Crystallizer water distribution method for casting of continuous casting machine and automatic system thereof

Abstract

The invention relates to the technical field of crystallizer water distribution, and discloses a crystallizer water distribution method for continuous casting machine pouring and an automatic system.The crystallizer water distribution method comprises the following steps that real-time pulling speed data A is collected; according to the real-time pulling speed data A, water quantity control parameters K and Z of the wide and narrow faces of the crystallizer are calculated through a preset sectional type water distribution algorithm; outputting calculation results K and Z; according to the output K and Z values, water distribution of the crystallizer is adjusted, and the stability of the crystallization process and the steel billet quality are guaranteed; the steps are automated, and the water distribution of the crystallizer is controlled in real time along with the change of the pulling speed by combining a PLC (Programmable Logic Controller) program with an existing machine. The automatic system comprises a pulling speed control module, a PLC program module, a water quantity control module, a data monitoring module and a fault diagnosis module. The water quantity of the crystallizer in the casting process of the continuous casting machine can be accurately controlled, so that the steel billet quality is improved, the production cost is reduced, and the production efficiency is improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of mold water distribution, and particularly relates to a mold water distribution method for continuous casting machine pouring and its automation system. Background Art

[0002] In the industrial crystallization process, the mold water distribution technology is one of the key factors affecting the quality of crystal products and production efficiency. Traditional mold water distribution methods usually rely on the experience of operators, and the water volume distribution of the mold is manually adjusted to control the growth and quality of crystals. This method has certain uncertainties and subjectivities, making it difficult to accurately control the growth rate and size of crystals, resulting in unstable quality of crystal products and low production efficiency.

[0003] The prior art generally includes the following methods: Fixed water distribution method: By fixing the water volume distribution of the mold, this method is simple and easy to implement, but it cannot be adjusted according to the actual production situation, resulting in difficult-to-guarantee crystal quality.

[0004] Manual adjustment method: The operator manually adjusts the water volume of the mold according to experience. This method depends on the skills and experience of the operator, but is easily affected by human factors and cannot respond in real time to changes in the production process.

[0005] Semi-automatic water distribution method: Simple automation equipment, such as solenoid valves, etc., is used for water volume adjustment, but this method usually can only achieve rough water volume control and cannot meet high-precision requirements.

[0006] Traditional methods are difficult to achieve precise control of the crystal growth process, resulting in uneven quality of crystal products. Manual adjustment and semi-automatic methods cannot respond in real time to changes in the production process, resulting in low production efficiency. Due to the inability to accurately control the water volume, energy waste occurs and the operating cost is relatively high. The automation level of the prior art is low, relying on operator intervention, increasing the risk of human error. Traditional water distribution methods are difficult to meet the requirements of different steel grades and composition changes, restricting their application scope in production.

[0007] In view of this, we propose a mold water distribution method for continuous casting machine pouring and its automation system. By writing the self-set water distribution method into the PLC program and combining with the existing machinery, real-time control of the mold water distribution with the change of drawing speed is achieved. This method has higher precision, automation level and adaptability, can effectively improve the quality of crystal products and production efficiency, reduce the operating cost, and reduce human error. Summary of the Invention

[0008] The present invention aims to solve the technical problem in the above prior art that the water volume range of the mold is relatively wide and the effect of controlling crystal growth and quality is not obvious.

[0009] To achieve the above object, the present invention provides the following technical solutions: A method for distributing water to a mold in continuous casting, comprising the following steps: S1. Real-time collection of casting speed data: The system monitors and collects the current casting speed value A in real time through a casting speed control module; S2. Judging the casting speed range: According to the collected casting speed value A, the system will judge the range it is in and calculate according to a preset water distribution formula; S3. Calculating the water distribution amount: According to different ranges where the casting speed value A is located, calculate the water control parameters K and Z for the wide and narrow surfaces of the mold through a preset segmented water distribution algorithm. K is the water amount of the wide surface of the mold, and Z is the water amount of the narrow surface of the mold; S4. Outputting control signals: After calculating K and Z, output the calculation results K and Z, convert these values into control signals, and output them to the mold water control module; S5. Adjusting the water amount: The mold water control module adjusts the water amount of the mold according to the received control signals, performs the water distribution operation, and ensures that the water amount matches the casting speed; S6. End: After completing the water distribution adjustment, the system process ends.

[0010] Preferably, in the water distribution formula, the calculation formula for the K value is K = A * kx; the calculation formula for the Z value is Z = A * zx, where kx and zx are constants for a specific casting speed range, and x ranges from 1 to 23.

[0011] An automatic system for distributing water to a mold in continuous casting, comprising: A casting speed control module, responsible for real-time collecting and transmitting the casting speed data of the continuous caster and inputting the data into the PLC program module; A PLC program module, which receives the casting speed data and calculates the water control parameters K and Z for the wide and narrow surfaces of the mold according to a preset segmented water distribution algorithm; A mold water control module, which receives the K and Z values output by the PLC program and adjusts the water distribution of the mold according to these parameters; A data monitoring module: monitors key parameters in the whole water distribution process, including casting speed and water amount, and feeds back to the PLC program in real time for timely adjustment; A fault diagnosis module: when an abnormality occurs in the system, it can automatically diagnose the cause of the fault and take corresponding measures to ensure the stable operation of the system.

[0012] Preferably, it further includes a user interface and a communication network module. The user interface includes an interface for inputting casting speed data and viewing the water distribution result. The communication network module is used to connect each module of the casting speed control module, the PLC program module, the mold water control module, the data monitoring module, the fault diagnosis module, and the user interface to ensure the real-time transmission of data and control signals.

[0013] Compared with the prior art, the technical effects and advantages of the present invention are as follows: The mold water distribution method for continuous casting machine casting accurately controls the water volume of the wide and narrow surfaces of the mold by collecting casting speed data in real time and using a preset segmented water distribution algorithm. The key of this method is to calculate the control parameters K and Z of the water volume through the formulas of K = A * kx and Z = A * zx according to different casting speed intervals, where kx and zx are constants for specific casting speed intervals, and x ranges from 1 to 23. This method can ensure that the water volume matches the casting speed, reduce defects such as center cracks, depressions, and scabs of the billet, thereby improving the quality of the billet.

[0014] The mold water distribution automation system for continuous casting machine casting of the present invention includes a casting speed control module, a PLC program module, a mold water control module, a data monitoring module, a fault diagnosis module, a user interface, and a communication network module. These modules work together to achieve real-time monitoring and control of the mold water volume. The system collects casting speed data in real time and automatically adjusts the water volume according to a predetermined water distribution algorithm without manual intervention. This kind of automation system can improve production efficiency, reduce operating costs, and reduce the error rate of manual operations.

[0015] The present invention improves the control accuracy of crystal growth and quality, optimizes the crystal grain size distribution, prevents supersaturation and the generation of secondary nuclei, reduces energy consumption and operating costs, ensures the stability of the crystallization process, and improves the quality of steel billets. Through automatic control, the system can respond to changes in the production process in real time, improve production efficiency, reduce operating costs, and reduce human errors. This innovative water distribution method and automation system can meet the requirements of different steel grades and composition changes, and has wide applicability and good market prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is the complete system flow of the present invention; Figure 2 It is the start-stop flowchart of converting the specific water distribution method of the present invention to the PLC. DETAILED DESCRIPTION OF THE INVENTION The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to 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.

[0017] The following will further elaborate on Figures 1 to 2 this application in detail. An automatic water distribution method for a mold in continuous casting machine pouring according to an embodiment of this application includes the following steps: S1. Real-time collection of casting speed data: The system monitors and collects the current casting speed value A in real time through the casting speed control module. S2. Determine the casting speed interval: According to the collected casting speed value A, the system will determine the interval it belongs to and calculate according to the preset water distribution formula. S3. Calculate the water distribution volume: According to different intervals where the casting speed value A is located, calculate the water volume control parameters K and Z for the wide and narrow faces of the mold through the preset segmented water distribution algorithm. In the water distribution formula, the calculation formula for the K value is K = A * kx; the calculation formula for the Z value is Z = A * zx, where kx and zx are constants for specific casting speed intervals, and x ranges from 1 to 23. S4. Output control signals: After calculating K and Z, output the calculation results K and Z, convert these values into control signals, and output them to the mold water control module. S5. Adjust the water volume: The mold water control module adjusts the water volume of the mold according to the received control signals, performs the water distribution operation, and ensures that the water volume matches the casting speed. S6. End: After completing the water distribution adjustment, the system process ends.

[0018] An automatic water distribution system for a mold in continuous casting machine pouring includes: A casting speed control module, responsible for collecting and transmitting the casting speed data of the continuous casting machine in real time and inputting the data into the PLC program module. A PLC program module, according to the preset segmented water distribution algorithm, receives the casting speed data and calculates the water volume control parameters K and Z for the wide and narrow faces of the mold. A mold water control module, receives the K and Z values output by the PLC program, and adjusts the water volume distribution of the mold according to these parameters. A data monitoring module: monitors the key parameters in the entire water distribution process, including casting speed and water volume, and feeds back to the PLC program in real time for timely adjustment. A fault diagnosis module: when an abnormality occurs in the system, it can automatically diagnose the cause of the fault and take corresponding measures to ensure the stable operation of the system. A user interface, including an interface for inputting casting speed data and viewing the water distribution results; A communication network module, used to connect each module of the casting speed control module, PLC program module, mold water control module, data monitoring module, fault diagnosis module, and user interface, ensuring real-time transmission of data and control signals.

[0019] The present invention mainly achieves real-time control of mold water distribution with the change of casting speed by writing the independently set water distribution method into the PLC program and combining it with the existing machinery.

[0020] Taking the casting speed data acquisition as the input end, calculating through the PLC independent program and outputting control signals to the mold water control end, the three items are linked together to form a feasible start-stop process of a monitoring and control system, used for real-time matching of casting speed and mold water volume. Matching corresponding mold water volumes at different casting speeds can effectively reduce defects such as center cracks, depressions, and scabs of the billet, improving the quality of the billet.

[0021] The base numbers (k value and z value) of the wide and narrow faces of the mold, these base numbers are used to calculate the water volume distribution of the mold, and a table reflecting the mold water distribution parameters during the continuous casting process, as shown in Table 1; Table 1 Mold water distribution parameter table during the continuous casting process As Figure 2 shown, the steps of the PLC flow chart of the mold water distribution method and its automation system for the continuous casting machine are as follows: 1. Start: The starting point of the process.

[0022] 2. Enter the real-time casting speed A: Input the current casting speed value A.

[0023] 3. Judge whether A < 0.6: If yes, perform the following calculations: K = A * k1, k1 = 1800 Z = A * z1, z1 = 300 If no, continue to the next step.

[0024] 4. Judge whether 0.6 ≤ A and A < 0.65: If yes, perform the following calculations: K = A * k2, k2 = 3076.92 Z = A * z2, z2 = 461.54 If no, continue to the next step.

[0025] 5. Judge whether 0.65 ≤ A and A < 0.7: If yes, perform the following calculations: K = A * k3, where k3 = 2857.14 Z = A * z3, where z3 = 428.57 If no, proceed to the next step; 6. Determine whether 0.7 ≤ A and A < 0.75: If yes, perform the following calculations: K = A * k4, where k4 = 2666.67 Z = A * z4, where z4 = 413.33 If no, proceed to the next step; 7. Determine whether 0.75 ≤ A and A < 0.8: If yes, perform the following calculations: K = A * k5, where k5 = 2625 Z = A * z5, where z5 = 387.5 If no, proceed to the next step; 8. Determine whether 0.8 ≤ A and A < 0.85: If yes, perform the following calculations: K = A * k6, where k6 = 2529.41 Z = A * z6, where z6 = 364.71 If no, proceed to the next step; 9. Determine whether 0.85 ≤ A and A < 0.9: If yes, perform the following calculations: K = A * k7, where k7 = 2500 Z = A * z7, where z7 = 344.44 If no, proceed to the next step; 10. Determine whether 0.9 ≤ A and A < 0.95: If yes, perform the following calculations: K = A * k8, where k8 = 2368.42 Z = A * z8, where z8 = 326.32 If no, proceed to the next step; 11. Determine whether 0.95 ≤ A and A < 1: If yes, perform the following calculations: K = A * k9, where k9 = 2050 Z = A * z9, where z9 = 320 If no, proceed to the next step; 12. Determine whether 1 ≤ A and A < 1.05: If yes, perform the following calculations: K = A * k10, where k10 = 1952.38 Z = A * z10, z10 = 304.76 If no, proceed to the next step; 13. Determine whether 1.05 ≤ A and A < 1.1: If yes, perform the following calculations: K = A * k11, k11 = 1863.64 Z = A * z11, z11 = 300 If no, proceed to the next step; 14. Determine whether 1.1 ≤ A and A < 1.15: If yes, perform the following calculations: K = A * k12, k12 = 1808.7 Z = A * z12, z12 = 286.96 If no, proceed to the next step; 15. Determine whether 1.15 ≤ A and A < 1.2: If yes, perform the following calculations: K = A * k13, k13 = 1766.67 Z = A * z13, z13 = 287.5 If no, proceed to the next step; 16. Determine whether 1.2 ≤ A and A < 1.25: If yes, perform the following calculations: K = A * k14, k14 = 1720 Z = A * z14, z14 = 276 If no, proceed to the next step; 17. Determine whether 1.25 ≤ A and A < 1.3: If yes, perform the following calculations: K = A * k15, k15 = 1692.31 Z = A * z15, z15 = 269.23 If no, proceed to the next step; 18. Determine whether 1.3 ≤ A and A < 1.35: If yes, perform the following calculations: K = A * k16, k16 = 1740.74 Z = A * z16, z16 = 274.07 If no, proceed to the next step; 19. Determine whether 1.35 ≤ A and A < 1.4: If yes, perform the following calculations: K = A * k17, k17 = 1821.43 Z = A * z17, z17 = 271.43 If no, proceed to the next step 20. Determine whether 1.4 ≤ A and A < 1.45: If yes, perform the following calculations: K = A * k18, k18 = 1793.1 Z = A * z18, z18 = 268.97 If no, proceed to the next step; 21. Determine whether 1.45 ≤ A and A < 1.5: If yes, perform the following calculations: K = A * k19, k19 = 1766.67 Z = A * z19, z19 = 273.33 If no, proceed to the next step; 22. Determine whether 1.5 ≤ A and A < 1.55: If yes, perform the following calculations: K = A * k20, k20 = 1774.19 Z = A * z20, z20 = 270.97 If no, proceed to the next step; 23. Determine whether 1.55 ≤ A and A < 1.6: If yes, perform the following calculations: K = A * k21, k20 = 1781.25 Z = A * z21, z20 = 262.5 If no, proceed to the next step; 24. Determine whether 1.6 ≤ A and A < 1.65: If yes, perform the following calculations: K = A * k22, k22 = 1727.27 Z = A * z22, z22 = 254.55 If no, proceed to the next step; 25. Determine whether A is greater than 1.65: If yes, perform the following calculations: K = A * k23, k23 = 3000 Z = A * z23, z23 = 500 If no, proceed to the next step; 6. Output K and Z: Output the calculation results K and Z.

[0026] 7. End: The end point of the process.

[0027] The present invention collects the drawing speed in real time through a drawing speed control module, automatically enters the drawing speed into the completed PLC program (including the complete water distribution method), and outputs the specific water volume control signal for the wide and narrow faces of the mold through processing. This control signal enables the mold water control module to complete the corresponding water volume change.

[0028] By collecting the drawing speed data in real time and applying a segmented water distribution algorithm, the present invention can accurately control the water volume distribution of the wide and narrow faces of the mold. This method ensures the precise control of the crystal growth rate and crystal size, thereby improving the uniformity and quality of the crystal products. Specifically, the water distribution formulas K = A * kx and Z = A * zx can calculate the accurate water volume control parameters K and Z according to different drawing speed intervals, so as to achieve precise water volume adjustment.

[0029] The present invention writes the water distribution method into the PLC program and combines it with the existing machinery to achieve the automatic control of the mold water distribution. This reduces human intervention, lowers the error rate of manual operation, and improves production efficiency. The automatic system automatically adjusts the water volume by monitoring the drawing speed data in real time, ensuring that the water volume of the mold matches the drawing speed, thereby improving the quality of the billet.

[0030] The water distribution method provided by the present invention can adapt to different steel grades and compositional changes. Through the preset segmented water distribution algorithm, the system can automatically adjust the water volume according to the actual production situation to meet the requirements of different steel grades and compositions. In addition, the system can also be optimized and adjusted according to the specific characteristics of the mechanical mechanism to ensure the operation efficiency and stability of the mechanical equipment.

[0031] Through precise water distribution control, the present invention can effectively reduce the defect rate of the billet when the drawing speed changes. The accuracy and automatic control of the water distribution method reduce the occurrence of defects such as center cracks, depressions, and scabs in the cast billet, thereby improving the quality of the billet.

[0032] By optimizing the water volume distribution of the mold, the present invention can reduce energy consumption and operating costs. Precise control of the water volume can avoid the generation of supersaturation and secondary nuclei, reduce resource waste, and improve production efficiency.

[0033] The automatic system of the present invention can respond to changes in the production process in real time and automatically adjust the water volume, thereby improving production efficiency. Automatic control reduces the time and energy of manual operation, improves production efficiency, and reduces the error rate of manual operation.

[0034] In summary, the mold water distribution method and its automatic system for continuous casting machine pouring of the present invention have significant improvements compared with the prior art in terms of precise control, high degree of automation, adaptability and flexibility, reduction of defect rate, reduction of operating costs, and improvement of production efficiency.

[0035] Finally, it should be noted that the above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements for some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A method for distributing water in a mold for continuous casting, characterized in that: The following steps are involved: S1. Real-time collection of pulling speed data: The system monitors and collects the current pulling speed value A in real time through the pulling speed control module; S2. Determine the pulling speed interval: Based on the collected pulling speed value A, the system will determine the interval it is in and calculate it according to the preset water distribution formula; S3, calculate the water distribution: according to the different intervals of the casting speed value A, the water control parameters K and Z of the wide and narrow sides of the crystallizer are calculated by the preset segmented water distribution algorithm, where K is the water volume on the wide side of the crystallizer, and Z is the water volume on the narrow side of the crystallizer; S4, output control signal: after calculating K and Z, output the calculation results K and Z, convert these values ​​into control signals, and output them to the crystallizer water control module; S5. Adjust the water volume: The crystallizer water control module adjusts the water volume of the crystallizer according to the received control signal and performs water distribution operation to ensure that the water volume matches the casting speed; S6. End: After the water distribution adjustment is completed, the system process ends.

2. The method for distributing water in a mold for pouring a continuous casting machine and the automation system thereof according to claim 1, characterized in that: In the water distribution formula, the calculation formula for the K value is K=A*kx; the calculation formula for the Z value is Z=A*zx, where kx and zx are constants for a specific pulling speed range, and x is 1 to 23.

3. A continuous casting machine casting mold water distribution automation system, characterized in that: include: Casting speed control module, responsible for real-time acquisition and transmission of casting speed data of the continuous casting machine, and inputting the data into the PLC program module; The PLC program module receives the casting speed data and calculates the water volume control parameters K and Z on the wide and narrow sides of the crystallizer according to the preset segmented water distribution algorithm; The crystallizer water control module receives the K and Z values ​​output by the PLC program and adjusts the water distribution of the crystallizer according to these parameters; Data monitoring module: monitors key parameters in the entire water distribution process, including pulling speed and water volume, and provides real-time feedback to the PLC program for timely adjustment; Fault diagnosis module: When the system is abnormal, it can automatically diagnose the cause of the fault and take corresponding measures to ensure the stable operation of the system.

4. The automatic water distribution system for a continuous casting machine according to claim 1, characterized in that: It also includes a user interface and a communication network module. The user interface includes an interface for inputting casting speed data and viewing water distribution results; the communication network module is used to connect the casting speed control module, PLC program module, crystallizer water control module, data monitoring module, fault diagnosis module and user interface modules to ensure real-time transmission of data and control signals.

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