Error-proofing control system and method for VAR (vacuum arc remelting) furnace

Abstract

The invention belongs to the field of vacuum consumable electric arc furnaces, and particularly relates to a VAR vacuum consumable electric arc furnace error-proofing control system and method.The error-proofing control system comprises an upper computer and a lower computer connected with the upper computer, and the lower computer is provided with a technological parameter control module, an arc stabilizing current control module and a deflation control module; the process parameter control module is used for sending a process parameter checking prompt instruction to the upper computer after arc starting of the electric arc furnace; the arc stabilizing current control module is used for detecting the arc stabilizing current state after arc starting of the electric arc furnace and judging whether a prompt instruction is sent to the upper computer or not according to the arc stabilizing current state. The deflation control module is used for detecting the real-time state of a locking valve switch of the electric arc furnace after smelting of the electric arc furnace is finished, controlling a deflation unit of the lower computer according to the real-time state of the locking valve switch and judging whether a prompt instruction is sent to the upper computer or not. According to the method, a perfect smelting mistake-proofing mechanism is formed. The problem of misoperation in the smelting process is solved.

Description

Technical Field

[0001] The invention belongs to the field of vacuum consumable arc furnaces, and particularly relates to an anti-error control system and method for a VAR vacuum consumable arc furnace. Background Art

[0002] The equipment used in the melting process of titanium alloys is a VAR vacuum consumable arc furnace. This equipment has a high degree of automation. If operators are not careful or negligent during work, some serious problems are likely to occur. For example, on the one hand, it will add many intermediate processes to the subsequent ingot production process and extend the production cycle of the ingot; on the other hand, it will lead to material scrap and serious quality hazards.

[0003] All along, the work team has conducted special training on employee misoperations frequently every year, but the problem of personnel misoperations still has not been completely solved, and personnel operation problems of varying degrees almost occur every year. Through long-term summary, it is concluded that the parts that are most prone to errors in the melting process are, specifically, in different stages of melting, it is easy to forget to check the process parameters after the arc is struck, forget to turn on the stabilizing arc current after the arc is struck, and perform incorrect gas release operations when the locking valve is not closed after melting ends.

[0004] In view of this, the present invention is specifically proposed. Summary of the Invention

[0005] The purpose of the present invention is to overcome the above-mentioned disadvantages of the prior art, and propose an anti-error control system and method for a VAR vacuum consumable arc furnace. The system is provided with a process parameter control module, a stabilizing arc current control module, and a gas release control module on the lower computer, forming a complete set of melting anti-error mechanisms, avoiding quality problems of titanium alloy ingots caused by misoperations, improving melting efficiency, increasing output, and ensuring the stability and reliability of the melting process.

[0006] In order to achieve the above purpose, the present invention adopts the following technical solutions:

[0007] On the one hand, the present invention provides an anti-error control system for a VAR vacuum consumable arc furnace, including a host computer and a slave computer connected thereto. The slave computer is provided with a process parameter control module, a stabilizing arc current control module, and a gas release control module;

[0008] The process parameter control module is used to send a prompt instruction for checking process parameters to the host computer after the arc furnace starts to strike an arc;

[0009] The stabilizing arc current control module is used to detect the state of the stabilizing arc current after the arc furnace starts to strike an arc, and judge whether to send a prompt instruction to the host computer according to the state of the stabilizing arc current;

[0010] The deflation control module is used to detect the real-time state of the locking valve switch of the electric arc furnace after the melting in the electric arc furnace ends, control the deflation unit of the lower computer according to the real-time state of the locking valve switch, and at the same time judge whether to send a prompt instruction to the upper computer.

[0011] Further, the process parameter control module includes sending a first prompt pop-up box for verifying process parameters to the upper computer within 3 minutes (including 3 minutes) after the electric arc furnace starts to arc.

[0012] Further, the stable arc current control module includes controlling the upper computer to read the real-time stable arc current of the electric arc furnace after the electric arc furnace starts to arc. If the upper computer does not detect the stable arc current, it is judged that the stable arc is not turned on, and a second prompt pop-up box indicating that the stable arc is not turned on is sent to the upper computer; otherwise, the second prompt pop-up box is not sent.

[0013] Further, the second prompt pop-up box pops up repeatedly at a set frequency until the upper computer detects the stable arc current.

[0014] Further, the deflation control module includes detecting the real-time state of the locking valve switch of the electric arc furnace after the melting in the electric arc furnace ends. If the locking valve is in the open state, it controls the deflation unit to close the deflation function and sends a third prompt pop-up box indicating that the locking valve is not closed to the upper computer; otherwise, it does not control the deflation unit and does not send the third prompt pop-up box at the same time.

[0015] Further, the lower computer is a PLC controller.

[0016] On the other hand, the present invention provides a VAR vacuum consumable electrode arc furnace error prevention control method. Based on the above-mentioned VAR vacuum consumable electrode arc furnace error prevention control system, it includes the following steps:

[0017] Step 1, complete the pre-melting preparation of the electric arc furnace;

[0018] Step 2, after the electric arc furnace starts to arc, start melting the charge, and at the same time sequentially execute the process parameter control module and the stable arc current control module to ensure that the process parameters have been verified and the stable arc current is in the on state;

[0019] Step 3, cool down after the melting of the charge is completed, and then take out the furnace after cooling; it should be added that the locking valve is closed to realize the cooling of the molten material in a vacuum state. After the cooling time reaches the process requirements, the locking valve is opened to take out the furnace;

[0020] Step 4, execute the deflation control module, and perform the deflation operation when ensuring that the closing valve is in the closed state;

[0021] Step 5, after the deflation ends, the normal production of one side of the furnace position is completed, and then the furnace head of the electric arc furnace rotates to the other closed furnace chamber to start production.

[0022] Compared with the prior art, the present invention has the following beneficial effects:

[0023] 1) A misoperation prevention control system for a VAR vacuum consumable arc furnace provided by the present invention forms a complete melting misoperation prevention mechanism by adding a process parameter control module, a stable arc current control module, and a gas release control module to the PLC controller. During the production process, if there is any negligence, as long as the operation is carried out according to the system regulations, many quality problems can be avoided. At the same time, it will enable better control of our process quality control points, bring many benefits to production, reduce many intermediate processes, shorten the production cycle of the ingot, improve production efficiency, and reduce production costs.

[0024] 2) The process parameter control module of the misoperation prevention control system of the present invention can avoid the problem that the executed process parameters do not match the actual process parameters, which may lead to the scrapping of the produced products.

[0025] 3) The stable arc current control module of the misoperation prevention control system of the present invention avoids the damage to the crucible wall and the bottom pad of the crystallizer and the occurrence of unsafe accidents caused by some abnormal arc lights during the arc starting stage; it ensures that the ingot melting pool tissue structure and the ingot body are consistent during the arc starting stage, and ensures the uniformity of the head and tail components;

[0026] 4) The gas release control module of the misoperation prevention control system of the present invention eliminates the situation where the operator performs gas release operations with the locking valve not closed due to communication errors; the realization of this function also avoids the situation where new employees misjudge during the operation process, resulting in oxidation of the ingot head, improves the ingot quality, and prevents the waste of materials caused by turning due to ingot oxidation. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The drawings here are incorporated into the specification and form a part of this specification, and are used together with the specification to explain the principle of the present invention.

[0028] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, for those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0029] Figure 1 It is a schematic diagram of the VAR vacuum consumable melting process;

[0030] Figure 2 It is a prompt pop-up window for process parameter verification in the embodiment of the present invention;

[0031] Figure 3 It is a logic diagram of the stable arc current control module of the misoperation prevention control system of the present invention;

[0032] Figure 4This is the prompt pop-up window for the arc stabilization not being turned on in the embodiments of the present invention;

[0033] Figure 5 This is the logic diagram of the gas release control module of the error prevention control system of the present invention;

[0034] Figure 6 This is the prompt pop-up window for the locking valve not being closed in the embodiments of the present invention;

[0035] Figure 7 This is the flowchart of the error prevention control method of the present invention. Detailed implementation manners

[0036] Here, the exemplary embodiments will be described in detail. The implementation manners described in the following exemplary embodiments do not represent all implementation manners consistent with the present invention. On the contrary, they are only examples consistent with some aspects of the present invention detailed in the appended claims.

[0037] On the one hand, please refer to Figures 1 to 6 , this embodiment provides an error prevention control system for a VAR vacuum consumable arc furnace, including a host computer and a slave computer connected thereto. A process parameter control module, an arc stabilization current control module, and a gas release control module are provided on the slave computer;

[0038] The process parameter control module is used to send a prompt instruction for verifying process parameters to the host computer after the arc furnace starts to arc;

[0039] The arc stabilization current control module is used to detect the arc stabilization current state after the arc furnace starts to arc, and judge whether to send a prompt instruction to the host computer according to the arc stabilization current state;

[0040] The gas release control module is used to detect the real-time state of the locking valve switch of the arc furnace after the arc furnace melting is completed (i.e., after melting - cooling - tapping), control the gas release unit of the slave computer according to the real-time state of the locking valve switch, and at the same time judge whether to send a prompt instruction to the host computer.

[0041] Among them, in this embodiment, the slave computer is a PLC controller.

[0042] After the arc furnace starts to arc (before formal melting), the verification of some key process parameters (such as important parameters like voltage, current, vacuum degree, melting speed, arc stabilization current, etc.) is also crucial. If the executed process parameters do not match the actual process parameters, the ingot produced will be a waste product. It can be seen that the verification of process parameters is particularly important. Therefore, as Figure 2 shown, in this embodiment, the error prevention control system includes a first prompt pop-up window for verifying process parameters sent to the host computer 3 minutes after the arc furnace starts to arc.

[0043] Specifically, a process verification prompt function is added to the arc furnace (VAR) PLC controller. After the arc is struck, regardless of whether the operator has verified the process parameters, the process parameter control module will pop up a window on the upper computer to remind the operator whether the operation has been completed, which can ensure the correctness of the process parameters.

[0044] For detailed description, in this embodiment, the scripting language involved in the process parameter control module is as follows:

[0045] IF(Recipe_Check == 0)

[0046] ShowPicture "Process not verified";

[0047] If(Recipe_Check == 1 && Recipe_vertify == 1)

[0048] ClosePicture "Process not verified";

[0049] Furthermore, the timely activation of the stable arc current during the melting process is crucial for product quality and is also the cornerstone for us to obtain qualified titanium alloy ingots. If the stable arc current is not activated in a timely manner, there will be significant differences in the composition of the ingot. If the stable arc current is activated in a timely manner, the stable arc can cause beneficial rotation of the molten pool. Therefore, as Figure 3 and Figure 4 shown, the anti-error control system of the present invention includes a stable arc current control module. Specifically, the stable arc current control module includes controlling the upper computer to read the real-time stable arc current of the arc furnace after the arc furnace starts to strike an arc. If the upper computer does not detect the stable arc current, it is determined that the stable arc is not activated, and a second prompt window indicating that the stable arc is not activated currently is sent to the upper computer; otherwise, the second prompt window is not sent.

[0050] Specifically, in this embodiment, a stable arc current prompt automatic pop-up window is added to the operation process in combination with the VAR vacuum consumable arc furnace PLC controller. After the arc is struck and melting starts, if the stable arc current control module detects that the operator has forgotten to activate the stable arc due to negligence, a window will automatically pop up on the upper computer to remind the operator to activate the stable arc current in a timely manner.

[0051] When the second prompt window is closed or switched to another interface, and the upper computer does not detect the stable arc current, the second prompt window pops up every 30s until the upper computer detects the stable arc current.

[0052] For detailed description, in this embodiment, the scripting language involved in the stable arc current control module is as follows:

[0053] If(coil_current>0 && coil_actual == 0)

[0054] ShowPicture "Stable arc not enabled";

[0055] If (coil_current > 0 && coil_actual > 0)

[0056] ClosePicture "Stable arc not enabled".

[0057] In this embodiment, the VAR consumable arc furnace equipment is a two-station type with a rotating furnace head for cyclic production. When the melting at one furnace position is completed and the furnace head needs to rotate to the other closed furnace chamber for production, the melting of one furnace of materials is completed. The vacuum melting production process is charging at position 1 - discharging - charging at position 2. Under the condition that all levels of pumps in the vacuum system are working normally, cyclic conversion production is carried out between positions 1 and 2. Currently, the VAR equipment relies on the closing of the blocking valve to achieve the vacuum state of the cooled materials, ensuring that the materials do not come into contact with the outside air at high temperatures. When the furnace chamber is close to the atmospheric state after outgassing, the furnace head can rotate freely and production can start at the adjacent furnace position. (It should be noted that during normal melting, the blocking valve is open. After melting is completed, the blocking valve needs to be closed to cool the melted materials in a vacuum state. At this time, the furnace chamber is in a vacuum state under the action of the vacuum pump group. After the cooling time reaches the process requirements, the blocking valve is opened to discharge the furnace. Due to the action of the vacuum pump group, if the furnace head needs to rotate, the furnace chamber needs to be outgassed to the atmospheric state so that the furnace head can be lifted to complete the rotation).

[0058] In the above normal operation process, due to the negligence of operators or poor communication, the blocking valve may be left open during outgassing. This causes a large amount of air to enter the furnace chamber, and the oxygen in the air reacts instantly with the crystallized ingot at high temperatures, resulting in severe oxidation of the head of the ingot. Severely oxidized materials are directly scrapped, and the production cycle of the finished ingot is also prolonged. Therefore, in the normal production process, the correct closing process of the blocking valve is extremely important, otherwise, it will seriously affect the composition and production efficiency of the ingot. For this reason, as Figure 5 and Figure 6 shown, the anti-error control system of this embodiment includes a outgassing control module. This outgassing control module includes detecting the open / closed state of the blocking valve and giving a prompt after the arc furnace melting is completed. If the blocking valve is in the open state, it controls the outgassing unit to close the outgassing function and sends a third prompt pop-up window indicating that the blocking valve is not closed to the host computer; otherwise, it does not control the outgassing function of the outgassing unit and does not send the third prompt pop-up window.

[0059] Specifically, in this embodiment, in combination with the PLC controller of the VAR vacuum consumable arc furnace, a function of prompting whether the blocking valve is closed after melting is added. If the blocking valve is not closed and the outgassing button is clicked, the outgassing button will not be enabled. If the pop-up window indicating that the blocking valve is closed disappears and the outgassing button is enabled, outgassing and subsequent operations can be performed at this time.

[0060] For detailed description, in this embodiment, the scripting language involved in the air release control module is as follows:

[0061] If (Melt_processEnd == 1 && State_LockValve == 0)

[0062] Disable Button “Air Release”;

[0063] ShowPicture “Lock Valve Not Closed”;

[0064] If (Melt_processEnd == 1 && State_LockValve == 1)

[0065] Enable Button “Air Release”;

[0066] ClosePicture “Lock Valve Not Closed”.

[0067] It should be noted that the prompt messages (such as the lock valve not being closed) displayed in the first prompt dialog box, the second prompt dialog box, and the third prompt dialog box are not limited, as long as they can clearly prompt the staff.

[0068] On the other hand, as Figure 7 shown, this embodiment provides a wrong prevention control method for a VAR vacuum consumable arc furnace. Based on the above-mentioned VAR vacuum consumable arc furnace wrong prevention control system, it includes the following steps:

[0069] Step 1: Complete the pre-melting preparation of the arc furnace;

[0070] Step 2: After the arc furnace is ignited, start melting the materials, and at the same time, sequentially execute the process parameter control module and the stable arc current control module to ensure that the process parameters have been verified and the stable arc current is in the on state;

[0071] Step 3: Cool down after the melting is completed. When the cooling time reaches the process requirements, open the lock valve to take out the furnace; among them, the lock valve is closed during the cooling process to cool the melted materials in a vacuum state;

[0072] Step 4: Execute the stable arc current control module. When ensuring that the closing valve is in the closed state, control the air release unit to open the air release function to perform the air release operation (that is, clicking the air release button can perform the air release and subsequent operations);

[0073] Step 5: After the air release is completed, the normal production of one side of the furnace position is completed. Subsequently, the furnace head of the arc furnace rotates to the other closed furnace chamber to start production.

[0074] The above are only specific embodiments of the present invention, enabling those skilled in the art to understand or implement the present invention. Various modifications to these embodiments will be obvious to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present invention.

[0075] It should be understood that the present invention is not limited to the content already described above, and various modifications and changes can be made without departing from its scope. The scope of the present invention is only limited by the appended claims.

Claims

1. A VAR vacuum consumable electrode arc furnace anti-mistake control system, characterized in that, It includes a host computer and a slave computer connected thereto. A process parameter control module, a stable arc current control module, and a gas release control module are provided on the slave computer; The process parameter control module is used to send a prompt instruction for verifying process parameters to the host computer after the electric arc furnace is started; The stable arc current control module is used to detect the stable arc current state after the electric arc furnace is started, and judge whether to send a prompt instruction to the host computer according to the stable arc current state; The gas release control module is used to detect the real-time state of the locking valve switch of the electric arc furnace after the melting of the electric arc furnace is completed, control the gas release unit of the slave computer according to the real-time state of the locking valve switch, and judge whether to send a prompt instruction to the host computer at the same time.

2. The anti-misoperation control system for VAR vacuum consumable arc furnace according to claim 1, wherein The process parameter control module includes a first prompt pop-up box for sending the verification of process parameters to the host computer within 3 minutes after the electric arc furnace is started.

3. The anti-misoperation control system for VAR vacuum consumable arc furnace according to claim 1, wherein, The stable arc current control module includes controlling the host computer to read the real-time stable arc current of the electric arc furnace after the electric arc furnace is started. If the host computer does not detect the stable arc current, it is judged that the stable arc is not turned on, and a second prompt pop-up box indicating that the stable arc is not turned on is sent to the host computer; Otherwise, the second prompt pop-up box is not sent.

4. The anti-misoperation control system of the VAR vacuum consumable arc furnace according to claim 3, characterized in that, The second prompt pop-up box pops up repeatedly at a set frequency until the host computer detects the stable arc current.

5. The anti-misoperation control system of the VAR vacuum consumable arc furnace according to claim 1, wherein, The gas release control module includes detecting the real-time state of the locking valve switch of the electric arc furnace after the melting of the electric arc furnace is completed. If the locking valve is in the open state, control the gas release unit to close the gas release function, and send a third prompt pop-up box indicating that the locking valve is not closed to the host computer; otherwise, the gas release unit is not controlled, and the third prompt pop-up box is not sent at the same time.

6. The anti-misoperation control system of the VAR vacuum consumable arc furnace according to claim 1, characterized in that, The slave computer is a PLC controller.

7. A method for error-proof control of a VAR vacuum consumable arc furnace, characterized in that, Based on the anti-error control system for VAR vacuum consumable arc furnace according to any one of claims 1 to 6, it includes the following steps: Step 1, complete the pre-melting preparation of the electric arc furnace; Step 2, start melting after the electric arc furnace is started, and sequentially execute the process parameter control module and the stable arc current control module to ensure that the process parameters have been verified and the stable arc current is in the on state; Step 3, cool after the melting is completed, and wait for cooling before discharging; Step 4, execute the gas release control module, and perform the gas release operation when ensuring that the closing valve is in the closed state; Step 5, after the gas release is completed, the normal production of one side of the furnace position is completed, and then the furnace head of the electric arc furnace rotates to the other closed furnace chamber to start production.

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