency and safety, so that the transfer trolley can maintain a relatively high speed within the safe range as much as possible.

[0091] Performing a hazard analysis based on the state of the molten aluminum in the smelting furnace and the current state of the ladle on the transfer trolley means:

[0092] Collecting the following parameters through sensors installed on the smelting furnace and the transfer trolley:

[0093] The current temperature of the molten aluminum in the smelting furnace and the temperature of the ladle on the transfer trolley the maximum value of the liquid level fluctuation height of the ladle the liquid level fluctuation frequency of the ladle the total weight of the ladle ;

[0094] Calculating the temperature difference coefficient between the smelting furnace and the ladle on the transfer trolley :

[0095] ; is the thermal expansion coefficient of aluminum, used to describe the influence of temperature change on the volume expansion of molten aluminum, is the temperature of the ladle on the transfer trolley the density of the molten aluminum at

[0096] ; is the reference temperature the density of the molten aluminum at is the preset density temperature coefficient of aluminum; the temperature difference coefficient reflects the temperature difference between the smelting furnace and the transfer trolley, and too large a temperature difference may cause splashing of the molten aluminum or thermal stress problems during pouring.

[0097] Calculating the liquid level fluctuation coefficient of the ladle on the transfer trolley :

[0098] ; is the acceleration due to gravity, is the liquid height of the ladle on the transfer trolley, is the mass of the liquid surface in the ladle, ; The liquid level fluctuation coefficient represents the degree of sloshing of the molten aluminum in the transfer trolley. Excessive fluctuations may cause the liquid to overflow or the trolley to tip over. Therefore, the risk of fluctuations is evaluated through this parameter.

[0099] Calculate the liquid level pressure difference coefficient between the melting furnace and the ladle on the transfer trolley :

[0100] ; is the temperature of the molten aluminum in the melting furnace is the density of the molten aluminum at is the liquid height of the molten aluminum in the melting furnace; The liquid level pressure difference coefficient is used to measure the liquid level pressure difference between the melting furnace and the ladle. Excessive pressure difference will cause liquid instability during pouring, increasing the risk of splashing or overflowing.

[0101] Calculate the danger degree value WX:

[0102] ; is a preset constant reference value for normalization. The effects of temperature difference and liquid level fluctuation are combined by squaring and taking the square root to ensure that the influence of each factor is taken into account; while the liquid level pressure difference is represented by an exponential term, so that when the pressure difference increases, the danger degree value WX will increase significantly. This non-linear design reflects the different degrees of influence of each factor on safety. The calculated WX can be used to determine whether adjustments need to be made to the pouring process. When WX exceeds the preset danger threshold, the system can take measures such as reducing the pouring speed or adjusting the angle to ensure safety. When WX does not exceed the preset danger threshold, the system can proceed according to the preset pouring strategy set to reduce the adjustment computing power, such as the pouring angle is 60 degrees and the pouring speed is 0.5 m / s and other standard pouring parameters under preset safe conditions. By analyzing the temperature difference, fluctuation amplitude and pressure difference, potential risks can be detected and handled in advance before pouring, avoiding unsafe situations during the pouring of molten aluminum and improving the stability of the entire system. When WX is small, it indicates that the temperature difference, fluctuation and pressure difference are all within the safe range, and the pouring process can proceed normally. When WX increases, it indicates that one or more of the temperature difference, fluctuation or pressure difference factors are approaching or exceeding the safe range, and the risk of the pouring process increases. At this time, the system may need to make adjustments, such as reducing the pouring speed, changing the pouring angle, or even suspending the operation.

[0103] Embodiment 2

[0104] Reference Figure 2 , the automatic aluminum liquid transfer into furnace system includes:

[0105] A data acquisition module that collects initial information of the aluminum liquid through sensors installed on the transfer trolley;

[0106] A transportation safety analysis module that conducts preset transportation safety analysis to ensure that the initial state of the aluminum water package formed by the aluminum liquid on the transfer trolley meets the standards of safe transportation;

[0107] A transfer module that performs transfer operations through the transfer trolley and conducts swing analysis in real time during the transfer operation, and dynamically adjusts the transfer strategy based on the swing analysis results;

[0108] A risk analysis module that conducts risk analysis based on the state of the aluminum water in the melting furnace and the current state of the aluminum water package on the transfer trolley before pouring;

[0109] An adaptive optimization module that adaptively optimizes and adjusts the pouring strategy based on the risk analysis results;

[0110] An execution module that converts the optimized pouring strategy into a parameter combination recognizable by the transfer trolley, enabling the transfer trolley to execute the optimized pouring strategy.

[0111] With the support of the risk analysis module and the adaptive optimization module, the system optimizes and adjusts various parameters during the pouring process. These adjustments are calculated based on real-time monitoring data (such as temperature difference, liquid level fluctuation, pressure difference), aiming to ensure the safety and stability of the aluminum liquid pouring process. The core task of the execution module is to convert these optimized pouring strategies into specific parameter combinations that the transfer trolley can execute. These parameters are the basis for the trolley to perform the pouring operation, ensuring that it can be safely and stably poured into the melting furnace 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 trolley, enabling the trolley to follow the optimized strategy during pouring without manual intervention.

[0112] The parameter combinations converted from the pouring strategy usually include:

[0113] Pouring speed: The pouring speed determines the flow rate of the aluminum liquid poured into the melting furnace. An overly fast pouring speed may cause liquid splashing, while an overly slow speed affects efficiency. The optimized pouring speed is determined based on data such as the swing index, temperature difference, and liquid level pressure difference, ensuring that the speed is within a safe range and meets the production efficiency requirements.

[0114] Pouring angle: The pouring angle determines the inclination direction of the aluminum liquid flowing out, which has a direct impact on the flow path and stability of the liquid. Through optimization, the system can set a suitable pouring angle to enable the aluminum liquid to be smoothly poured into the melting furnace without lateral splashing.

[0115] Pouring acceleration: The pouring acceleration controls the initial acceleration and deceleration of the pouring process, ensuring smooth flow of the molten aluminum and avoiding sloshing caused by sudden acceleration or deceleration. The optimized pouring acceleration parameters help the trolley complete actions smoothly at different pouring stages (start, acceleration, constant speed, deceleration).

[0116] Pouring flow rate: Adjusts the flow rate of the molten aluminum poured into the melting furnace per unit time to meet production requirements. Based on the current state of the melting furnace (such as temperature and liquid level) and the results of hazard analysis, the system can set an appropriate flow rate to prevent the risk of overflow due to too fast pouring of the liquid.

[0117] Pouring start and end times: By precise control of the pouring start and end times, the duration of the molten aluminum poured into the melting furnace can be determined. Combining parameters such as temperature and liquid level fluctuations, the system can set the optimal pouring time period to ensure an appropriate pouring volume and avoid the stability of the pouring process being affected by liquid level fluctuations.

[0118] Refer to Figure 3 , 2 is the AGV trolley, 1 is the base placed on the AGV trolley 2, i.e., the transfer trolley, 3 is the tipping bracket, 4 is the power mechanism for driving the tipping bracket 3 to rotate. The power mechanism can be a commonly used oil cylinder or other components that can drive the tipping bracket 3 to rotate, so that the ladle on the tipping bracket 3 can pour the molten aluminum into the melting furnace. In the description of the present invention, the use principle of the transfer trolley is defaulted to the description of its integrated tipping device. Pour the molten aluminum in the ladle into the melting furnace. The ladle is placed on the tipping bracket 3 of the tipping device through a hoisting mechanism, and at the same time, a transfer trolley is added to achieve the purpose of automatic transfer. The tipping device is pre-set with a load-bearing capacity of: it can pour 30 tons of molten aluminum. Through the molten aluminum automatic transfer into furnace system of the present invention, the trolley can perform transfer operations after picking up the ladle from the warehouse, and pour the molten aluminum beside the furnace. Moreover, multiple melting furnaces can be used in conjunction with one tipping device without manual intervention, liberating manpower and improving the safety and reliability of the overall molten aluminum automatic transfer into furnace.

[0119] The above formulas are all dimensionless and take their numerical values for calculation. The formulas are obtained by collecting a large amount of data for software simulation to get a formula closest to the actual situation. The preset parameters in the formulas are set by those skilled in the art according to the actual situation.

[0120] It should be understood that in various embodiments of the present application, the magnitudes of the sequence numbers of the above processes do not mean the order of execution. The order of execution of each process should be determined by its function and internal logic, and should not constitute any limitation to the implementation process of the embodiments of the present application.

[0121] Those of ordinary skill in the art can realize that the units and algorithm steps of each example described in combination with the embodiments disclosed herein can be implemented by electronic hardware or a combination of computer software and electronic hardware. Whether these functions are executed in a hardware or software manner depends on the specific application and design constraints of the technical solution. Professional technicians can use different methods to implement the described functions for each specific application, but such implementation should not be considered to exceed the scope of this application.

[0122] Those skilled in the art can clearly understand that for the convenience and conciseness of description, the specific working processes of the systems, devices, and units described above can refer to the corresponding processes in the foregoing method embodiments and will not be elaborated herein.

[0123] As described above, the above is only the specific implementation manner of this application, but the protection scope of this application is not limited thereto. Any person skilled in the art within the technical scope disclosed by this application can easily think of changes or substitutions, which should be covered within the protection scope of this application. Therefore, the protection scope of this application shall be subject to the protection scope of the claimed rights.

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; 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 ladle formed by the aluminum liquid on the transfer vehicle meets the standards for safe transportation; 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 swing index is used to evaluate the stability of the aluminum liquid level during transportation. 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 the 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 Density of aluminum liquid under 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 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.

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: 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.

5. The method for automatically transporting molten aluminum into a furnace according to claim 4, 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.

6. 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 4, 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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