Bottom pouring type pouring machine control system and working method thereof

Abstract

The invention discloses a bottom pouring type casting machine control system and a working method thereof, the bottom pouring type casting machine control system is used for controlling a bottom pouring type casting machine to carry out casting operation, and the bottom pouring type casting machine control system comprises a positioning module used for positioning the position of a pouring gate of a mold box needing to be poured; the temperature control module is used for controlling the temperature of molten iron in the casting ladle and comprises a temperature sensor and a plasma heating mechanism; the automatic pouring module comprises a weighing sensor I and a plug rod driving unit of a plug rod mechanism, the weighing sensor I is cushioned between the casting ladle mounting flange plate and the transverse frame, and the plug rod driving unit can drive a plug rod to control the opening degree of a water outlet in the bottom of the casting ladle; the PLC is electrically connected with the positioning module, the temperature sensor, the plasma heating mechanism, the first weighing sensor, the plug rod driving unit and the HMI upper computer. The temperature of the molten iron is detected and corrected in real time, the precise pouring temperature is guaranteed, meanwhile, the amount of the molten iron output by the pouring ladle is detected in real time, and precise casting is guaranteed.

Description

Technical Field

[0001] The present invention relates to the technical field of metallurgical casting, and in particular to a bottom pouring type casting machine control system and a working method thereof. Background Art

[0002] Existing bottom-pouring casting processes rely heavily on manual operation, resulting in low control accuracy, unstable processes, and inconsistent production cycles, making them difficult to meet the requirements of high-precision casting. In recent years, control systems using industrial cameras to monitor the pouring process have gradually emerged, but these systems only control the pouring speed. Existing bottom-pouring casting systems lack real-time monitoring and automated management of molten iron temperature and production process data, resulting in low production efficiency and significant fluctuations in product quality.

[0003] For example, the invention patent with the announcement number CN105127405A discloses a line laser automated bottom pouring pouring machine, which includes: a pouring ladle, a ladle cover device, a transverse moving trolley, a longitudinal moving trolley, a tilting device, a plug rod device, and a line laser control system; the plug rod device is arranged on the upper side of the tilting device; the tilting device is arranged on the upper side of the pouring ladle; the plug rod device is controlled by a servo motor to control the plug rod stroke, thereby controlling the molten iron flow rate for pouring; the line laser control system is composed of a line laser emitting device and a line laser receiving device. The line laser automated bottom pouring pouring machine in the technical solution of this invention can realize the automation and precision of molten iron pouring, avoiding the problems of wrong pouring, miscasting or inaccurate pouring. However, there is no real-time monitoring of the molten iron temperature, and no detection of the production process data, which cannot meet the production requirements of high-quality casting products.

[0004] In order to overcome the above problems, a bottom pouring casting machine control system and a working method thereof are needed. Summary of the Invention

[0005] The purpose of the present invention is to provide a bottom pouring casting machine control system and a working method thereof, which detects the molten iron temperature and corrects it in real time, ensuring accurate pouring temperature, and at the same time performs real-time detection of the output molten iron volume of the ladle, ensuring accurate casting.

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

[0007] The present invention provides a bottom pouring machine control system for controlling the bottom pouring machine to perform casting and pouring operations, comprising:

[0008] A positioning module is used to locate the gate position of the casting box and drive the longitudinal frame and the transverse frame to move along the longitudinal track and the transverse guide rail respectively so that the casting ladle is located above the casting box;

[0009] A temperature control module, for controlling the temperature of the molten iron in the ladle, comprising a temperature sensor and a plasma heating mechanism, wherein the temperature sensor is used to detect the temperature of the molten iron in the ladle, and the plasma heating mechanism is capable of heating the molten iron in the ladle;

[0010] An automatic pouring module, comprising a load cell 1 and a stopper rod drive unit of a stopper rod mechanism, wherein the load cell 1 is provided between the ladle mounting flange and the transverse frame, and the stopper rod drive unit is capable of driving the stopper rod of the stopper rod mechanism to move back and forth in a vertical direction, thereby controlling the opening of the water outlet at the bottom of the ladle;

[0011] A PLC controller is electrically connected to the positioning module, the temperature sensor, the plasma heating mechanism, a weighing sensor and the plug rod driving unit; and the PLC controller is communicatively connected to the HMI host computer.

[0012] Furthermore, the positioning module includes a visual sensor, servo motor 1 and servo motor 2. The visual sensor is arranged at the bottom of the transverse frame through a bracket and can capture and locate the gate of the mold box. The servo motor 1 and servo motor 2 drive the longitudinal frame and the transverse frame to move respectively.

[0013] Furthermore, the temperature control module also includes an infrared imaging camera. A flow channel is also provided below the water outlet. The flow channel is arranged at an angle, and the upper end of the flow channel is connected directly below the water outlet. The bottom end of the flow channel guides the molten iron into the gate of the mold box; the infrared imaging camera is arranged below the transverse frame through a bracket and can measure the temperature of the molten iron flowing in the flow channel in real time. The infrared imaging camera feeds back the temperature signal to the PLC controller.

[0014] Furthermore, it also includes an inoculant preparation module, which includes an inoculant feeding mechanism; the infrared imaging camera includes a laser induced breakdown spectroscopy module, and the infrared imaging camera can also measure the composition of the flowing molten iron in real time. The PLC controller adjusts the inoculant feeding mechanism in real time to supply the inoculant along the flow according to the flow rate, temperature and composition of the molten iron in the flow trough.

[0015] Furthermore, the inoculant feeding mechanism includes a hopper, a discharge pipe joint, an auger shaft, a servo motor three and a feeding pipe. The hopper stores the flow-following inoculant, the discharge pipe joint is horizontally arranged on the side wall of the bottom cone of the hopper, the auger shaft is horizontally arranged in the bottom cone of the hopper and the discharge pipe joint, the servo motor three is arranged on the opposite side wall of the bottom cone of the hopper, and the servo motor three drives the auger shaft to rotate; the top end of the feeding pipe is connected to the port of the discharge pipe joint, and the outlet end of the feeding pipe is located above the bottom end of the flow trough.

[0016] Furthermore, the base of the hopper is mounted on the transverse frame via a second weighing sensor, and both the second weighing sensor and the third servo motor are electrically connected to the PLC controller.

[0017] Furthermore, it also includes a slag blocking plate, the top of which is fixed to the outer wall of the water outlet through a hoop, and the main body of the slag blocking plate is vertically arranged between the water outlet and the infrared imaging camera.

[0018] Furthermore, a guide plate for guiding slag is provided at the bottom end of the slag baffle, and the guide plate is a C-shaped insulation material plate with the opening facing downward. The guide plate guides the slag of the molten iron in the flow trough to both sides; the detection laser landing point of the infrared imaging camera is located in the detection area below the guide plate.

[0019] Furthermore, it also includes a sealing component, which is arranged at the bottom end of the flow channel and can seal the bottom end of the flow channel that is not positioned directly above the gate.

[0020] The present invention also discloses a working method of a bottom pouring pouring machine control system, which uses any of the above-mentioned bottom pouring pouring machine control systems to control the bottom pouring pouring machine to perform automatic pouring operations.

[0021] Compared with the prior art, the present invention has the following beneficial technical effects:

[0022] The control system for the bottom pouring machine of the present invention, through the provision of a positioning module, enables the longitudinal and transverse frames to accurately carry the ladle and position it above the mold box for pouring molten iron. By adding a plasma heating mechanism to the transverse frame, the molten iron in the ladle can be heated at any time, ensuring the pouring temperature. A pair of weight sensors detect the weight of the ladle, achieving control of the pouring volume and improving pouring accuracy. The control system for the bottom pouring machine of the present invention detects the molten iron temperature and makes real-time corrections, ensuring accurate pouring temperature. It also performs real-time detection of the molten iron output from the ladle, ensuring precise casting.

[0023] Furthermore, a visual sensor is used to locate the pouring gate, facilitating control of servo motors 1 and 2, ensuring accurate movement of the ladle above the pouring gate and preventing spilled molten iron from spilling. Simultaneously, the visual sensor also measures the height of the molten iron level within the pouring gate, facilitating flow control and maintaining a stable level within the gate, thereby ensuring pouring quality. A launder beneath the outlet allows for temperature measurement of the spread molten iron, improving accuracy. It also facilitates the flow-through supply of inoculant, preventing degradation caused by adding the inoculant to the ladle. By monitoring the flow, temperature, and composition of the molten iron within the launder in real time and adjusting the inoculant supply according to an empirical formula, superior casting quality can be achieved. Servo motor 3 controls the auger shaft speed to adjust the inoculant supply. Load cell 2 allows for real-time monitoring of the added and remaining inoculant levels within the hopper, ensuring precise control of addition. By adding a slag baffle, the molten iron flowing out of the water outlet can be prevented from splashing toward the infrared imaging camera, thus preventing high-temperature metal slag from damaging the equipment and also reducing the impact of splashing on the measuring laser beam. By adding a guide plate at the bottom of the slag baffle, the slag of the molten iron in the flow trough is diverted to prevent it from appearing in the detection area, that is, the impact of the slag on the laser induced breakdown spectrum of the infrared imaging camera is avoided, and the accuracy of the measured analysis components is guaranteed. This is also the advantage of adding a flow trough. If the detection area of the infrared imaging camera is set on the pouring liquid surface, the impact of slag will not be avoided. By the plug rod of the plug rod mechanism pushing out to close the water outlet, the sealing assembly closes the bottom end of the flow trough, thereby reducing the dripping waste of the residual molten iron during the movement process and improving economic benefits. By electrically interlocking the solenoid valve of the control cylinder and the control relay of the plug rod mechanism, the overflow of molten iron caused by malfunction is avoided. By connecting with the MES system, the informatization of the pouring process is realized, and a connection is established with material feeding and inventory, thereby stabilizing production capacity. By adding a learning module, a big data analysis module, and an AI intelligent voice module, the intelligence level of the control system of the bottom pouring pouring machine of the present invention is improved, which facilitates the optimization of the production pouring rhythm and process and improves the quality of casting products.

[0024] The bottom pouring pouring machine control system working method of the present invention reduces manual operation content, realizes automatic and intelligent pouring, can realize real-time monitoring of temperature and molten iron composition, and ensures casting quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present invention will be further described below with reference to the accompanying drawings.

[0026] Figure 1 This is a schematic diagram of the application of the control system of the bottom pouring pouring machine of the present invention;

[0027] Figure 2This is a schematic diagram of the control system composition of the bottom pouring pouring machine of the present invention;

[0028] Figure 3 This is a schematic diagram of the main cross-sectional structure of the water outlet of the ladle of the present invention;

[0029] Figure 4 This is a schematic diagram of the main cross-sectional structure of the inoculant feeding mechanism of the present invention;

[0030] Figure 5 It is a schematic diagram of the cross-sectional structure of the flow channel of the present invention from above.

[0031] Explanation of the accompanying symbols: 1. Longitudinal frame; 2. Transverse frame; 3. Ladle; 301. Water outlet; 4. Plug rod mechanism; 5. Visual sensor; 6. Weighing sensor 1; 7. Temperature sensor; 8. Plasma heating mechanism; 9. Infrared imaging camera; 10. Servo motor 1; 11. Servo motor 2; 12. Inoculant feeding mechanism; 121. Discharge pipe joint; 122. Auger shaft; 123. Servo motor 3; 124. Feeding pipe; 125. Weighing sensor 2; 13. Flow chute; 14. Slag baffle; 141. Guide plate; 15. Mould box; 151. Gate; 16. Cylinder; 17. Gate; 18. Electric control cabinet; 19. Detection area. DETAILED DESCRIPTION

[0032] The core of the present invention is to provide a bottom pouring casting machine control system and its working method, which detects the molten iron temperature and corrects it in real time, ensuring accurate pouring temperature. At the same time, the output molten iron volume of the ladle is detected in real time, ensuring accurate casting.

[0033] The following will be combined with the accompanying drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0034] In the description of the present invention, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inside", "outside", etc., indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore should not be understood as limiting the present invention.

[0035] With reference to the accompanying drawings, Figure 1 This is a schematic diagram of the application of the control system of the bottom pouring pouring machine of the present invention; Figure 2This is a schematic diagram of the control system composition of the bottom pouring pouring machine of the present invention; Figure 3 This is a schematic diagram of the main cross-sectional structure of the water outlet of the ladle of the present invention; Figure 4 This is a schematic diagram of the main cross-sectional structure of the inoculant feeding mechanism of the present invention; Figure 5 It is a schematic diagram of the cross-sectional structure of the flow channel of the present invention from above.

[0036] In one embodiment, the present invention provides a bottom pouring machine control system for controlling the bottom pouring machine to perform automatic pouring operations, and is particularly suitable for a bottom pouring machine in the form of a track gantry. The control system includes:

[0037] The positioning module is used to locate the pouring gate 151 of the mold box 15 to be poured, and drives the longitudinal frame 1 and transverse frame 2 to move along the longitudinal track and transverse guide rails respectively, so that the ladle 3 is positioned above the mold box 15 and pours molten iron into the pouring gate 151. The longitudinal frame 1 moves longitudinally along the longitudinal track laid on the workshop floor, and the transverse frame 2 is installed on the transverse guide rails of the longitudinal frame 1. The pouring ladle 3 is mounted on the transverse frame 2.

[0038] The temperature control module is used to control the temperature of the molten iron in the ladle 3, and includes a temperature sensor 7 and a plasma heating mechanism 8. The temperature sensor 7 is used to detect the temperature of the molten iron in the ladle 3, and the plasma heating mechanism 8 can heat the molten iron in the ladle 3. When the temperature of the molten iron in the ladle 3 is lower than the set range, the plasma heating mechanism 8 starts to work to heat the molten iron in the ladle, so that the temperature of the molten iron is kept within the set range.

[0039] The automatic pouring module includes a load cell 6 and a stopper rod drive unit for the stopper rod mechanism 4. The load cell 6 is placed between the ladle 3 mounting flange and the transverse frame 2. In practice, there are multiple load cells 6, spaced apart at intervals along the outer bottom edge of the ladle 3 mounting flange. The load cells 6 measure the weight of the ladle 3 in real time and provide feedback to the PLC controller. The stopper rod drive unit drives the stopper rod of the stopper rod mechanism 4 in vertical reciprocating motion, thereby controlling the opening of the water outlet 301 at the bottom of the ladle 3. Specifically, the stopper rod drive unit utilizes an electric push rod or hydraulic cylinder to drive a transmission rod, thereby achieving reciprocating motion of the stopper rod.

[0040] A PLC controller is electrically connected to the positioning module, temperature sensor 7, plasma heating mechanism 8, load cell 6, and the plug rod drive unit. The PLC controller is communicatively connected to an HMI host computer, whose touch screen facilitates human-computer interaction. The PLC controller and the HMI host computer are loaded with control programs.

[0041] By installing a positioning module, the longitudinal frame 1 and the transverse frame 2 precisely carry the ladle 3 above the mold box 15 for pouring molten iron. By adding a plasma heating mechanism 8 to the transverse frame 2, the molten iron in the ladle 3 can be heated at any time, ensuring the pouring temperature. By detecting the weight of the ladle 3 using a weight sensor 6, the pouring amount is controlled, improving pouring accuracy. The bottom pouring machine control system of the present invention detects the molten iron temperature and makes real-time corrections, ensuring accurate pouring temperature. It also performs real-time detection of the molten iron output from the ladle, ensuring precise casting.

[0042] In one embodiment of the present invention, Figure 1 and Figure 2 As shown, the positioning module includes a vision sensor 5, servo motor 10, and servo motor 2 11. The vision sensor 5 is mounted on the bottom of the transverse frame 2 via a bracket and can capture and locate the gate 151 of the mold box 15. Servo motor 10 and servo motor 2 11 drive the movement of the longitudinal frame 1 and transverse frame 2, respectively. The PLC controller is connected to servo motor 10 and servo motor 2 11 via a driver.

[0043] Specifically, the visual sensor 5 uses an industrial camera to capture images, not only capturing the position of the pouring gate 151 but also the height of the molten iron level within the pouring gate 151, facilitating the PLC controller to control the level. The PLC controller includes a PID control module that controls the stopper rod drive unit to drive the stopper rod based on the level of the molten iron within the pouring gate 151, thereby adjusting the opening of the water outlet 301 and precisely controlling the molten iron flow rate to maintain a stable molten iron level within the pouring gate 151.

[0044] Obviously, a line laser device may be added to monitor the height of the molten iron level in the pouring nozzle 151. Similar simple replacement methods fall within the scope of protection of the present invention.

[0045] By setting the visual sensor 5, the position of the pouring gate 151 is located, which is convenient for controlling the action of servo motor 10 and servo motor 2 11, so that the ladle 3 is accurately moved to the top of the pouring gate 151 to prevent the spilled molten iron from spilling out; at the same time, the visual sensor 5 can also collect the height of the molten iron liquid level in the pouring gate 151, which is convenient for controlling the molten iron flow rate to achieve the stability of the molten iron liquid level in the pouring gate 151 and ensure the pouring quality.

[0046] In one embodiment of the present invention, Figure 1 and Figure 3As shown, the temperature control module also includes an infrared imaging camera 9. A chute 13 is also provided below the water outlet 301. The chute 13 is tilted, with its upper end directly below the water outlet 301. The bottom of the chute 13 directs the molten iron into the pouring gate 151 of the molding box 15. The infrared imaging camera 9 is mounted below the transverse frame 2 via a bracket and is capable of real-time temperature measurement of the molten iron flowing within the chute 13. The infrared imaging camera 9 provides feedback of the temperature signal to the PLC controller.

[0047] Specifically, if Figure 1 and Figure 3 As shown, the system also includes an inoculant preparation module, which includes an inoculant feeding mechanism 12. The infrared imaging camera 9 includes a laser-induced breakdown spectroscopy module, which integrates LIBS detection capabilities. The infrared imaging camera 9 can also measure the composition of the flowing molten iron in real time. The PLC controller adjusts the inoculant feeding mechanism 12 to supply inoculant in real time based on the flow rate, temperature, and composition of the molten iron in the launder 13.

[0048] The chute 13 provided below the water outlet 301 guides the molten iron. This not only allows for temperature measurement of the spread molten iron, improving temperature measurement accuracy, but also facilitates the flow-by-flow supply of inoculant, avoiding inoculant degradation caused by adding the inoculant to the ladle 3. By real-time monitoring of the flow rate, temperature, and composition of the molten iron within the chute 13 and adjusting the inoculant supply according to an empirical formula, better casting quality can be achieved.

[0049] In one embodiment of the present invention, Figure 1 and Figure 4 As shown, the inoculant feeding mechanism 12 includes a hopper, a discharge pipe joint 121, an auger shaft 122, a servo motor 123, and a feeding pipe 124. The hopper stores the flowing inoculant and is mounted on the transverse frame 2. The discharge pipe joint 121 is horizontally mounted on the side wall of the hopper's bottom cone. The auger shaft 122 is horizontally mounted within the hopper's bottom cone and the discharge pipe joint 121. The servo motor 123 is mounted on the opposite side wall of the hopper's bottom cone and drives the auger shaft 122 to rotate. The top end of the feeding pipe 124 is connected to the port of the discharge pipe joint 121, and the outlet end of the feeding pipe 124 is located above the bottom end of the flow trough 13.

[0050] Specifically, if Figure 4 As shown, the base of the hopper is installed on the transverse frame 2 through a weighing sensor 2 125, and multiple weighing sensors 2 125 are evenly distributed around the circumference between the base of the hopper and the transverse frame 2. The weighing sensor 2 125 and the servo motor 3 123 are both electrically connected to the PLC controller.

[0051] Specifically, if Figure 4As shown, the port of the feed pipe joint 121 is a downward elbow, and the top of the feed pipe 124 is connected to the bottom of the elbow through a pipe clamp. The bottom end of the feed pipe 124 is set as a flat mouth, and the length direction of the flat mouth is parallel to the width direction of the flow channel 13, so as to evenly distribute the material.

[0052] The rotation speed of the auger shaft 122 is controlled by the servo motor 3 123 to adjust the inoculant supply. The setting of the weighing sensor 2 125 can monitor the addition and remaining amount of the inoculant in the hopper in real time, ensuring accurate addition control.

[0053] In one embodiment of the present invention, Figure 1 、 Figure 3 and Figure 5 As shown, it also includes a slag blocking plate 14 , the top of which is fixed to the outer wall of the water outlet 301 through a hoop, and the main body of the slag blocking plate 14 is vertically disposed between the water outlet 301 and the infrared imaging camera 9 .

[0054] Specifically, if Figure 3 and Figure 5 As shown, the bottom end of the slag baffle 14 is also provided with a deflector 141 for diverting slag. Deflector 141 is a C-shaped insulating plate with a downward opening. Deflector 141 extends into the trough 13 without contacting the bottom surface of the trough 13. Deflector 141 diverts slag from the molten iron in the trough 13 to the sides. The detection laser of the infrared imaging camera 9 is located in the detection area 19 below the deflector 141. No slag will pass through the detection area 19.

[0055] By adding a slag retaining plate 14, the molten iron flowing out of the water outlet 301 can be prevented from splashing toward the infrared imaging camera 9, thus preventing the high-temperature metal slag from damaging the equipment and also reducing the impact of the splashing on the measuring laser beam. By adding a guide plate 141 at the bottom of the slag retaining plate 14, the slag of the molten iron in the flow trough 13 is diverted to prevent it from appearing in the detection area 19, that is, the impact of the slag on the laser-induced breakdown spectrum of the infrared imaging camera 9 is avoided, ensuring the accuracy of the measured analysis components. This is also the advantage of adding a flow trough 13. If the detection area of the infrared imaging camera 9 is set on the liquid surface of the pouring gate 151, the impact of the slag will not be avoided.

[0056] In one embodiment of the present invention, Figure 3 and Figure 5As shown, the control system of the bottom pouring pouring machine of the present invention further includes a sealing assembly, which is disposed at the bottom end of the chute 13. The sealing assembly is capable of sealing the bottom end of the chute 13 that is not positioned directly above the pouring gate 151. In other words, during the movement of the ladle 3, although the stopper rod of the stopper rod mechanism 4 blocks the water outlet 301, molten iron remains at the bottom end of the water outlet 301 and on the chute 13. The sealing assembly seals the bottom end of the chute 13, thereby reducing the waste of the residual molten iron from dripping during the movement process.

[0057] Specifically, if Figure 3 and Figure 5 As shown, the sealing assembly includes a cylinder bracket, a cylinder 16, and a gate 17. Cylinder 16 is mounted head-down on the sidewall at the bottom end of the flow channel 13 through the cylinder bracket. The bottom end of the piston rod of cylinder 16 is connected to gate 17 via a thermal insulation pad and a locking fastener. The cylinder bracket and gate 17 are made of thermally insulating material. Guide grooves for gate 17 are defined in the cylinder bracket and the sidewall at the bottom end of the flow channel 13. Gate 17 can seal the bottom end of the flow channel 13.

[0058] It should be noted that the cylinder 16 adopts a cylinder with a higher heat resistance grade, and the solenoid valve that controls the cylinder 16 is electrically interlocked with the control relay of the plug rod mechanism 4. The control cylinder 16 can only be pushed out when the plug rod of the plug rod mechanism 4 is pushed out to close the water outlet 301.

[0059] When the stopper rod of the stopper rod mechanism 4 pushes out to seal the water outlet 301, the sealing assembly seals the bottom end of the launder 13, thereby reducing the amount of residual molten iron that drips and wastes during movement, thereby improving economic efficiency. The electrical interlocking between the solenoid valve of the control cylinder 16 and the control relay of the stopper rod mechanism 4 prevents molten iron overflow due to malfunction.

[0060] In one embodiment of the present invention, the HMI host computer is communicatively connected to the MES system. The HMI host computer utilizes a wireless data exchange module to wirelessly transmit data with the factory's MES system, collecting and analyzing electric furnace molten iron status information and laboratory data in real time to optimize the pouring cycle and production process. The control system of the present invention automatically generates a product number each time ladle 3 is filled with iron, and associates the molten iron composition, temperature, and pouring parameters with the product number. All data is then uploaded to the MES system via a wireless network, enabling full-process data traceability.

[0061] Specifically, the HMI host computer internal control software platform also integrates a learning module, a big data analysis module and an AI intelligent voice module. The control system can adjust the pouring parameters in real time to ensure the stability and efficiency of the production process.

[0062] Among them, the learning module means that during manual operation, the PLC records the corresponding relationship between all operation points and time to make a mathematical model. By releasing the mathematical model, the output action form during automatic pouring is consistent with manual operation.

[0063] The big data analysis module is used in equipment operation and maintenance. It converts equipment operation data, fault data, mechanism data, sample enhancement data, and expert knowledge data into samples and knowledge. It deeply integrates sample enhancement, large models, digital twins, and other technologies to create intelligent equipment operation and maintenance applications.

[0064] The AI intelligent voice module enables workers to control production equipment through voice commands in certain industrial safety scenarios. For example, workers can say commands such as "Start the air cooling equipment" or "Adjust the compressed air to 4 kg," improving operational convenience and efficiency. Voice control is particularly advantageous when both hands are occupied or in complex operating environments.

[0065] By connecting with the MES system, the informatization of the pouring process is realized, and a connection is established with material feeding and inventory, thereby stabilizing production capacity. By adding a learning module, a big data analysis module, and an AI intelligent voice module, the intelligence level of the control system of the bottom pouring pouring machine of the present invention is improved, which facilitates the optimization of the production pouring rhythm and process and improves the quality of casting products.

[0066] The control system for the bottom pouring machine of the present invention operates as follows: The system power is turned on by operating the panel buttons of the electrical control cabinet 18. The servo drive, various load cells, temperature sensors, infrared imaging camera 9, and visual sensor 5 all perform self-tests. The PID control module of the PLC controller sets initial parameters, and the HMI host computer connects to the MES system to prepare for wireless data exchange. The HMI host computer's local database synchronizes past production data for comparison and analysis of new production data. The operator enters the production batch number and process parameters on the HMI host computer. First, a transfer vehicle delivers molten iron to the ladle 3. When the transfer vehicle approaches, the ladle 3's lid automatically opens, and the pouring machine prepares to enter the feeding state. The cathode of the plasma heating mechanism 8 automatically rises to a preset height, awaiting the pre-addition of molten iron. Once the molten iron is transferred from the transfer vehicle, load cell 6 begins monitoring its weight, and the real-time weight of the molten iron is wirelessly transmitted to the HMI host computer. Molten iron composition data from the laboratory is wirelessly transmitted to the HMI host computer control platform via the MES. Various production conditions such as temperature and molten iron feed flow rate are monitored in real time through sensors to ensure that there are no abnormalities. Automatic control of the pouring process: Under the guidance of the gate 151 position provided by the visual sensor 5 and the internal coordinates of the control platform, the PLC controller outputs instructions, and the servo motor 10 and the servo motor 2 11 respectively drive the longitudinal frame 1 and the transverse frame 2 to move, so that the ladle 3 moves to the top of the mold box 15 to be poured, and the bottom end of the flow channel 13 is aligned with the gate 151. Under the output instructions of the PLC controller, the plug rod drive unit starts to move to open the water outlet 301. The red-hot molten iron flows out of the water outlet 301, flows into the flow channel 13, and then flows into the gate 151 from the bottom end of the flow channel 13. The weighing sensor 16 starts to monitor the real-time weight of the ladle 3 during the pouring process. During the pouring process, the visual sensor 5 monitors the liquid level of the gate 151, and the PID control module adjusts the pouring flow rate according to the sensor feedback to ensure the stability of the liquid level. At the same time, the infrared imaging camera 9 detects the temperature and composition of the molten iron flowing in the flow trough 13 in real time and feeds it back to the PLC controller. The PLC controller controls the servo motor 3 123 to drive the auger shaft 122 to add an appropriate amount of inoculant. After the pouring is completed, the plug rod closes the water outlet 301 and moves again to the top of the next mold box 15 to be poured, and pours again. The production data will be stored in the local database of the HMI host computer and uploaded to the MES system in real time via wireless communication for remote monitoring and production analysis. Abnormal detection and alarm processing: If the composition detection system finds that the molten iron composition is unqualified, the system will immediately stop pouring and trigger an alarm. When qualified, pouring continues until the weight reaches the preset value. When the liquid level or weight parameters exceed the preset range, the system automatically adjusts the PID parameters, or issues an alarm and stops the operation when it cannot be corrected. Data recording and feedback optimization: After each pouring is completed, all production data will be recorded in the local database and uploaded to the cloud storage at the same time.The data includes weight, component test results, sensor feedback information, pouring flow rate, abnormal handling, etc. The control system generates feedback reports based on this data to help analyze and optimize subsequent production processes.

[0067] In summary, the bottom pouring casting machine control system of the present invention, through the provision of a positioning module, enables the longitudinal frame 1 and the transverse frame 2 to accurately carry the ladle 3 and position it above the mold box 15 for pouring molten iron; by adding a plasma heating mechanism 8 to the transverse frame 2, the molten iron in the ladle 3 can be heated at any time, ensuring the pouring temperature; and by detecting the weight of the ladle 3 through the weight sensor 6, the pouring amount is controlled, thereby improving the pouring accuracy. The bottom pouring casting machine control system of the present invention detects the molten iron temperature and makes real-time corrections, ensuring accurate pouring temperature, while also performing real-time detection of the output molten iron from the ladle, ensuring accurate casting. In addition, the visual sensor 5 is provided to locate the position of the pouring gate 151, facilitating the control of the operation of servo motor 10 and servo motor 2 11, so that the ladle 3 is accurately moved above the pouring gate 151 to prevent the spilled molten iron from escaping. At the same time, the visual sensor 5 can also detect the height of the molten iron liquid level in the pouring gate 151, facilitating the control of the molten iron flow rate to achieve a stable molten iron liquid level in the pouring gate 151 and ensure the casting quality. The molten iron is diverted by providing a flow trough 13 below the water outlet 301. On the one hand, the temperature of the spread molten iron can be measured, improving the accuracy of temperature measurement. On the other hand, it facilitates the supply of inoculant along the flow, avoiding the degradation of the inoculant caused by the inoculant being added to the ladle 3. By real-time monitoring of the flow rate, temperature, and composition of the molten iron in the flow trough 13, the supply of inoculant is adjusted according to an empirical formula, achieving better casting quality. The supply of inoculant is adjusted by controlling the speed of the auger shaft 122 through the servo motor 3 123. By setting the weighing sensor 2 125, the addition amount and the remaining amount of the inoculant in the hopper can be monitored in real time, ensuring precise control of the addition. By adding a slag baffle 14, the molten iron flowing out of the water outlet 301 can be prevented from splashing toward the infrared imaging camera 9, avoiding damage to the equipment by high-temperature metal slag while also reducing the impact of splashing on the measurement laser beam. By adding a guide plate 141 at the bottom of the slag baffle 14, the slag of the molten iron in the flow trough 13 is diverted to avoid it appearing in the detection area 19, that is, the impact of the slag on the laser induced breakdown spectrum of the infrared imaging camera 9 is avoided, ensuring the accuracy of the measurement and analysis of the components. This is also the advantage of adding a flow trough 13. If the detection area of the infrared imaging camera 9 is set on the liquid surface of the gate 151, the impact of the slag will not be avoided. By pushing out the plug rod of the plug rod mechanism 4 to close the water outlet 301, the sealing assembly closes the bottom end of the flow trough 13, thereby reducing the waste of residual molten iron dripping during movement and improving economic benefits. By electrically interlocking the solenoid valve of the control cylinder 16 and the control relay of the plug rod mechanism 4, overflow of molten iron caused by malfunction is avoided.By connecting with the MES system, the informatization of the pouring process is realized, and a connection is established with material feeding and inventory, thereby stabilizing production capacity. By adding a learning module, a big data analysis module, and an AI intelligent voice module, the intelligence level of the control system of the bottom pouring pouring machine of the present invention is improved, which facilitates the optimization of the production pouring rhythm and process and improves the quality of casting products.

[0068] The present invention also discloses a working method of a bottom pouring machine control system, which uses the bottom pouring machine control system described in any of the above embodiments to control the bottom pouring machine to perform automatic pouring operations.

[0069] The bottom pouring pouring machine control system working method of the present invention reduces manual operation content, realizes automatic and intelligent pouring, can realize real-time monitoring of temperature and molten iron composition, and ensures casting quality.

[0070] Furthermore, compared to the existing method of adding inoculant within the ladle 3, the present invention employs a method of adding inoculant with the flow, which reduces inoculant decay and improves inoculant utilization. Furthermore, the amount of inoculant added is adjusted in real time based on the flow rate, temperature, and composition of the molten iron within the launder 13, thereby improving the accuracy of inoculant addition and, in turn, the quality of the casting.

[0071] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. Reference can be made to the common and similar parts between the various embodiments. For the devices disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple, and the relevant parts can be referred to the method description.

[0072] The embodiments described above are merely descriptions of preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Without departing from the spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by persons skilled in the art shall fall within the scope of protection defined by the claims of the present invention.

Claims

1. A bottom pouring machine control system for controlling a bottom pouring machine to perform casting and pouring operations, characterized in that: include: A positioning module is used to locate the position of the gate (151) of the casting box (15) to be cast, and drive the longitudinal frame (1) and the transverse frame (2) to move along the longitudinal track and the transverse guide rail respectively, so that the ladle (3) is located above the casting box (15); a temperature control module for controlling the temperature of the molten iron in the ladle (3), comprising a temperature sensor (7) and a plasma heating mechanism (8), wherein the temperature sensor (7) is used to detect the temperature of the molten iron in the ladle (3), and the plasma heating mechanism (8) is capable of heating the molten iron in the ladle (3); An automatic pouring module comprises a weighing sensor (6) and a plug rod driving unit of a plug rod mechanism (4), wherein the weighing sensor (6) is arranged between the mounting flange of the ladle (3) and the transverse frame (2), and the plug rod driving unit is capable of driving the plug rod of the plug rod mechanism (4) to move back and forth in a vertical direction, thereby controlling the opening of the water outlet (301) at the bottom of the ladle (3); A PLC controller is electrically connected to the positioning module, the temperature sensor (7), the plasma heating mechanism (8), a weighing sensor (6) and the plug rod driving unit; the PLC controller is communicatively connected to an HMI host computer.

2. The bottom pouring machine control system according to claim 1, characterized in that: The positioning module includes a visual sensor (5), a servo motor 1 (10) and a servo motor 2 (11); the visual sensor (5) is arranged at the bottom of the transverse frame (2) through a bracket and can capture and position the gate (151) of the molding box (15); the servo motor 1 (10) and the servo motor 2 (11) respectively drive the longitudinal frame (1) and the transverse frame (2) to move.

3. The bottom pouring casting machine control system according to claim 1, characterized in that: The temperature control module further comprises an infrared imaging camera (9); a flow channel (13) is further provided below the water outlet (301); the flow channel (13) is arranged at an angle; the upper end of the flow channel (13) is connected to the water outlet (301); the bottom end of the flow channel (13) guides the molten iron into the pouring gate (151) of the molding box (15); the infrared imaging camera (9) is provided below the transverse frame (2) through a bracket and is capable of measuring the temperature of the molten iron flowing in the flow channel (13) in real time; the infrared imaging camera (9) feeds back a temperature signal to the PLC controller.

4. The bottom pouring machine control system according to claim 3, characterized in that: The invention also includes an inoculant preparation module, the inoculant preparation module includes an inoculant feeding mechanism (12); the infrared imaging camera (9) includes a laser induced breakdown spectroscopy module, the infrared imaging camera (9) is also capable of measuring the composition of the flowing molten iron in real time, and the PLC controller adjusts the inoculant feeding mechanism (12) in real time according to the flow rate, temperature and composition of the molten iron in the flow trough (13) to supply the inoculant along with the flow.

5. The bottom pouring casting machine control system according to claim 4, characterized in that: The inoculant feeding mechanism (12) comprises a hopper, a discharge pipe joint (121), an auger shaft (122), a servo motor (123) and a feeding pipe (124); the hopper stores the flowing inoculant; the discharge pipe joint (121) is horizontally arranged on the side wall of the bottom cone of the hopper; the auger shaft (122) is horizontally arranged in the bottom cone of the hopper and the discharge pipe joint (121); the servo motor (123) is arranged on the opposite side wall of the bottom cone of the hopper; the servo motor (123) drives the auger shaft (122) to rotate; the top end of the feeding pipe (124) is connected to the port of the discharge pipe joint (121); the outlet end of the feeding pipe (124) is located above the bottom end of the flow trough (13).

6. The bottom pouring machine control system according to claim 5, characterized in that: The base of the hopper is mounted on the transverse frame (2) via a second weighing sensor (125), and the second weighing sensor (125) and the third servo motor (123) are both electrically connected to the PLC controller.

7. The bottom pouring machine control system according to claim 4, characterized in that: It also includes a slag blocking plate (14), the top of which is fixed to the outer wall of the water outlet (301) via a hoop, and the main body of the slag blocking plate (14) is vertically arranged between the water outlet (301) and the infrared imaging camera (9).

8. The bottom pouring machine control system according to claim 7, characterized in that: The bottom end of the slag baffle (14) is also provided with a guide plate (141) for guiding slag, and the guide plate (141) is a C-shaped insulation material plate with an opening facing downward. The guide plate (141) guides the slag of the molten iron in the flow channel (13) to both sides; the detection laser landing point of the infrared imaging camera (9) is located in the detection area (19) below the guide plate (141).

9. The bottom pouring machine control system according to claim 3, characterized in that: It also includes a sealing component, which is arranged at the bottom end of the flow channel (13) and can seal the bottom end of the flow channel (13) that is not positioned directly above the gate (151).

10. A method for operating a control system of a bottom pouring machine, characterized in that: The bottom pouring pouring machine control system according to any one of claims 1 to 9 is used to control the bottom pouring pouring machine to perform automatic pouring operations.

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