High-temperature molten metal intelligent equipment for casting production

Abstract

The invention relates to the technical field of casting, and discloses high-temperature molten metal intelligent equipment for casting production, which comprises a material conveying belt, a material storage box, a smelting furnace and a quantitative furnace, a dry pot is erected on a rack, an expansion type liquid containing basin is additionally arranged under the dry pot, and a material is input into the material storage box through the obliquely arranged material conveying belt; the material storage box guides materials to enter the inner conveying belt, the materials are conveyed to the tail end through the inner conveying belt and then fall into the smelting furnace through a pipeline, the materials are converted into a molten state from a solid state through the smelting furnace, the molten-state materials are output into the quantitative furnace, and high-temperature-resistant electromagnetic proportional valves are installed at the bottom of the quantitative furnace and the bottom of the smelting furnace. The liquid level error is reduced by 50% through combined closed-loop control of the electromagnetic proportional valve and laser ranging, interference of bubbles and adhesion objects is eliminated in cooperation with the oscillation assembly, it is ensured that the size consistency of die castings is improved, the laser ranging sensor feeds back the liquid level in real time at high frequency, the opening adjustment response time of the electromagnetic valve is shortened, and the high-speed continuous production requirement is met.

Description

Technical Field

[0001] The invention relates to the field of casting, and more particularly to a high-temperature metal molten state intelligent device for casting production. Background Art

[0002] In traditional casting equipment, liquid level control mostly relies on mechanical float valves or manual observation, which has the following defects: the accumulation of bubbles on the surface of the molten metal causes the float to misjudge the liquid level height, the molten metal adheres to the furnace wall after cooling to form a "false liquid level", the laser ranging sensor readings are distorted, and the mechanical valve adjustment is delayed, making it difficult to adapt to the flow rate changes required for high-speed continuous production. Summary of the invention

[0003] The present invention provides a high-temperature metal molten state intelligent equipment for casting production, which solves the technical problems in related technologies.

[0004] The present invention provides a high-temperature metal molten state intelligent equipment for casting production, comprising a frame, a material conveyor belt, a material storage box, a melting furnace, a quantitative furnace, a dry pot, a liquid level component and an oscillation component; The liquid level components include a high temperature resistant electromagnetic proportional valve and a laser distance sensor; The material conveyor belt, storage box, melting furnace, dosing furnace and dry pot are set on the frame, and an expandable liquid holding basin is added directly below the dry pot. The material to be melted is input into the storage box through the inclined material conveyor belt. The storage box is used to guide the material into the internal conveyor belt. The internal conveyor belt transports the material to the end and then falls into the melting furnace through the pipeline. The material is converted from solid to molten through the melting furnace, and the molten material is output to the dosing furnace. A high-temperature resistant electromagnetic proportional valve is installed at the bottom of the dosing furnace and the melting furnace, and a laser ranging sensor is installed on the top of the dosing furnace and the melting furnace to monitor the liquid level in real time and dynamically adjust the valve opening. Electric heating components are pre-buried in the inner walls of the melting furnace and the dosing furnace to maintain the molten metal in a molten state after power is turned on. The oscillation assembly is installed on the outer walls on both sides of the furnace body of the quantitative furnace. The oscillation assembly includes an oscillation motor, a connecting rod and an amplitude controller. The connecting rod is inserted into the outer wall of one side of the quantitative furnace. The output end of the oscillation motor is connected to the rod end of the connecting rod. The amplitude controller is connected to the control end of the oscillation motor through telecommunication. The oscillation assembly can drive the furnace body of the quantitative furnace to swing back and forth by a certain amplitude to ensure that the bubbles in the molten liquid in the furnace body and the partial molten state adhere to the furnace body wall.

[0005] Furthermore, it also includes an exhaust gas component, which includes a high-temperature resistant pipe and an exhaust pump. Exhaust ports are added to the tops of the melting furnace and the quantitative furnace, and are connected to the exhaust pump at the rear of the frame through the high-temperature resistant pipe.

[0006] Further, the pump outlet of the air extraction pump is connected in series with a cyclone separator and an activated carbon adsorption tank, and the waste gas in the melting furnace and the metering furnace meets the emission standards. The air extraction pump and the electric heating element in the melting furnace start and stop synchronously.

[0007] Further, a circle of compressed air nozzles is arranged annularly at the edge of the dry pot. The compressed air nozzles are connected to the output end of a high-pressure air pump to form a downward air flow barrier by the supply of the high-pressure air pump. The air curtain is linked with the high-temperature resistant electromagnetic proportional valve at the bottom of the metering furnace.

[0008] Further, the heating assembly includes a spiral induction heating coil group arranged on the outer walls of the melting furnace and the metering furnace, and is connected to a high-frequency power module at the rear of the frame through a water-cooled cable.

[0009] Further, temperature sensors are also embedded in the inner walls of the melting furnace and the metering furnace, and the heating power is dynamically adjusted through a controller installed on the frame.

[0010] Further, a flap sealing mechanism is arranged at the top of the storage bin. The flap is kept normally closed by a torsion spring. When the material is conveyed to the top of the storage bin through an inclined conveyor belt, the gravity of the material presses the flap to open and slide into the internal conveyor belt. The conveyor belt conveys the material to the end and then falls into the melting furnace through a pipeline.

[0011] Further, the high-temperature resistant electromagnetic proportional valve is composed of a silicon carbide matrix and a silicon nitride coating, and the temperature resistance limit of the high-temperature resistant electromagnetic proportional valve is greater than or equal to 1600 °C.

[0012] Further, a thermal circulation interlayer is provided on the outer wall of the melting furnace, and the thermal circulation interlayer is used for thermal circulation to adjust the waste heat reuse in the melting furnace and the metering furnace.

[0013] Further, an alarm assembly is also included. The alarm assembly includes a buzzer and an emergency stop switch. The emergency stop switch is arranged on the control end of the equipment, and the buzzer is used to prompt the staff to intervene in case of an emergency.

[0014] The beneficial effects of the present invention are as follows: The present invention reduces the liquid level error by 50% through the combined closed-loop control of the electromagnetic proportional valve and the laser ranging, and cooperates with the oscillation assembly to eliminate the interference of bubbles and adhesions, ensuring the improvement of the dimensional consistency of die-castings. The laser ranging sensor provides real-time feedback of the liquid level at a high frequency, and the response time of the solenoid valve opening adjustment is shortened, meeting the requirements of high-speed continuous production; At the same time, the dual-mode heating (electric heating wire, induction coil) cooperates with the closed-loop control, reducing the temperature fluctuation of the molten metal, avoiding the material lattice defects caused by temperature deviation. The temperature control limit of the silicon carbide-based valve and the silicon nitride coating is high, and the service life is improved compared with the original floating ball valve. Description of the Drawings

[0015] Figure 1It is a schematic structural diagram of a high-temperature metal molten state intelligent device proposed by the present invention for casting production; Figure 2 It is of the present invention Figure 1 side view; Figure 3 It is of the present invention Figure 1 bottom view; Figure 4 It is of the present invention Figure 2 schematic structural diagram of the metering furnace in Figure 5 It is of the present invention Figure 1 schematic structural diagram of the dry pot and the expanded solution basin in.

[0016] In the figure: 100, frame; 200, material conveyor belt; 300, storage bin; 400, melting furnace; 410, heating component; 500, dry pot; 510, compressed air nozzle; 600, expanded solution basin; 700, metering furnace; 710, furnace body; 720, oscillating motor; 730, laser distance sensor; 740, electric heating element; 750, high-temperature resistant electromagnetic proportional valve; 760, connecting rod; 800, exhaust gas component. Detailed implementation manners

[0017] Now, the subject matter described herein will be discussed with reference to example embodiments. It should be understood that discussing these embodiments is only to enable those skilled in the art to better understand and thus implement the subject matter described herein. Without departing from the protection scope of the content of this specification, changes can be made to the functions and arrangements of the elements discussed. Each example can omit, substitute, or add various processes or components as needed. Additionally, the features described relative to some examples can also be combined in other examples.

[0018] As Figures 1-5 shown, a high-temperature metal molten state intelligent device for casting production includes a frame 100, a material conveyor belt 200, a storage bin 300, a melting furnace 400, a metering furnace 700, a dry pot 500, a heating component 410, a liquid level component, an exhaust gas component 800, an oscillating component, and an alarm component; wherein the liquid level component includes a high-temperature resistant electromagnetic proportional valve 750 and a laser distance sensor 730; wherein the exhaust gas component 800 includes a high-temperature resistant pipeline and an air extraction pump; Among them, the frame 100 adopts a stepped stainless steel frame structure. The material conveyor belt 200, the storage bin 300, the melting furnace 400, the metering furnace 700, and the crucible 500 are installed on the frame 100. Among them, the material to be melted is input into the storage bin 300 through the inclined material conveyor belt 200. The storage bin 300 is used to guide the material into the internal conveyor belt. The internal conveyor belt transports the material to the end and then falls into the melting furnace 400 through a pipeline. After passing through the melting furnace 400, the material is changed from a solid state to a molten state. The molten material is output into the metering furnace 700. High-temperature resistant electromagnetic proportional valves 750 are installed at the bottoms of the metering furnace 700 and the melting furnace 400. Laser distance sensors 730 are installed at the tops of both the metering furnace 700 and the melting furnace 400, which are used to monitor the liquid level in real time, dynamically adjust the valve opening, and the target flow error ≤ ±0.8 mm; It should be noted that the high-temperature resistant electromagnetic proportional valve 750 is composed of a silicon carbide matrix + a silicon nitride coating, and the temperature resistance ≥ 1600 °C; It should be noted that a primary screen is set at the connection between the storage bin 300 and the melting furnace 400 to intercept large particle impurities in the material and prevent clogging of the electric heating element 740 of the melting furnace 400; Exhaust gas extraction ports are added to the tops of both the melting furnace 400 and the metering furnace 700, and are connected to an exhaust gas pump at the rear of the frame 100 through high-temperature resistant pipelines. The pump outlet of the exhaust gas pump is connected in series with a cyclone separator (primary dust removal) and an activated carbon adsorption tank (secondary purification). Finally, the exhaust gas is discharged up to standard through a chimney. The exhaust gas pump and the electric heating element 740 of the melting furnace 400 start and stop synchronously. The system is equipped with a differential pressure sensor, which triggers an alarm and switches to a standby channel when the filter is blocked; Among them, it should be noted that the oscillation assembly is installed on the outer walls of both sides of the furnace body 710 of the metering furnace 700. The oscillation assembly includes an oscillation motor 720, a connecting rod 760, and an amplitude controller. The connecting rod 760 penetrates through the outer wall of one side of the metering furnace 700. The output end of the oscillation motor 720 is connected to the rod end of the connecting rod 760. The amplitude controller is connected to the control end of the oscillation motor 720 through telecommunications. The oscillation assembly can drive the furnace body 710 of the metering furnace 700 to swing back and forth by a certain amplitude, ensuring that the bubbles and part of the molten state in the molten liquid in the furnace body 710 adhere to the wall of the furnace body 710, affecting the measurement of the laser distance sensor 730; It should be noted that a flap sealing mechanism is set at the top of the storage bin 300, and the flap is kept normally closed by a torsion spring; When the material is transported to the top of the storage bin 300 through the inclined conveyor belt, the gravity of the material presses the flap to open and slide into the internal conveyor belt. The conveyor belt transports the material to the end and then falls into the melting furnace 400 through a pipeline.

[0019] Electric heating elements 740 are embedded in the inner walls of both the melting furnace 400 and the metering furnace 700. After being powered on, they maintain the molten metal in a molten state. A thermal circulation sandwich layer is provided on the outer wall of the melting furnace 400, which can be used for thermal circulation to adjust some waste heat or heat reuse; The electric heating element 740 includes, but is not limited to, heating elements such as electric heating wires and electric heating rods; A circle of compressed air nozzles 510 (tilt angle 30°) is arranged annularly at the edge of the crucible 500. The compressed air nozzles 510 are connected to the output end of a high-pressure air pump, and a downward air flow barrier is formed by the supply of air from the high-pressure air pump. The air curtain is linked with the high-temperature resistant electromagnetic proportional valve 750 at the bottom of the metering furnace 700. When the valve of the high-temperature resistant electromagnetic proportional valve 750 opens, it starts automatically and stops with a 5-second delay after closing; An expanded solution basin 600 (depth 1.5 times the basic model) is added directly below the crucible 500. A weighing sensor is embedded at the bottom, a diversion groove interface is provided on the side wall, a 15° inclined diversion groove (surface sprayed with silicon carbide anti-sticking coating) is welded, and the end flange is connected to an external safety container.

[0020] The heating assembly 410 includes a spiral induction heating coil group arranged on the outer walls of the melting furnace 400 and the metering furnace 700, and is connected to a high-frequency power module (built-in IGBT power unit and air-cooled radiator) at the rear of the frame 100 through a water-cooled cable.

[0021] At the same time, temperature sensors are embedded in the inner walls of the melting furnace 400 and the metering furnace 700, and the controller dynamically adjusts the heating power with a temperature fluctuation ≤ ±3°C.

[0022] The liquid level assembly is controlled by a closed-loop combination of an electromagnetic proportional valve and a laser rangefinder, with an error ≤ ±0.8 mm; The alarm assembly includes a buzzer and an emergency stop switch. The emergency stop switch is set on the control end of the equipment, and the buzzer is used to prompt the staff to intervene in case of an emergency.

[0023] The working principle is as follows: I. Material transportation and pretreatment Flap seal feeding: The material is conveyed by an inclined conveyor belt to the top of the storage bin 300. When the gravity of the material presses the flap seal mechanism (normally closed by a torsion spring), the flap opens downward to form a feed inlet; The material slides onto the conveyor belt inside the storage bin 300, and the end of the conveyor belt vertically guides the material into the melting furnace 400 through a pipe. The flap is reset by the torsion spring after the material passes through, preventing the heat in the furnace from escaping; II. Melting and temperature control Dual-mode heating system: Internal heating by the electric heating element 740: Electric heating elements 740 are embedded in the inner wall of the melting furnace 400, directly conducting heat to the material to quickly reach the melting point; External heating by induction coil: The outer wall of the melting furnace 400 is covered with a spiral induction heating coil. An alternating magnetic field is generated through a high-frequency power module (controlled by IGBT), and the eddy current in the molten metal generates heat, achieving high-efficiency heating (temperature fluctuation ≤ ±3°C). Thermal cycle sandwich layer: The outer wall of the melting furnace 400 is provided with a double-layer sandwich structure, introducing waste heat gas to circulate, preheating newly incoming materials or assisting in heating the workshop, with an energy-saving efficiency increase of 15% - 20%. Stable maintenance of the molten state: The temperature sensor monitors the temperature of the molten metal in the melting furnace 400 in real time, and the data is fed back to the controller to dynamically adjust the power of the electric heating element 740 and the frequency of the induction coil, ensuring that the molten metal is always within the target melting range (such as for aluminum alloy: 660°C ± 3°C).

[0024] III. Quantitative transportation and liquid level control Precise flow control by electromagnetic proportional valve: High-temperature resistant electromagnetic proportional valves 750 (silicon carbide matrix + silicon nitride coating) are installed at the bottoms of the melting furnace 400 and the metering furnace 700, and the valve opening is controlled by the liquid level data real-time feedback by the laser distance sensor 730. When the laser distance measurement detects that the liquid level in the melting furnace 400 is lower than the set value, the controller increases the valve opening; when the liquid level approaches the upper limit, the valve linearly reduces the opening, achieving a flow error ≤ ±0.8 mm. Oscillation defoaming and adhesion removal Oscillation motors 720 are installed on both sides of the metering furnace 700, and the furnace body 710 is driven to swing back and forth at a frequency of 5 - 10 Hz (amplitude 3 - 5 mm) through the connecting rod 760. Function of swinging: Promote the floating and bursting of air bubbles in the molten metal, reducing the interference of liquid level fluctuations on laser distance measurement. Strip the residual metal adhesion layer on the furnace wall to avoid distortion of liquid level detection.

[0025] IV. Exhaust gas treatment and environmental protection emission Multi-stage purification process: The air extraction ports at the tops of the melting furnace 400 and the metering furnace 700 are connected to the air extraction pump through high-temperature resistant pipes, and the exhaust gas is discharged from the pump outlet. It should be added that the discharged exhaust gas passes through in sequence: Cyclone separator: Particles ≥ 10 μm are separated by centrifugal force, and the dust removal efficiency ≥ 90%. Activated carbon adsorption tank: Adsorb volatile organic compounds (VOCs) and harmful gases (such as zinc vapor), with a purification rate ≥ 85%.

[0026] The purified exhaust gas is discharged through the chimney, meeting the comprehensive emission standard of air pollutants.

[0027] Intelligent maintenance mechanism: The differential pressure sensor monitors the filter status. When the differential pressure is greater than 500Pa, an alarm is triggered and the filter automatically switches to the backup filter channel. At the same time, a buzzer reminds maintenance personnel to replace the filter element.

[0028] 5. Die casting operation and safety protection Dry pot 500 air curtain isolation: Compressed air nozzles 510 (inclined at 30°) are arranged in a ring around the edge of the dry pot 500, and a high-pressure air pump (0.8 MPa) supplies air to form a downward air curtain barrier.

[0029] Linkage control: When the solenoid valve at the bottom of the quantitative furnace 700 is opened, the air curtain starts synchronously; it stops after a delay of 5 seconds after the valve is closed to ensure that the molten metal completely flows into the dry pot 500 before removing the protection.

[0030] Overflow emergency treatment: The expandable liquid basin 600 (1.5 times the depth of the basic model) receives the overflowing metal liquid, and the weighing sensor monitors the liquid basin load in real time: When the load is ≥ the set threshold, the buzzer alarm is triggered and the power supply to the melting furnace 400 and the quantitative furnace 700 is cut off; The overflow liquid is quickly introduced into an external safety container through a 15° inclined guide trough (silicon carbide anti-stick coating) to avoid ground contamination.

[0031] 6. System closed-loop control logic Multi-component linkage timing Stage 1 (feeding): conveyor belt starts → flap opens → material enters the furnace → vacuum pump runs synchronously.

[0032] Stage 2 (melting): electric heating element 740 + induction coil heating → closed-loop temperature regulation → periodic fine-tuning of the opening of the solenoid valve.

[0033] Stage 3 (die casting): the solenoid valve of the dosing furnace 700 is opened → the air curtain is started → the molten metal is poured into the dry pot 500 → the oscillation components work synchronously.

[0034] Fault response levels: Level 1 alarm (weighing over limit / temperature over limit): buzzer alarm, automatically close all valves in the system.

[0035] Secondary alarm (filter blockage / air curtain failure): The emergency stop switch is triggered, the system is powered off and the operation interface is locked.

[0036] The embodiments of the present invention are described above, but the present invention is not limited to the above-mentioned specific implementation modes. The above-mentioned specific implementation modes are merely illustrative and not restrictive. Under the guidance of the present invention, ordinary technicians in this field can also make many forms, all of which are within the protection of the present invention.

Claims

1. A high-temperature molten metal intelligent equipment for casting production, characterized in that: It comprises a frame (100), a material conveyor belt (200), a material storage box (300), a melting furnace (400), a quantitative furnace (700), a dry pot (500), a liquid level component and an oscillation component; The liquid level component includes a high temperature resistant electromagnetic proportional valve (750) and a laser distance sensor (730); The material conveyor belt (200), the material storage box (300), the melting furnace (400), the quantitative furnace (700), and the dry pot (500) are mounted on the frame (100). At the same time, an expandable liquid containing basin (600) is added directly below the dry pot (500). The material to be melted is input into the material storage box (300) through the inclined material conveyor belt (200). The material storage box (300) is used to guide the material into the internal conveyor belt. The internal conveyor belt conveys the material to the end and then falls into the melting furnace (400) through a pipeline. After the melting The furnace (400) converts the material from a solid state to a molten state, and the molten material is output to the dosing furnace (700). A high temperature resistant electromagnetic proportional valve (750) is installed at the bottom of the dosing furnace (700) and the melting furnace (400). A laser distance measuring sensor (730) is installed at the top of the dosing furnace (700) and the melting furnace (400) to monitor the liquid level in real time and dynamically adjust the valve opening. Electric heating elements (740) are pre-buried in the inner walls of the melting furnace (400) and the dosing furnace (700) to maintain the metal liquid in a molten state after power is turned on. The oscillation assembly is installed on the outer walls on both sides of the furnace body (710) of the quantitative furnace (700). The oscillation assembly includes an oscillation motor (720), a connecting rod (760) and an amplitude controller. The connecting rod (760) is inserted into the outer wall of one side of the quantitative furnace (700). The output end of the oscillation motor (720) is connected to the rod end of the connecting rod (760). The amplitude controller is connected to the control end of the oscillation motor (720) via telecommunication. The oscillation assembly can drive the furnace body (710) of the quantitative furnace (700) to swing back and forth by a certain amplitude, thereby ensuring that the bubbles in the molten liquid in the furnace body (710) and the partial molten state adhere to the wall of the furnace body (710).

2. The high-temperature molten metal intelligent equipment for casting production according to claim 1 is characterized in that: It also includes an exhaust gas component (800), which includes a high-temperature resistant pipe and an exhaust pump. The tops of the melting furnace (400) and the quantitative furnace (700) are both provided with exhaust ports, which are connected to the exhaust pump at the rear of the frame (100) through the high-temperature resistant pipe.

3. The high-temperature molten metal intelligent equipment for casting production according to claim 2 is characterized in that: The pump outlet of the vacuum pump is connected in series with a cyclone separator and an activated carbon adsorption tank, so that the waste gas in the melting furnace (400) and the quantitative furnace (700) meets the emission standards, and the vacuum pump and the electric heating element (740) in the melting furnace (400) are started and stopped synchronously.

4. The high-temperature molten metal intelligent equipment for casting production according to claim 6 is characterized in that: A circle of compressed air nozzles (510) are arranged in a ring around the edge of the dry pot (500). The compressed air nozzles (510) are connected to the output end of a high-pressure air pump. The high-pressure air pump supplies air to form a downward airflow barrier. The air curtain is linked to a high-temperature resistant electromagnetic proportional valve (750) at the bottom of the quantitative furnace (700).

5. The high-temperature molten metal intelligent equipment for casting production according to claim 4 is characterized in that: The heating assembly (410) comprises a spiral induction heating coil group arranged on the outer walls of the melting furnace (400) and the dosing furnace (700), and connected to a high-frequency power supply module at the rear of the frame (100) via a water-cooling cable.

6. The high-temperature molten metal intelligent equipment for casting production according to claim 5, characterized in that: Temperature sensors are also embedded in the inner walls of the melting furnace (400) and the dosing furnace (700), and the heating power is dynamically adjusted by a controller installed on the frame (100).

7. The high-temperature molten metal intelligent equipment for casting production according to claim 6, characterized in that: A flap sealing mechanism is provided at the top of the material storage box (300), and the flap is kept in a normally closed state by a torsion spring. When the material is transported to the top of the material storage box (300) via the inclined conveyor belt, the gravity of the material presses the flap to open and slide into the internal conveyor belt. The conveyor belt transports the material to the end, and the material falls into the melting furnace (400) through a pipeline.

8. The high-temperature molten metal intelligent equipment for casting production according to claim 7, characterized in that: The high temperature resistant electromagnetic proportional valve (750) is composed of a silicon carbide substrate and a silicon nitride coating. The temperature resistance limit of the high temperature resistant electromagnetic proportional valve (750) is greater than or equal to 1600°C.

9. The high-temperature molten metal intelligent equipment for casting production according to claim 8, characterized in that: A heat cycle interlayer is provided on the outer wall of the melting furnace (400), and the heat cycle interlayer is used for heat cycle regulation to recycle waste heat in the melting furnace (400) and the quantitative furnace (700).

10. The high temperature molten metal intelligent equipment for casting production according to claim 9, characterized in that: It also includes an alarm component, which includes a buzzer and an emergency stop switch. The emergency stop switch is set on the control end of the equipment, and the buzzer is used to prompt staff to intervene when an emergency occurs.

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