Batching system for metal smelting and batching method thereof

Abstract

The invention relates to a batching system for molten metal smelting and a batching method thereof, belongs to the technical field of molten metal smelting, and aims to solve the problems of low manual operation efficiency and high smelting batching cost of molten metal smelting batching, and the batching system comprises a basic data module, a process standard module, a smelting parameter module and a batching calculation module, the storage module is used for storing material data of materials required by molten metal smelting; the process standard module is used for storing process data related to the smelting process of the molten metal to be smelted; the smelting parameter module is used for storing various smelting data; and the ingredient calculation module calls data of the basic data module, the process standard module and the smelting parameter module and automatically generates an ingredient list of the molten metal to be smelted. The to-be-smelted metal liquid is accurately and rapidly burdening, and repeated manual burdening is avoided.

Description

Technical Field

[0001] The invention relates to the technical field of molten metal smelting for casting, in particular to a batching of raw materials for molten metal smelting. Background Art

[0002] In the casting production process, the core of cost control in the smelting process lies in the optimization design of smelting efficiency and proportioning scheme. Research shows that under the premise of ensuring the qualified rate of smelting composition, minimizing raw material consumption and maximizing energy utilization by establishing a dynamic proportioning model has become the key technical path for the industry to achieve cost reduction and efficiency improvement. The current mainstream smelting proportioning method generally has the following technical bottlenecks: First, it relies on the serial iterative mode (detection-adjustment-re-inspection) of operator experience judgment and spectral detection, resulting in an average of 3-5 composition corrections per batch, extending the single furnace smelting cycle by 25%-40%; Second, the existing technology mostly adopts semi-automatic data processing methods (such as the Excel calculation method disclosed in CN103489130A), which has three significant defects: (1) the update of the material basic database lags, and the chemical composition fluctuation data of the raw material inventory cannot be obtained in real time; (2) there are too many manual intervention links, and the formula calculation process is significantly affected by subjective experience bias; (3) there is a lack of dynamic cost accounting module, which makes it difficult to achieve multi-objective optimization under the condition of meeting the composition constraints. The above-mentioned technical defects directly lead to an average raw material waste rate of more than 3.5% in existing casting production, and the smelting energy consumption index is 18%-22% higher than the theoretical optimal value, which seriously restricts the industry's intelligent upgrading process. Summary of the Invention

[0003] In view of the above problems of low molten metal smelting efficiency and high smelting batching cost in the casting industry, it is necessary to propose a batching system and batching method for molten metal smelting, which can automatically calculate the optimal batching plan, reduce the batching cost, improve the smelting efficiency, and reduce the smelting cost.

[0004] A batching system for molten metal smelting, including a basic data module, a process standard module, a smelting parameter module and a batching calculation module.

[0005] The basic data module is used to store material data of materials required for molten metal smelting, such as material composition, material quantity, material unit price, etc.

[0006] The process standard module is used to store process data related to the smelting process of the molten metal to be smelted;

[0007] The smelting parameter module is used to store smelting data such as furnace specifications, element burnout rate, molten metal brand, and molten metal weight;

[0008] The ingredient calculation module calls the data of the basic data module, the process standard module and the smelting parameter module to automatically generate the ingredient list of the molten metal to be smelted.

[0009] A batching method for molten metal smelting, comprising:

[0010] S01, preparation for molten metal smelting, i.e. material storage, furnace cleaning, process issuance, etc.

[0011] S02, generating a heat plan for castings to be poured;

[0012] S03, generating a list of ingredients for molten metal smelting;

[0013] S04, obtaining the ingredient list, the control device of the smelting process obtains the ingredient list of the molten metal to be smelted;

[0014] S05, the smelting process sends the obtained ingredient list to each operating equipment, and each operating equipment prepares the ingredients for the molten metal to be smelted based on the received data or information.

[0015] The beneficial effects of the technical solution of the present invention are: accurate and rapid batching of molten metal to be smelted is achieved, repeated manual batching is avoided, production efficiency is improved, production costs are reduced, and full automation of the smelting process is achieved. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a flow chart of the batching method for molten metal smelting. DETAILED DESCRIPTION

[0017] In order to more clearly illustrate the technical solution of the present invention, the technical solution of the invention content is described in detail with reference to the accompanying drawings. Obviously, the following descriptions are some typical embodiments of the present invention. For ordinary technicians in this field, other solutions can be obtained based on these embodiments without paying any creative work.

[0018] The present invention aims to enhance the intelligence and digitization of the smelting process, to realize the automation of the batching link in the molten metal smelting process, to improve the accuracy and efficiency of the batching of molten metal smelting, and to reduce the cost of molten metal smelting.

[0019] In one embodiment, a batching system for molten metal smelting includes a basic data module, a process standard module, a smelting parameter module, and a batching calculation module.

[0020] The basic data module is used to store material data of materials required for molten metal smelting, such as material composition, material quantity, material unit price and other material data;

[0021] The process standard module is used to store process data related to the smelting process of the molten metal to be smelted, such as the composition control requirements of the molten metal, the performance indicators of the metal products, the proportion of materials, etc.;

[0022] The smelting parameter module is used to store smelting data such as furnace specifications, element burnout rate, molten metal brand, and molten metal weight;

[0023] The ingredient calculation module calls the data of the basic data module, the process standard module and the smelting parameter module to automatically generate the ingredient list of the molten metal to be smelted.

[0024] As a supplement to this embodiment, the material data also includes the batch of the material, so that different batches of similar materials can be selected according to the requirements of the molten metal composition, thereby achieving refined smelting control of the molten metal; that is, achieving the accuracy of the molten metal smelting ingredients.

[0025] As a supplement to this embodiment, the ingredient calculation module can also calculate the theoretical cost of the generated ingredient list, thereby providing a cost control standard for the smelting of the molten metal and achieving the smelting of the molten metal at the optimal cost.

[0026] As a supplement to this embodiment, the ingredient calculation module can also perform ingredient calculation on the basic data of the material according to the metal liquid composition control requirements of the process standard module to verify the correctness of the ingredient list.

[0027] By implementing the batching system for molten metal smelting, the smelting of molten metal can realize the transmission of data and information with the assistance of the system, thereby realizing the automation and intelligence of the smelting process.

[0028] Another embodiment, a batching method for molten metal smelting, comprises:

[0029] S11, molten metal smelting preparation, i.e., preparatory work for the smelting process, including the preparation of materials, furnaces, processes, etc., in order to smelt qualified molten metal to be smelted, specifically, such as material storage, furnace cleaning, process issuance, etc.;

[0030] S12, generating a heat plan for castings to be poured; specifically, the batching calculation module can generate a heat plan for the molten metal to be smelted based on the smelting data of the smelting parameter module and the process data of the process standard module, wherein the heat plan includes the material, grade, weight of the molten metal and product information of the corresponding castings;

[0031] S13, generating a bill of materials for molten metal smelting; specifically, the bill of materials calculation module generates the bill of materials using a genetic algorithm based on the data recorded in the current heat plan, combined with the material data in the basic data module and the smelting data in the smelting parameter module;

[0032] S14, obtaining the ingredient list, the control device of the smelting process obtains the ingredient list of the molten metal to be smelted;

[0033] S15, the smelting process sends the obtained ingredient list to each operating equipment, and each operating equipment prepares the ingredients for the molten metal to be smelted based on the received data or information.

[0034] As a supplement to this embodiment, in S13, the ingredient list can also be verified. Specifically, when all material batches of the historical heat and the current heat are consistent, the ingredient calculation module calls the ingredient data of the historical molten metal of the same material and brand, and checks it with the generated ingredient list of the current heat. If any inconsistencies are found, the calculation is performed again to generate the ingredient list of the current heat with the best cost and the highest efficiency.

[0035] As a supplement to this embodiment, in S13, the ingredient calculation module can also compare the theoretical composition of the molten metal smelted using the ingredient list with the composition control requirements of the molten metal in the process standard module to find out the difference between the two, so as to adjust the material ratio of the ingredient list, optimize the ingredient list, and improve the accuracy of the composition of the smelted molten metal.

[0036] The above embodiment is only a description of a typical application of the technical solution of the present invention, and reasonable expansion can be made on a reasonable basis without requiring creative work.

Claims

1. A batching system for molten metal smelting, characterized in that: Including basic data module, process standard module, smelting parameter module and ingredient calculation module, The basic data module is used to store material data of materials required for molten metal smelting; The process standard module is used to store process data related to the smelting process of the molten metal to be smelted; The smelting parameter module is used to store various smelting data; The ingredient calculation module calls the data of the basic data module, the process standard module and the smelting parameter module to automatically generate the ingredient list of the molten metal to be smelted.

2. The batching system for molten metal smelting according to claim 1, characterized in that: The ingredient calculation module can also calculate the theoretical cost of the generated ingredient list.

3. The batching system for molten metal smelting according to claim 1, characterized in that: The batching calculation module can also calculate the composition of the basic data of the material according to the metal liquid composition control requirements of the process standard module.

4. A batching method for a batching system based on molten metal smelting, characterized in that: include, S01, molten metal smelting preparation; S02, generating a heat plan for castings to be poured; S03, generating a list of ingredients for molten metal smelting; S04, obtaining the ingredient list, the control device of the smelting process obtains the ingredient list of the molten metal to be smelted; S05, the smelting process sends the obtained ingredient list to each operating equipment, and each operating equipment prepares the ingredients for the molten metal to be smelted based on the received data or information.

5. The batching method for molten metal smelting according to claim 4, characterized in that: In S02, the batching calculation module may generate a heat plan for the molten metal to be smelted according to the smelting data of the smelting parameter module and the process data of the process standard module.

6. The batching method for molten metal smelting according to claim 5, characterized in that: In S03, the batching calculation module generates the batching list using a genetic algorithm based on the data recorded in the current heat plan, combined with the material data in the basic data module and the smelting data in the smelting parameter module.

7. The batching method for molten metal smelting according to claim 5, characterized in that: In S03, the ingredient list may also be verified.

8. The batching method for molten metal smelting according to claim 7, characterized in that: The method for verifying the ingredients is as follows: When all material batches of the historical heat and the current heat are consistent, the ingredient calculation module calls the historical ingredient data of the molten metal of the same material and brand, and checks it with the generated ingredient list of the current heat. It finds the inconsistencies and calculates them again to generate the ingredient list of the current heat with the best cost and highest efficiency.

9. The batching method for molten metal smelting according to claim 5, characterized in that: In S03, the ingredient calculation module can also compare the theoretical composition of the molten metal melted using the ingredient list with the composition control requirements of the molten metal in the process standard module to find out the difference between the two and adjust the material ratio of the ingredient list.

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