Method, device and system for automatically heating melt in furnace body of medium-frequency induction furnace

Abstract

The invention discloses a method, a device and a system for automatically heating melt of a furnace body of a medium-frequency induction furnace, and the method comprises the following steps: obtaining standard process parameters of a current process, the standard process parameters comprising a target melting temperature; real-time state parameters are obtained, the real-time state parameters comprise the real-time weight in the furnace, the amount of remaining molten iron in the furnace and the real-time molten iron temperature, and the weight of the remaining molten iron is triggered and locked through a furnace body seating signal; according to the standard process parameters and the real-time state parameters, the temperature rise electric power amount is predicted; and controlling the induction furnace power frequency converter to execute heating operation based on the heating power amount. Through accurate electric quantity prediction and automatic control, large temperature fluctuation is avoided, the stability of molten iron components is guaranteed, the rejection rate and energy consumption waste caused by temperature fluctuation are reduced, the production continuity and stability are improved, and the core defects that in the prior art, manual operation efficiency is low, and temperature fluctuation is large are effectively overcome.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of metallurgy, and particularly relates to a method, device and system for automatically heating molten bath of a medium-frequency induction furnace body. BACKGROUND

[0002] In casting production, the quality of castings has strict requirements on the content of molten iron, especially when adjusting the trace element composition in the molten state of molten iron, different chemical materials need to be put in relying on a specific molten iron temperature. The current industry generally adopts a manual operation mode. After the power supply is put into operation, the temperature of the molten iron needs to be measured manually at a high frequency. When the temperature is too high, the power is reduced, and when the temperature is too low, the power is increased. Not only is it time-consuming and labor-intensive, but it is also difficult to avoid large fluctuations in the temperature.

[0003] Large fluctuations in the temperature of the molten bath are not simply a process appearance problem, but can cause a series of chain effects. From the metallurgical aspect, carbides and graphite morphology in the molten iron are extremely sensitive to temperature. For example, the spheroidization rate of ductile cast iron may decrease by 15% when the temperature fluctuates by ±30℃, which directly leads to substandard mechanical properties. From the production quality aspect, when the temperature fluctuation exceeds ±50℃, the sand hole defect rate of automobile castings will increase from 3% to 12%, and the energy consumption of subsequent heat treatment will also increase. From the cost and efficiency aspect, frequent manual adjustment of power not only consumes a large amount of manpower and time, but also may cause power waste due to untimely adjustment, and even damage the continuity of production, forming a vicious cycle of material failure, composition out of control, equipment damage and cost soaring.

[0004] The existing manual control mode cannot meet the production requirements of high quality and high efficiency, and an automatic solution that can accurately control the temperature of the molten bath is needed to break through the limitations of the traditional mode. SUMMARY

[0005] The present application solves the technical problems of time-consuming and labor-intensive, large temperature fluctuations, poor stability of molten iron composition, high scrap rate and energy waste caused by manual temperature measurement and power adjustment during the heating process of the molten bath of the existing medium-frequency induction furnace.

[0006] In one aspect, the present application provides a method for automatically heating the molten bath of a medium-frequency induction furnace body, comprising:

[0007] obtaining standard process parameters of the current process, the standard process parameters comprising a target melting temperature;

[0008] obtaining real-time state parameters, the real-time state parameters comprising a real-time weight in the furnace, a remaining molten iron amount in the furnace and a real-time molten iron temperature, the remaining molten iron weight being locked through a furnace body seating signal;

[0009] predicting a heating power amount according to the standard process parameters and the real-time state parameters;

[0010] Based on the heating power, control the induction furnace power frequency converter to perform the heating operation.

[0011] Further, the heating power is predicted according to the standard process parameters and the real-time state parameters, including:

[0012] According to the real-time weight in the furnace and the remaining molten iron in the furnace, the melting amount is determined;

[0013] According to the formula:

[0014] E=U×(M / 1000)×[(T0-T) / 100]

[0015] Iterative update the heating power;

[0016] Wherein, E is the heating power, U is the heating original unit, M is the melting amount, T0 is the target melting temperature, and T is the real-time molten iron temperature;

[0017] The iterative update is triggered by the change amount of the weighing instrument signal being greater than 50 kg or the temperature change amount being greater than 5℃.

[0018] Further, the induction furnace power frequency converter is determined to be in the associated operating condition, and the associated operating condition includes the main on-off switch being turned on, the associated auxiliary equipment being put into operation, the load characteristics being stably matched, and the effective start operation instruction.

[0019] Further, based on the heating power, the induction furnace power frequency converter is controlled to perform the heating operation, including:

[0020] According to the input power, it is determined whether the heating operation is completed;

[0021] After determining that the heating operation is completed, the induction furnace power frequency converter is controlled to perform the holding operation.

[0022] Further, the determination method of the input power includes:

[0023] Determine the power supply relationship between the power supply and the furnace body;

[0024] When one power supply supplies power to a single furnace body, the input power is calculated according to the number of power pulses;

[0025] When one power supply supplies power to multiple furnace bodies, the power values received by the frequency conversion cabinets of the furnace bodies are read according to the preset time interval, and the input power of each furnace body is determined based on the power values and the power supply time of each furnace body.

[0026] Further, the induction furnace power frequency converter is controlled to perform the heating operation based on the heating power, including:

[0027] According to the formula:

[0028] P0=η×U×(M / 1000)×k

[0029] determining an initial power;

[0030] wherein η is a heat transfer efficiency coefficient, and k is a power margin coefficient;

[0031] generating a power control curve, the power control curve comprising an initial curve and a decay curve, the decay curve having a starting point of T≥T0-100℃, and the decay curve function P(t)=P0×exp(-0.015 × t);

[0032] According to the formula:

[0033] E’=E+σ·A·ε·(T 4 -T env 4 )·t

[0034] dynamically correcting the heating power;

[0035] wherein σ is the Stefan-Boltzmann constant, A is the effective heat dissipation area of the molten pool, ε is the emissivity of the molten iron surface, T is the real-time molten iron temperature, Tenv is the ambient temperature, and t is the cumulative heating time;

[0036] When E i ≥0.95E’ or T≥T0, switch to the holding mode.

[0037] Further, the power control in the holding stage comprises:

[0038] the holding power P h =α·M;

[0039] When T<T0-ΔT h , increase the power to P h +ΔP;

[0040] When T>T0+ΔT h , decrease the power to P h -ΔP;

[0041] wherein ΔP=K p ·e(t)+K i ·∫e(t)dt, e(t)=T-T0, K p is a proportional gain coefficient, and K i is an integral gain coefficient.

[0042] Another aspect of the embodiment of the present application provides an automatic molten bath heating device for a medium-frequency induction furnace body, the device comprising:

[0043] a first obtaining module, configured to obtain a standard process parameter of a current process, the standard process parameter comprising a target melting temperature;

[0044] A second acquisition module acquires real-time state parameters, the real-time state parameters including a real-time weight in the furnace, a residual molten iron amount in the furnace and a real-time molten iron temperature, and the residual molten iron weight is triggered and locked by a furnace body seating signal;

[0045] A processing module predicts a heating power according to the standard process parameters and the real-time state parameters;

[0046] A control module controls an inductive furnace power frequency converter to perform a heating operation based on the heating power.

[0047] Further, the processing module comprises:

[0048] A first determination unit is configured to determine a melting amount according to the real-time weight in the furnace and the residual molten iron amount in the furnace;

[0049] A second determination unit is configured to determine the heating power according to a formula:

[0050] E=Ux(M / 1000)x[(T0-T) / 100]

[0051] The heating power is iteratively updated;

[0052] Wherein, E is the heating power, U is a heating original unit, M is the melting amount, T0 is a target melting temperature, and T is the real-time molten iron temperature;

[0053] A triggering unit is configured to control the iteration to be triggered by a change amount of a weighing instrument signal being greater than 50 kg or a temperature change amount being greater than 5 DEG C.

[0054] In still another aspect, the embodiment of the present application provides a middle-frequency inductive furnace body molten bath automatic heating system, which comprises a middle-frequency inductive furnace body molten bath automatic heating device.

[0055] The middle-frequency inductive furnace body molten bath automatic heating device is controlled by the above-mentioned middle-frequency inductive furnace body molten bath automatic heating method.

[0056] The embodiment of the present application acquires the standard process parameters of the current process, the standard process parameters including the target melting temperature; acquires the real-time state parameters, the real-time state parameters including the real-time weight in the furnace, the remaining molten iron quantity in the furnace and the real-time molten iron temperature, the remaining molten iron weight being triggered and locked by the furnace body seating signal; according to the standard process parameters and the real-time state parameters, the heating power is predicted; based on the heating power, the frequency converter of the induction furnace power supply is controlled to perform the heating operation. The embodiment of the present application acquires the standard process parameters and the real-time state parameters automatically, predicts the heating power and controls the frequency converter to run, replaces the manual temperature measurement and power adjustment, reduces the labor and time cost; at the same time, through the accurate power prediction and automatic control, the temperature is prevented from fluctuating greatly, the stability of the molten iron composition is ensured, the waste rate and energy waste caused by the temperature fluctuation are reduced, the production continuity and stability are improved, and the core defects of low manual operation efficiency and large temperature fluctuation in the prior art are effectively solved. BRIEF DESCRIPTION OF DRAWINGS

[0057] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed to be used in the embodiment description will be briefly introduced as follows. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without any creative effort on the basis of these drawings.

[0058] Figure 1 The flowchart of one embodiment of the present application is shown in the figure.

[0059] Figure 2 The flowchart of another embodiment of the present application is shown in the figure, and the step S13 of the first embodiment is improved in the present embodiment.

[0060] Figure 3 The flowchart of another embodiment of the present application is shown in the figure, and the step S24 of the second embodiment is improved in the present embodiment.

[0061] Figure 4 The flowchart of another embodiment of the present application is shown in the figure, and the step S25 of the second embodiment is improved in the present embodiment.

[0062] Figure 5 The structural diagram of one embodiment of the present application is shown in the figure.

[0063] Figure 6 The computer internal structure diagram of another embodiment of the present application is shown in the figure. DETAILED DESCRIPTION

[0064] In order to make the technical problems, technical solutions and beneficial effects solved by the present application clearer, the present application will be further described in detail below in combination with the drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and do not limit the present application.

[0065] When the embodiments of the present application refer to "first", "second" and the like ordinal numbers, it should be understood that they are merely used for differentiation unless they express the order according to the context.

[0066] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "mounting", "connection" and "linking" should be understood in a broad sense, for example, it can be fixed connection, or detachable connection, or integral connection; it can be mechanical connection, or electrical connection; it can be direct connection, or indirect connection through intermediate medium, or internal connection of two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0067] First embodiment

[0068] Please refer to Figure 1 The present embodiment provides an automatic heating method for a medium-frequency induction furnace body, comprising S11-S16, wherein:

[0069] S11: obtaining the standard process parameters of the current process, the standard process parameters including the target melting temperature.

[0070] In the present embodiment, the standard process parameters are input by the user through the human-machine interface (HMI), and the core parameter target melting temperature (T0) is determined according to the casting material quality and the molten iron composition requirement (such as the target temperature is set to 1520℃ when adjusting the composition of nodular cast iron). The system stores the parameter to the PLC controller as the reference for subsequent heating.

[0071] S12: obtaining the real-time state parameters, the real-time state parameters including the real-time weight in the furnace, the remaining molten iron quantity in the furnace and the real-time molten iron temperature, and the remaining molten iron weight is locked through the furnace body seating signal triggering.

[0072] As a preferred scheme but not a limitation, the real-time weight in the furnace of the present embodiment is collected in real time by the weight measuring instrument at the bottom of the furnace body. The weight measuring instrument outputs a DC4-20mA analog signal, which is converted to the actual weight value (unit: kg) by the PLC, and the tare weight of the furnace body is automatically subtracted (tare correction), and only the molten metal weight is retained.

[0073] The remaining molten iron quantity in the furnace is the "seating signal" triggered when the furnace is placed in position after tapping, and the system locks the weight of the molten iron in the furnace at this time (corrected by peeling) after a delay of 5 seconds, as the "remaining molten iron weight" (a fixed value until the next update after tapping).

[0074] The real-time molten iron temperature can be collected by a temperature measuring instrument inserted into the molten iron, which outputs a DC 4-20 mA analog signal, and the PLC converts it into a temperature value (unit: °C) with a sampling frequency of 1 time / second to ensure real-time performance. Alternatively, the real-time molten iron temperature can also be provided by a fixed wireless temperature measuring instrument, a handheld temperature measuring instrument, an HMI input temperature value, or through other device communication.

[0075] S13: Predict the heating power according to the standard process parameters and real-time state parameters.

[0076] Please refer to Figure 2 , S13 includes the following sub-steps S131-S132, wherein:

[0077] S131: Determine the melting quantity according to the real-time weight in the furnace and the remaining molten iron quantity in the furnace.

[0078] The melting quantity (M) = real-time weight in the furnace - remaining molten iron quantity in the furnace, representing the actual weight of the molten iron that needs to be heated at present (for example, if the real-time weight in the furnace is 4000 kg and the remaining molten iron is 1000 kg, then M = 3000 kg).

[0079] S132: Iteratively update the heating power according to the formula.

[0080] The formula is: E = U × (M / 1000) × [(T0-T) / 100)]

[0081] Wherein:

[0082] E is the heating power (unit: kWh);

[0083] U is the original unit of heating (unit: kWh / TON / 100℃, set according to the equipment specification book, such as U = 75 for a certain type of induction furnace);

[0084] T0 is the target melting temperature, and T is the real-time molten iron temperature (unit: °C);

[0085] The iteration update trigger condition is that when the weight change within 30 seconds is greater than 50 kg (such as adding cold charge) or the temperature change within 30 seconds is greater than 5℃, the E is automatically recalculated to ensure that it matches the real-time state.

[0086] The above steps S131-S132 solve the deviation problem caused by traditional manual estimation of electric quantity, and through weight / temperature change triggered iterative updating, the electric quantity prediction is dynamically matched with the real-time state of molten iron, and the risk of over-temperature or under-temperature is reduced.

[0087] S14: Based on the heating electric quantity, the induction furnace power supply frequency converter is controlled to perform the heating operation.

[0088] In some embodiments, as a preferred solution but not limited, the following checking steps need to be performed before S14:

[0089] Determine that the induction furnace power supply frequency converter is in the associated operating condition.

[0090] Wherein, the associated operating condition includes: the main on-off switch is on (the high-voltage power supply is connected), the associated auxiliary machines such as cooling fan / water pump are in normal operation, the load characteristics are stable (the molten iron weight matches the frequency converter power), there is no fault alarm signal (such as overvoltage, overcurrent), the user triggers the start operation instruction (button or HMI instruction).

[0091] After meeting the conditions, the PLC sends a control signal to the frequency converter, the frequency converter outputs according to the preset power, and the input electric quantity is accumulated in real time. The advance determination of the associated operating condition increases the safety check link, avoids the power waste and equipment damage caused by the equipment running with faults or load mismatch, and improves the system operation safety.

[0092] S15: Determine whether the heating operation is completed according to the input electric quantity.

[0093] In this embodiment, the determination method of the input electric quantity includes:

[0094] Single furnace single power supply: the electric quantity pulse number is collected through the multifunctional instrument, and according to the formula:

[0095] E i =N p ×K p

[0096] The input electric quantity is converted, wherein: N p is the pulse number of the electric meter, and K p is the pulse electric quantity coefficient.

[0097] Multi-furnace single power supply: the power value (kW) of each furnace frequency conversion cabinet is collected every 1 second, the power sum (kW·s) within 1 second is accumulated and converted into kWh (1kWh=3600kW·s) as the input electric quantity of the furnace.

[0098] The embodiment provides a method for determining input power when a power supply supplies power to multiple furnace bodies, solves the problem of inaccurate power allocation when multiple furnaces share a power supply, ensures accurate measurement of the power for heating of each furnace, and avoids temperature loss of control of part of the furnace body caused by uneven power distribution.

[0099] When the input power is greater than or equal to the predicted heating power (E), it is determined that the heating is completed.

[0100] S16: After determining that the heating operation is completed, the power supply frequency converter of the induction furnace is controlled to perform a holding operation.

[0101] The PLC controls the frequency converter to switch to low-power output (for example, 30% of the rated power), maintains the temperature of the molten iron, and provides a stable environment for composition adjustment.

[0102] The embodiment of the present application obtains standard process parameters of the current process, the standard process parameters including a target melting temperature; obtains real-time state parameters, the real-time state parameters including a real-time weight in the furnace, a remaining molten iron amount in the furnace and a real-time molten iron temperature, the remaining molten iron weight being locked by a furnace seating signal trigger; predicts a heating power based on the standard process parameters and the real-time state parameters; and controls a power supply frequency converter of the induction furnace to perform a heating operation based on the heating power. The embodiment of the present application automatically obtains standard process parameters and real-time state parameters, predicts a heating power and controls the frequency converter to run, replaces manual temperature measurement and power adjustment, reduces labor and time costs; at the same time, through accurate power prediction and automatic control, temperature fluctuations are avoided, the stability of the molten iron composition is ensured, the waste rate and energy waste caused by temperature fluctuations are reduced, the production continuity and stability are improved, and the core defects of low manual operation efficiency and large temperature fluctuations in the prior art are effectively solved.

[0103] Second embodiment

[0104] The embodiment refines the power control logic of the heating and holding stages based on the first embodiment:

[0105] As a preferred solution rather than a limitation, please refer to Figure 3 S24: The control of the power supply frequency converter of the induction furnace to perform a heating operation based on the heating power includes the following steps S241-S244, wherein:

[0106] S241: The initial power is determined according to the first formula.

[0107] The first formula: P0 = η × U × (M / 1000) × k;

[0108] Wherein:

[0109] η is the heat transfer efficiency coefficient (0.7-0.9, corrected according to the aging degree of the equipment);

[0110] k is the power margin coefficient (1.05-1.2, compensating for heat loss);

[0111] If U=75, M=3000kg, η=0.8, k=1.1, then P0=0.8×75×3×1.1=198kW.

[0112] S242: generating the power control curve.

[0113] Initial curve: running at initial power P0 during the initial heating period (T

[0114] Decay curve: when T≥T0-100℃, running at P(t)=P0×exp(-0.015 × t) (t is the decay time, unit: min), gradually reducing the power to avoid overheating.

[0115] S243: dynamically correcting the heating power according to the second formula.

[0116] Second formula: E'=E+σ·A·ε·(T 4 -T env 4 )·t;

[0117] Wherein:

[0118] σ is the Stefan-Boltzmann constant (5.67×10 -8 W / (m 2 ·K 4 ));

[0119] A is the effective heat dissipation area of the molten pool (calculated according to the furnace mouth diameter, for example, if the diameter is 1.5m, then A≈1.77m 2 );

[0120] ε is the emissivity of the molten iron surface (0.75-0.8);

[0121] T env is the ambient temperature (unit: K);

[0122] t is the cumulative heating time (unit: min).

[0123] S244: when E i ≥0.95E' or T≥T0, switch to the holding mode.

[0124] E i is the actual input power, and any condition is met to stop heating and enter the holding mode.

[0125] The above steps S241-S244 introduce initial power calculation, combine heat transfer efficiency coefficient and power margin coefficient, dynamically match initial power output with molten iron weight and equipment efficiency, avoid energy waste or insufficient heating caused by one-size-fits-all power setting; generate power control curve (initial curve + attenuation curve), reduce power through exponential attenuation function when approaching target temperature, effectively offset the thermal inertia of the intermediate frequency induction furnace, and solve the problem of easy over-temperature in the later stage of traditional heating. Based on the Stefan-Boltzmann law, the heat dissipation correction is introduced, the environmental temperature, molten pool heat dissipation and other factors are taken into account in the power prediction, the heating power is more in line with the actual heat loss, and the temperature fluctuation range is further reduced. Through the setting of E i ≥ 0.95E' or T≥T0, the double condition switching logic takes into account the cumulative power and real-time temperature, ensures more accurate heating endpoint judgment, and lays a stable foundation for the subsequent holding stage.

[0126] As a preferred solution rather than a limitation, please refer to Figure 4 S25: holding stage power control includes the following steps S251-S253, wherein:

[0127] S251: holding power P h = α·M.

[0128] α is the unit weight holding coefficient (0.008-0.012kW / kg, for example, if M=3000kg, then P h =24-36kW).

[0129] S252: when T h <T0-ΔT, increase the power to P h +ΔP;

[0130] S253: when T>T0+ΔT h , reduce the power to P h -ΔP.

[0131] ΔTh is the holding fluctuation threshold (5-8℃);

[0132] ΔP=K p ·e(t)+K i ·∫e(t)dt, e(t)=T-T0, where e(t)=T-T0 (temperature deviation), K p is the proportional gain (8-12), K i is the integral gain (0.2-0.5), which quickly eliminates the temperature deviation through PI adjustment.

[0133] The steps S251-S253 define the heat preservation power reference, so that the heat preservation power is directly related to the molten iron weight, the problems of "overheating of light weight molten iron and rapid cooling of heavy weight molten iron" caused by fixed power heat preservation are avoided, the PI regulation algorithm is introduced, the temperature deviation is quickly responded through proportional gain, the accumulated error is eliminated through integral gain, and the dynamic fine adjustment of the power in the heat preservation stage is realized, the temperature fluctuation in the heat preservation stage is controlled within ±5℃ through the setting of the temperature difference threshold to trigger the power adjustment, a stable temperature environment is provided for the molten iron composition adjustment (such as trace element deployment), and the unqualified rate of castings caused by temperature fluctuation is significantly reduced.

[0134] Third embodiment

[0135] Please refer to Figure 5 In still another aspect, the embodiment of the present application provides a molten bath automatic heating device for a medium-frequency induction furnace body, comprising:

[0136] A first acquisition module 110 acquires standard process parameters of a current process, and the standard process parameters include a target melting temperature;

[0137] A second acquisition module 120 acquires real-time state parameters, and the real-time state parameters include a real-time weight in the furnace, a residual molten iron amount in the furnace and a real-time molten iron temperature, and the residual molten iron weight is locked through a furnace body seating signal;

[0138] A processing module 130 predicts a heating power amount according to the standard process parameters and the real-time state parameters;

[0139] A control module 140 controls an induction furnace power frequency converter to perform a heating operation based on the heating power amount.

[0140] The processing module comprises:

[0141] A first determination unit is configured to determine a melting amount according to the real-time weight in the furnace and the residual molten iron amount in the furnace;

[0142] A second determination unit is configured to determine the target melting temperature according to a formula:

[0143] E=Ux(M / 1000)x[(T0-T) / 100]

[0144] The heating power amount is iteratively updated;

[0145] E is the heating power amount, U is a heating original unit, M is the melting amount, T0 is the target melting temperature, and T is the real-time molten iron temperature;

[0146] A triggering unit is configured to control the iteration to be triggered by a change amount of a weighing instrument signal being greater than 50kg or a temperature change amount being greater than 5℃.

[0147] The module of the embodiment is the same as the corresponding step of the first embodiment, and will not be described here.

[0148] The embodiment of the present application acquires the standard process parameters of the current process, the standard process parameters including the target melting temperature; acquires the real-time state parameters, the real-time state parameters including the real-time weight in the furnace, the remaining molten iron quantity in the furnace and the real-time molten iron temperature, the remaining molten iron weight being triggered and locked by the furnace body seating signal; according to the standard process parameters and the real-time state parameters, the heating power is predicted; and based on the heating power, the frequency converter of the induction furnace power supply is controlled to perform the heating operation. The embodiment of the present application acquires the standard process parameters and the real-time state parameters automatically, predicts the heating power and controls the frequency converter to run, replaces the manual temperature measurement and power adjustment, reduces the labor cost and time cost; at the same time, through the accurate power prediction and automatic control, the temperature fluctuation is avoided, the stability of the molten iron composition is ensured, the waste rate and energy waste caused by the temperature fluctuation are reduced, the production continuity and stability are improved, and the core defects of low manual operation efficiency and large temperature fluctuation in the prior art are effectively solved.

[0149] In still another aspect, the embodiment of the present application provides a molten bath automatic heating system for a medium-frequency induction furnace body, which comprises a molten bath automatic heating device for a medium-frequency induction furnace body.

[0150] The molten bath automatic heating device for a medium-frequency induction furnace body is controlled by the molten bath automatic heating method for a medium-frequency induction furnace body of one or more embodiments.

[0151] Those skilled in the art can clearly understand that, for the convenience and brevity of description, only the division of the above functional modules is taken as an example for illustration, and in actual application, the above functions can be completed by different functional modules according to needs, that is, the internal structure of the device is divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device and unit described above can refer to the corresponding process in the foregoing method embodiments, and will not be described here.

[0152] The embodiment of the present application also provides a computer storage medium, which stores a computer program, and the program is executed by a processor to implement the molten bath automatic heating method for a medium-frequency induction furnace body in each of the foregoing embodiments.

[0153] Those skilled in the art can understand that all or part of the processes in the above-mentioned embodiment methods can be completed by a computer program instructing relevant hardware, and the computer program can be stored in a non-volatile computer readable storage medium. When the computer program is executed, the processes of the above-mentioned embodiments of the automatic heating method of the medium induction furnace body soup can be included. In the embodiments provided in the present application, any reference to memory, storage, database or other medium can include non-volatile and / or volatile memory. Non-volatile memory can include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM) or flash memory. Volatile memory can include random access memory (RAM) or external cache memory. As an illustration but not limitation, RAM is available in various forms, such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDR SDRAM), enhanced SDRAM (ESDRAM), synchronous link (Synchlink) DRAM (SLDRAM), memory bus (Rambus) direct RAM (RDRAM), direct memory bus dynamic RAM (DRDRAM), and memory bus dynamic RAM (RDRAM), etc.

[0154] Alternatively, the integrated unit of the present application can be stored in a computer readable storage medium if it is realized in the form of a software function module and sold or used as an independent product. Based on this understanding, the technical solutions of the embodiments of the present application can be embodied in the form of a software product, which is stored in a storage medium and includes a plurality of instructions for causing a computer device (which can be a personal computer, terminal, or network device, etc.) to execute all or part of the embodiments of the present application. The foregoing storage medium includes mobile storage devices, RAM, ROM, magnetic or optical discs, and various media that can store program codes.

[0155] Corresponding to the above-mentioned computer storage medium, in one embodiment, a computer device is also provided, which includes a memory, a processor and a computer program stored in the memory and executable on the processor, wherein the processor executes the program to realize the automatic heating method of the medium induction furnace body soup in the above-mentioned embodiments.

[0156] The computer device can be a terminal, and its internal structure diagram can be as follows Figure 6As shown. The computer device includes a processor, a memory, a network interface, a display screen and an input device connected by a system bus. Among them, the processor of the computer device is used to provide computing and control capabilities. The memory of the computer device includes a non-volatile storage medium, an internal memory. The non-volatile storage medium stores an operating system and a computer program. The internal memory provides an environment for the operating system and the computer program in the non-volatile storage medium to run. The network interface of the computer device is used to communicate with the external terminal through the network connection. The computer program is executed by the processor to implement an intermediate frequency induction furnace body molten soup automatic heating method. The display screen of the computer device can be a liquid crystal display screen or an electronic ink display screen, and the input device of the computer device can be a touch layer overlaid on the display screen, or a key, trackball or touchpad arranged on the computer device shell, or an external keyboard, touchpad or mouse, etc.

[0157] The embodiment of the present application obtains the standard process parameters of the current process, the standard process parameters including the target melting temperature; obtains the real-time state parameters, the real-time state parameters including the real-time weight in the furnace, the remaining molten iron quantity in the furnace and the real-time molten iron temperature, the remaining molten iron weight being triggered and locked by the furnace body seating signal; according to the standard process parameters and the real-time state parameters, the heating power is predicted; based on the heating power, the frequency converter of the induction furnace power supply is controlled to perform the heating operation. The embodiment of the present application automatically obtains the standard process parameters and the real-time state parameters, predicts the heating power and controls the frequency converter to run, replaces the manual temperature measurement and power adjustment, reduces the labor and time cost; at the same time, through the accurate power prediction and automatic control, the temperature is prevented from fluctuating greatly, the stability of the molten iron composition is ensured, the waste rate and energy waste caused by the temperature fluctuation are reduced, the production continuity and stability are improved, and the core defects of low manual operation efficiency and large temperature fluctuation in the prior art are effectively solved.

[0158] The technical features of the above embodiments can be combined arbitrarily, and to make the description concise, not all possible combinations of the technical features in the above embodiments are described, but as long as the combinations of the technical features do not exist contradictions, they should be considered as the scope of the present application.

[0159] The above embodiments only express several implementation manners of the present application, the description is more specific and detailed, but it should not be understood as the limitation of the patent scope of the present application. It should be pointed out that for ordinary skilled in the art, without departing from the concept of the present application, a number of modifications and improvements can be made, which belong to the protection scope of the present application. Therefore, the protection scope of the present application patent should be subject to the appended claims.

Claims

1. A method for automatically heating a bath in an intermediate frequency induction furnace, characterized by, The method comprises the following steps: obtaining standard process parameters of the current process, the standard process parameters comprising a target melting temperature; obtaining real-time state parameters, the real-time state parameters comprising a real-time weight in the furnace, a remaining molten iron amount in the furnace and a real-time molten iron temperature, the remaining molten iron weight being locked by a furnace body seating signal trigger; predicting a heating power amount according to the standard process parameters and the real-time state parameters; controlling an inductive furnace power frequency converter to perform a heating operation based on the heating power amount.

2. The method of claim 1, wherein the temperature of the molten bath is automatically increased by the induction heating of the furnace body. The method of predicting the heating power amount according to the standard process parameters and the real-time state parameters comprises the following steps: determining a melting amount according to the real-time weight in the furnace and the remaining molten iron amount in the furnace; iteratively updating the heating power amount according to the formula: E = U x (M / 1000) x [(T0-T) / 100] wherein E is the heating power amount, U is a heating original unit, M is the melting amount, T0 is the target melting temperature, and T is the real-time molten iron temperature; the iteration being triggered by a change amount of a weighing instrument signal being greater than 50 kg or a temperature change amount being greater than 5℃. Before the step of controlling the inductive furnace power frequency converter to perform the heating operation based on the heating power amount, the method further comprises the following steps:

3. The method of claim 2, wherein the temperature of the molten bath is automatically increased by the induction heating of the molten bath in the furnace body of the intermediate frequency induction furnace. determining that the inductive furnace power frequency converter is in a relevant operation condition, the relevant operation condition comprising a main on-off switch being turned on, a relevant auxiliary machine device being put into operation, a stable matching of load characteristics and an effective start operation instruction. After the step of controlling the inductive furnace power frequency converter to perform the heating operation based on the heating power amount, the method comprises the following steps:

4. The method of claim 3, wherein the temperature of the molten bath is automatically increased by the induction heating of the molten bath in the furnace body of the intermediate frequency induction furnace. determining whether the heating operation is completed according to the input power amount; controlling the inductive furnace power frequency converter to perform a holding operation after determining that the heating operation is completed. The method of determining the input power amount comprises the following steps:

5. The method of claim 4, wherein the temperature of the molten bath is automatically increased by the induction heating of the furnace body. determining a power supply relationship between the power supply and the furnace body; when one power supply is for single furnace body power supply, calculating the input power amount according to a power amount pulse number; when one power supply is for multi-furnace body power supply, reading power values received by frequency conversion cabinets of each furnace body according to a preset time interval, and determining input power amounts of each furnace body based on the power values and power supply time of each furnace body. The step of controlling the inductive furnace power frequency converter to perform the heating operation based on the heating power amount comprises the following steps:

6. The method of claim 2, wherein the temperature of the molten bath is automatically increased by the induction heating of the furnace body. determining an initial power according to the formula: P0 = η x U x (M / 1000) x k wherein η is a heat transfer efficiency coefficient, and k is a power margin coefficient; generating a power control curve, the power control curve comprising an initial curve and a decay curve, a starting point of the decay curve being T≥T0-100℃, and a decay curve function being P(t) = P0 x exp(-0.015 x t); dynamically correcting the heating power amount according to the formula: E = σ x A x (T-Tenv) x t wherein σ is a Stefan-Boltzmann constant, A is an effective heat dissipation area of a molten pool, ε is an iron surface emissivity, T is the real-time molten iron temperature, Tenv is an environment temperature, and t is a cumulative heating time. E' = E + σ · A · ε · (T 4 - T env 4 ) · t The power control in the holding stage comprises the following steps: The method comprises the following steps: When E i Switch to hold mode when E ≥ 0.95E' or T ≥ To.

7. The method of claim 6, wherein the temperature of the molten bath is automatically increased by the induction heating of the furnace body. a first obtaining module, configured to obtain standard process parameters of the current process, the standard process parameters comprising a target melting temperature; The holding power P h = a · M; When T < T0- ΔT h power to P h + ΔP; when T > T0+ ΔT h reduce power to P h - ΔP; where ΔP = K p • e(t) + K i • ∫e(t)dt, e(t) = T - T0, K p is a proportional gain coefficient, K i is an integral gain coefficient.

8. An automatic heating device for a medium frequency induction furnace, characterized in that, a second obtaining module, configured to obtain real-time state parameters, the real-time state parameters comprising a real-time weight in the furnace, a remaining molten iron amount in the furnace and a real-time molten iron temperature, the remaining molten iron weight being locked by a furnace body seating signal trigger; a processing module, configured to predict a heating power amount according to the standard process parameters and the real-time state parameters. ​ ​ The control module controls the induction furnace power frequency converter to perform the temperature rising operation based on the temperature rising power amount.

9. The automatic heating device for the medium frequency induction furnace according to claim 8, wherein The processing module comprises: A first determination unit is configured to determine the melting amount according to the real-time weight in the furnace and the remaining molten iron amount in the furnace. A second determination unit is configured to update the temperature rising power amount iteratively according to the formula: E=U×(M / 1000)×[(T0-T) / 100] E is the temperature rising power amount, U is the original unit of the temperature rising, M is the melting amount, T0 is the target melting temperature, and T is the real-time molten iron temperature. A triggering unit is configured to trigger the update of the temperature rising power amount iteratively when the change amount of the weighing instrument signal is greater than 50 kg or the temperature change amount is greater than 5 DEG C. The automatic temperature rising system of the medium-frequency induction furnace body molten bath comprises an automatic temperature rising device of the medium-frequency induction furnace body molten bath.

10. An automatic heating system for a medium frequency induction furnace, characterized in that, The automatic temperature rising device of the medium-frequency induction furnace body molten bath is controlled by the automatic temperature rising method of the medium-frequency induction furnace body molten bath according to any one of claims 1 to 7. ​

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