Novel quantitative pouring control system capable of reducing pipe weight fluctuation

Abstract

The invention relates to the technical field of metal pouring, and discloses a novel quantitative pouring control system capable of reducing pipe weight fluctuation. Comprising an interval formulating module for formulating a pouring control interval of pouring equipment, a sub-stage dividing module for dividing a pouring stage into a socket stage, a straight pipe stage and a spigot stage, and a data acquisition module for calculating a socket calibration displacement value, a straight pipe calibration displacement value and a spigot calibration displacement value and judging whether to send out a pouring control early warning prompt or not. The pouring control module is used for controlling pouring equipment to execute a pouring control instruction; the method not only can ensure that the amount of molten iron turned out in unit time of the fan-shaped ladle is kept constant to achieve the effect of molten iron constant flow, but also can ensure that the wall thickness of the cast pipe at different positions is uniform and consistent, the quality risk that the local wall of the cast pipe is thin or the wall thickness is thick is reduced, the overweight rate of the cast pipe can be better controlled, and the production efficiency is improved. And the fluctuation amplitude of the pouring weight of the cast pipe is greatly reduced, so that the waste amount of molten iron resources is effectively reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of metal casting, more particularly, to a novel quantitative pouring control system for reducing pipe weight fluctuation. BACKGROUND

[0002] The equipment for pouring liquid metal into a rotating mold, filling and solidifying into a casting under the action of centrifugal force is called centrifugal casting equipment. In the casting of pipe fittings, horizontal centrifugal casting equipment is often used to complete the pouring operation of pipe fittings. In order to ensure that the actual pipe fitting casting weight can be infinitely close to the calibrated pipe fitting casting weight, quantitative pouring control is needed for the pipe fitting casting process, so as to reduce the fluctuation range of the pipe fitting casting weight.

[0003] The patent application with the publication number CN103273051A discloses an automatic pouring control method, controller and control system. In the measuring process, the original measuring instrument can be replaced by a smaller range and more accurate measuring instrument. The maximum allowable error of the change amount of the tundish storing molten metal can reach and exceed the measuring amount of the measuring instrument for measuring the pouring amount of molten metal, so as to provide accurate molten metal pouring amount data for the automatic pouring control process, and determine whether the molten metal pouring amount reaches the rated value, thereby solving the problem that small castings cannot be produced by using the automatic pouring method in the prior art. The existing pipe pouring control system realizes the pouring control effect of the pipe fitting casting weight by the movement principle of the sector package tilting mechanism and the control mode of the sector package falling back from the main machine walking to the set position. Since the inner cavity of the sector package will gradually form slag during use, the volume of each sector in the sector package will change, and the amount of molten iron poured out of each sector will also be different. At this time, the mode of tilting the sector package at a constant speed will cause the wall thickness of the cast pipe to be different at different positions, which is prone to cause local thin wall or wall thickness quality risk of the pipe, and the weight range of the cast pipe fittings also has a large fluctuation phenomenon, thereby failing to meet the demand for quantitative pouring and accurate control in the pipe casting process.

[0004] In view of this, the present application provides a novel quantitative pouring control system for reducing pipe weight fluctuation to solve the above problems. SUMMARY

[0005] In order to overcome the above-mentioned defects of the prior art and achieve the above-mentioned purpose, the present application provides the following technical scheme: a novel quantitative pouring control system for reducing pipe weight fluctuation, applied to a pouring controller, comprising: an interval setting module, which sets the pouring control interval of the pouring equipment based on the dynamic balance criterion after the starting time; The sub-stage division module divides the pouring stage into a socket stage, a straight pipe stage and a spigot stage based on the segmented pouring criterion, and determines a socket calibration quantity, a straight pipe calibration quantity and a spigot calibration quantity; The data acquisition module is composed of a first data acquisition unit, a second data acquisition unit and a third data acquisition unit. The first data acquisition unit acquires the socket molten iron pouring quantity of the pouring control interval in the socket stage, calculates the socket calibration displacement value, and determines whether to issue a pouring control early warning prompt. The second data acquisition unit acquires the straight pipe molten iron pouring quantity of the pouring control interval in the straight pipe stage, calculates the straight pipe calibration displacement value, and determines whether to issue a pouring control early warning prompt. The third data acquisition unit acquires the spigot molten iron pouring quantity of the pouring control interval in the spigot stage, calculates the spigot calibration displacement value, and determines whether to issue a pouring control early warning prompt. The pouring control module formulates a pouring control instruction to control the pouring equipment to execute the pouring control instruction.

[0006] Further, the dynamic balance criterion is that the time length of a pouring control interval is the average of the maximum and minimum time lengths of a standard angle of a sector package rotation; The pouring control interval formulation method is: A rotation of 3 degrees is recorded as a standard angle, and the maximum and minimum time lengths of a standard angle of a sector package rotation are queried by the pouring controller; The maximum and minimum time lengths of a standard angle of a sector package rotation are added and averaged to calculate the time length of a pouring control interval. The starting time is taken as the interval starting point, and the time after the time length of a pouring control interval is taken as the interval ending point. The time period between the interval starting point and the interval ending point is recorded as a pouring control interval.

[0007] Further, the segmented pouring criterion is that the transfer line of the pipe type is taken as the pouring critical position of adjacent sub-stages. The division method of the socket stage, the straight pipe stage and the spigot stage is: The pipe type design drawing of the pouring equipment is queried by the pouring controller, and the socket structure, the straight pipe structure and the spigot structure are marked on the pipe type design drawing. A first transfer line is drawn at the connection between the socket structure and the straight pipe structure along the radial direction of the pipe type, and a second transfer line is drawn at the connection between the straight pipe structure and the spigot structure. The part of the pouring stage before pouring to the first transfer line is recorded as the socket stage, the part of the pouring stage between the first transfer line and the second transfer line is recorded as the straight pipe stage, and the remaining part of the pouring stage is recorded as the spigot stage.

[0008] Further, the calculation method of the spout calibration displacement value is: In the spout stage, the first time and the last time of the pouring control interval are marked, and the pressure values of the sector at the first time and the last time are detected by the pressure sensor, which are recorded as the spout starting weight value and the spout ending weight value respectively; The spout starting weight value is subtracted from the spout ending weight value to calculate the spout molten iron pouring amount; The spout molten iron pouring amount is divided by the spout calibration amount to calculate the first pouring ratio, and the first pouring ratio is multiplied by the length of the spout structure to calculate the spout calibration displacement value.

[0009] Further, the determination method of whether to issue a pouring control warning prompt is: The displacement data in a pouring control interval is detected in real time by the displacement sensor on the pouring equipment, which is recorded as the spout real-time displacement value; When the spout real-time displacement value is equal to the spout calibration displacement value, it is determined that no pouring control warning prompt is issued; When the spout real-time displacement value is not equal to the spout calibration displacement value, it is determined that a pouring control warning prompt is issued.

[0010] Further, the calculation method of the straight pipe calibration displacement value is: In the straight pipe stage, the time when the spout calibration amount is completely poured is recorded as the straight pipe execution time, and the pressure values of the sector at the straight pipe execution time and after a pouring control interval are detected by the pressure sensor, which are recorded as the straight pipe starting weight value and the straight pipe ending weight value respectively; The straight pipe starting weight value is subtracted from the straight pipe ending weight value to calculate the straight pipe molten iron pouring amount; The straight pipe molten iron pouring amount is divided by the straight pipe calibration amount to calculate the second pouring ratio, and the second pouring ratio is multiplied by the length of the straight pipe structure to calculate the straight pipe calibration displacement value.

[0011] Further, the determination method of whether to issue a pouring control warning prompt is: The displacement data in a pouring control interval is detected in real time by the displacement sensor on the pouring equipment, which is recorded as the straight pipe real-time displacement value; When the straight pipe real-time displacement value is equal to the straight pipe calibration displacement value, it is determined that no pouring control warning prompt is issued; When the straight pipe real-time displacement value is not equal to the straight pipe calibration displacement value, it is determined that a pouring control warning prompt is issued.

[0012] Further, the calculation method of the spout calibration displacement value is: In the insertion stage, the time when the straight pipe calibration quantity is all poured out is recorded as the insertion execution time, the pressure values of the sector package at the insertion execution time and after a pouring control interval are detected by the pressure sensor, and are recorded as the insertion starting weight value and the insertion termination weight value respectively; The insertion starting weight value is subtracted from the insertion termination weight value to calculate the insertion molten iron pouring quantity; The insertion molten iron pouring quantity is divided by the insertion calibration quantity to calculate the third pouring ratio, and the third pouring ratio is multiplied by the length of the insertion structure to calculate the insertion calibration displacement value.

[0013] Further, the judgment method whether to issue a pouring control warning prompt is: The displacement data in a pouring control interval is detected in real time by the displacement sensor on the pouring equipment, and is recorded as the insertion real-time displacement value; When the insertion real-time displacement value is equal to the insertion calibration displacement value, it is judged that no pouring control warning prompt is issued; When the insertion real-time displacement value is not equal to the insertion calibration displacement value, it is judged that a pouring control warning prompt is issued.

[0014] Further, the pouring control instruction includes an increase pouring equipment moving speed instruction and a decrease pouring equipment moving speed instruction; The formulation method of the increase pouring equipment moving speed instruction and the decrease pouring equipment moving speed instruction is: When the spout real-time displacement value is greater than the spout calibration displacement value, the straight pipe real-time displacement value is greater than the straight pipe calibration displacement value, or the insertion real-time displacement value is greater than the insertion calibration displacement value, a decrease pouring equipment moving speed instruction is formulated; When the spout real-time displacement value is less than the spout calibration displacement value, the straight pipe real-time displacement value is less than the straight pipe calibration displacement value, or the insertion real-time displacement value is less than the insertion calibration displacement value, an increase pouring equipment moving speed instruction is formulated.

[0015] The technical effects and advantages of the novel quantitative pouring control system for reducing pipe weight fluctuation are: (1) By formulating a pouring control interval, the pouring control of the pouring equipment can be limited in time, realizing the effect of approaching real-time pouring control, avoiding the hysteresis of delayed pouring control, and realizing the quantitative and independent molten iron pouring effect of different positions of the casting pipe by dividing the pouring process into the spout stage, the straight pipe stage and the insertion stage, and ensuring the independent division effect of different pouring positions of the casting pipe.

[0016] (2) through the real-time molten iron pouring amount of the segmental ladle in the spigot stage, straight pipe stage and spigot stage, the real-time displacement amplitude of the pouring equipment is calculated, that is, the pouring situation in different pouring stages is accurately analyzed, the dynamic correlation effect between the real-time molten iron pouring amount and the pouring equipment transverse displacement amplitude is realized, the molten iron pouring amount of the segmental ladle per unit time can be kept constant, the effect of constant molten iron flow is achieved, the dependence of the traditional ladle change control is avoided, meanwhile, the uniformity of the wall thickness of the casting pipe at different positions can be ensured, the quality risk of the local thin wall or thick wall of the casting pipe is reduced, the casting pipe overweight rate can be better controlled, the pouring weight fluctuation amplitude of the casting pipe is greatly reduced, and then the waste amount of molten iron resources is effectively reduced, and the pouring manufacturing cost is reduced. BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure 1 A module schematic diagram of a novel quantitative pouring control system for reducing pipe weight fluctuation is provided for the first embodiment of the present application. Figure 2 A structure schematic diagram of a pouring equipment is provided for the first embodiment of the present application. Figure 3 A pipe weight scatter plot is provided for the first embodiment of the present application. Figure 4 A flowchart of a novel quantitative pouring control method for reducing pipe weight fluctuation is provided for the second embodiment of the present application. DETAILED DESCRIPTION

[0018] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0019] Embodiment one: please refer to Figures 1-3 The novel quantitative pouring control system for reducing pipe weight fluctuation described in the present embodiment is applied to a pouring controller, which comprises: An interval setting module determines the starting time of the pouring equipment, and after the starting time, the pouring control interval of the pouring equipment is set based on the dynamic balance criterion. The pouring equipment is a water-cooled horizontal metal centrifugal pouring equipment for pouring and manufacturing metal pipe, and the pouring equipment is a device with multiple mechanism combinations, specifically, the pouring equipment includes a pouring main machine, a sector-shaped ladle and a pressure sensor, etc., wherein the pouring main machine has a pipe type inside for containing molten iron and casting pipe, the pouring main machine is provided with moving wheels at the bottom, the sector-shaped ladle is driven to rotate by the extension and retraction of the electric extension and retraction module to realize the overturning of the molten iron in the sector-shaped ladle, thereby pouring the molten iron in the sector-shaped ladle, and the pressure sensor is located at the bottom of the sector-shaped ladle to detect the weight change of the sector-shaped ladle in real time.

[0020] Specifically as Figure 2 shown, in Figure 2 , SX is the sector-shaped ladle, CK is the pouring equipment, JZ is the spout, LC is the chute, the rotation directions of the sector-shaped ladle and the pipe type are shown by the corresponding arrows, and the horizontal moving direction of the pouring equipment is to the right.

[0021] The starting moment refers to the moment when the molten iron flows into the pipe type for the first time to cast the pipe, and serves as the starting moment of the pouring control system for pouring control, when the molten iron in the sector-shaped ladle is poured into the pouring equipment and flows into the pipe type, the molten iron will flow through the spout, the chute and other components of the pouring equipment, therefore, the moment when the sector-shaped ladle pours the molten iron for the first time is not the starting moment, but the moment when the sector-shaped ladle pours the molten iron is taken as the starting point, and the time length of the molten iron flowing through the spout, the chute and other components is accumulated to obtain the starting moment; Specifically, when the starting moment is determined, first, the moment when the sector-shaped ladle pours the molten iron into the spout of the pouring equipment for the first time is recorded as the reference moment, then the time length of the molten iron flowing through the spout and the chute is queried after the molten iron flows through the spout and the chute, and finally the moment after one time length is recorded as the starting moment with the reference moment as the starting point.

[0022] It should be noted that when the molten iron flows through the spout and the chute, the flow state of the molten iron in the spout and the chute is full, so that the storage capacity of the molten iron in the spout and the chute is fixed, that is, the maximum capacity of the spout plus the maximum capacity of the chute, and in the case that the flow state of the molten iron in the spout and the chute is full, the flow speed of the molten iron in the spout and the chute is consistent, therefore, the time length of the molten iron flowing in the spout and the chute is fixed.

[0023] After the starting moment is determined, the time span for pouring control of the pouring equipment, that is, the pouring control interval, needs to be determined, so that the pouring control interval can serve as a standard time unit for subsequent pouring control of the pouring equipment, and can also limit the time of the pouring control of the pouring equipment, to ensure that the pouring control interval can achieve the effect of periodic and infinitely close to real-time control of the pouring of the pouring equipment.

[0024] In the preparation of pouring control interval, it is necessary to ensure that the length of a pouring control interval can meet the needs of molten iron pouring data collection of pouring equipment, and also can realize the real-time and accurate control of the molten iron pouring quantity of pouring equipment, so it is necessary to prepare the pouring control interval under the limitation of dynamic pouring criterion.

[0025] The dynamic balance criterion is that the length of a pouring control interval is the average value of the maximum value and the minimum value of the length of a standard angle of the sector package rotation, that is, the length of the pouring control interval is related to the rotation angle of the sector package, so that the pouring control interval can be limited and determined based on the molten iron quantity poured by the sector package.

[0026] After the dynamic balance is determined, the pouring control interval needs to be prepared. Specifically, first, a rotation of 3 degrees is recorded as a standard angle, the maximum length and the minimum length of the sector package rotation of a standard angle are queried by the pouring controller, then the maximum length and the minimum length of the sector package rotation of a standard angle are added and averaged to calculate the length of the pouring control interval, finally, the starting time is taken as the interval starting point, the time after the length of a pouring control interval is taken as the interval ending point, and the time period between the interval starting point and the interval ending point is recorded as the pouring control interval.

[0027] For example, the length of the pouring control interval is 0.2S, that is, every 0.2S, the pouring process of the pouring equipment is collected, analyzed and controlled.

[0028] The sub-stage division module divides the pouring stage into sub-stages based on the segmented pouring criterion and determines the corresponding sub-pouring quantity of the sub-stage, the sub-stage includes the socket stage, the straight pipe stage and the socket stage; When the pouring equipment pours molten iron into the casting pipe, the whole pouring process of the casting pipe is recorded as a pouring stage. Since the structure and position of the casting pipe during pouring are not fixed, the corresponding pouring stage is different when the casting pipe is in different positions and structures, therefore, the pouring stage needs to be divided into multiple continuous and different sub-stages. Specifically, the sub-stage includes the socket stage, the straight pipe stage and the socket stage; wherein the socket stage refers to the pouring process of the structure at the front position of the casting pipe, the straight pipe stage refers to the pouring process of the structure at the middle position of the casting pipe, and the socket stage refers to the pouring process of the structure at the rear position of the casting pipe.

[0029] When the pouring stage is divided into sub-stages, the segmented pouring criterion needs to be based on to ensure the accuracy of the division of each sub-stage and ensure that the socket stage, the straight pipe stage and the socket stage are in adjacent and continuous state. The segmental pouring criterion is that the pipe-shaped transfer line is taken as the pouring critical position of adjacent sub-stages, so as to ensure that the adjacent two sub-stages are in a continuous state during pouring and ensure that the pouring processes of different stages and positions of the casting pipe can be continuous and uninterrupted.

[0030] The division method of the socket stage, the straight pipe stage and the spigot stage is as follows: The pipe type design drawing of the pouring equipment is inquired through the pouring controller, and the socket structure, the straight pipe structure and the spigot structure are marked on the pipe type design drawing; A first transfer line is drawn at the connection of the socket structure and the straight pipe structure along the radial direction of the pipe type, and a second transfer line is drawn at the connection of the straight pipe structure and the spigot structure; the first transfer line and the second transfer line are respectively used to represent the critical positions of the socket structure and the straight pipe structure and the straight pipe structure and the spigot structure, thereby serving as the basis for distinguishing the socket stage, the straight pipe stage and the spigot stage; The part of the pouring stage before the first transfer line is recorded as the socket stage, the part of the pouring stage between the first transfer line and the second transfer line is recorded as the straight pipe stage, and the remaining part of the pouring stage is recorded as the spigot stage.

[0031] It should be noted that the socket stage, the straight pipe stage and the spigot stage correspond to different pouring positions of the pipe type, and for the same reason, when the pipe type is poured in the socket stage, the straight pipe stage and the spigot stage, the parts poured are the socket position, the straight pipe position and the spigot position of the casting pipe, respectively, so as to realize the effect of the stage-by-stage pouring of the casting pipe.

[0032] After the pouring stage is divided into the socket stage, the straight pipe stage and the spigot stage, according to the pouring process requirements of the casting pipe, the amount of molten iron required by each sub-stage is fixed, so it is necessary to set the amount of molten iron of the socket stage, the straight pipe stage and the spigot stage to a fixed value respectively, so as to ensure the quantitative effect of the casting pipe during subsequent pouring.

[0033] Specifically, the amount of molten iron required by the socket stage, the straight pipe stage and the spigot stage is uniformly referred to as sub-pouring quantity, and the sub-pouring quantity can represent the amount of molten iron poured in different sub-stages; the sub-pouring quantity includes socket calibration quantity, straight pipe calibration quantity and spigot calibration quantity. The socket calibration quantity is used to calibrate the amount of molten iron poured in the socket stage, the straight pipe calibration quantity is used to calibrate the amount of molten iron poured in the straight pipe stage, and the spigot calibration quantity is used to calibrate the amount of molten iron poured in the spigot stage; the socket calibration quantity, the straight pipe calibration quantity and the spigot calibration quantity are set according to the actual manufacturing process requirements of the casting pipe; for example, when the total amount of molten iron poured into the casting pipe is 100KG, the socket calibration quantity is 10KG, the straight pipe calibration quantity is 82KG, and the spigot calibration quantity is 8KG.

[0034] The data acquisition module is composed of a first data acquisition unit, a second data acquisition unit and a third data acquisition unit. The data acquisition module is used for comprehensively collecting overall data in the pipe casting process. The collected data includes all data in the socket stage, the straight pipe stage and the socket stage. In order to independently collect data in different sub-stages, the data acquisition module needs to be divided into three parts. The data acquisition module is composed of a first data acquisition unit, a second data acquisition unit and a third data acquisition unit.

[0035] It should be noted that when determining the starting moment, the socket and the chute of the pouring device are full of molten iron. Therefore, in the molten iron pouring in the socket stage, the straight pipe stage and the socket stage, the weight of the molten iron poured out of the sector-shaped package is consistent with the weight of the molten iron flowing out of the chute, and the flow speed of the molten iron in the chute is constant.

[0036] The first data acquisition unit collects the socket molten iron pouring amount of the pouring device in the pouring control interval in the socket stage, calculates the socket calibration displacement value of the pouring device in combination with the socket calibration amount, and determines whether to issue a pouring control warning prompt. In the socket stage of the pipe casting, the related data of the real-time pouring process need to be collected and analyzed, so as to collect and analyze the quantitative pouring of the socket stage in real time. The socket molten iron pouring amount refers to the weight of the molten iron poured out of the sector-shaped package into the chute in one pouring control interval. Since the inner cavity of the socket and the chute is full of molten iron, the weight of the molten iron poured out of the sector-shaped package is consistent with the weight of the molten iron flowing out of the chute into the pipe type. That is, the weight of the molten iron poured into the pipe type in one pouring control interval in the socket stage can be represented.

[0037] Specifically, when collecting the socket molten iron pouring amount, the pressure change value of the sector-shaped package in one pouring control interval is detected in real time by the pressure sensor at the bottom of the sector-shaped package, and the pressure change value is recorded as the socket molten iron pouring amount.

[0038] Since the pipe type has a length, and the molten iron flowing out of the chute needs to flow to different positions in the pipe type to realize the centrifugal separation casting operation of the socket structure, the straight pipe structure and the socket structure, to ensure that the molten iron at different positions can be cast to different positions of the pipe under the combined action of the centrifugal separation of the pouring device and the external cooling system, and to ensure the uniformity of the pipe wall thickness of the pipe.

[0039] The ladle calibration displacement value refers to the horizontal displacement amplitude of the casting equipment corresponding to the ladle molten metal pouring amount in a pouring control interval in the ladle stage, so that the ladle calibration displacement value can be used as the amplitude value of the horizontal displacement of the casting equipment in the ladle stage, and as a basis for judging whether the subsequent pipe type inner ladle structure pouring thickness is uniform and quantitative; The calculation method of the ladle calibration displacement value is: In the ladle stage, the first time and the last time of the pouring control interval are marked, and the pressure values of the sector at the first time and the last time are detected by the pressure sensor, which are respectively recorded as the ladle starting weight value and the ladle ending weight value; The ladle molten metal pouring amount is calculated by subtracting the ladle starting weight value from the ladle ending weight value; The calculation formula of the ladle molten metal pouring amount is: ; In the formula, is the ladle molten metal pouring amount, is the ladle starting weight value, is the ladle ending weight value; The first pouring ratio is calculated by dividing the ladle molten metal pouring amount by the ladle calibration amount, and the ladle calibration displacement value is calculated by multiplying the first pouring ratio by the length of the ladle structure, which is obtained by querying the pipe type design drawing; The calculation formula of the ladle calibration displacement value is: ; In the formula, is the ladle calibration displacement value, is the length of the ladle structure, is the ladle calibration amount.

[0040] After the ladle calibration displacement value is calculated, the horizontal displacement amplitude of the casting equipment corresponding to the ladle molten metal pouring amount in a pouring control interval in the ladle stage can be determined, and then the ladle calibration displacement value is compared with the actual horizontal displacement amplitude of the casting equipment, so as to judge whether the casting equipment has the abnormal phenomenon of too large or too small horizontal displacement amplitude, and as a basis for issuing the pouring control warning prompt; Specifically, the pouring control early warning prompt is a warning prompt for an abnormal situation that the horizontal transverse amplitude of the pouring equipment is too large or too small. When the horizontal transverse amplitude of the pouring equipment is too large or too small, it indicates that the speed of the horizontal transverse movement of the pouring equipment in the pouring control interval is too fast or too slow. At the same time, when the speed of the horizontal transverse movement of the pouring equipment in the pouring control interval is too fast, the amount of molten iron flowing into the local position of the pipe type is relatively large. At this time, the molten iron is separated to the inner wall of the pipe type under the centrifugal separation action of the pouring equipment, resulting in that the local position of the pipe type has a phenomenon of too thick pipe wall, and also causing a negative impact on the quantitative pouring of the subsequent molten iron, and easily causing the phenomenon of non-quantitative molten iron pouring and large weight fluctuation of the pipe.

[0041] The determination method of whether to issue the pouring control early warning prompt is: The displacement data in one pouring control interval is detected in real time by the displacement sensor on the pouring equipment, which is recorded as the spout real-time displacement value; The spout real-time displacement value is compared with the spout calibration displacement value; When the spout real-time displacement value is equal to the spout calibration displacement value, it indicates that the actual horizontal transverse amplitude of the pouring equipment in the pouring control interval is consistent with the calibrated horizontal transverse amplitude. At this time, the phenomenon of different wall thicknesses of the spout position of the pipe does not occur, and it is determined that the pouring control early warning prompt is not issued; When the spout real-time displacement value is not equal to the spout calibration displacement value, it indicates that the actual horizontal transverse amplitude of the pouring equipment in the pouring control interval is inconsistent with the calibrated horizontal transverse amplitude. At this time, the phenomenon of different wall thicknesses of the spout position of the pipe occurs, and it is determined that the pouring control early warning prompt is issued.

[0042] The second data acquisition unit acquires the straight pipe molten iron pouring amount of the pouring equipment in the pouring control interval in the straight pipe stage, calculates the straight pipe calibration displacement value of the pouring equipment in combination with the straight pipe calibration amount, and determines whether to issue the pouring control early warning prompt; In the pouring of the straight pipe stage of the pipe, the related data of the real-time pouring process need to be acquired and analyzed, so as to acquire and analyze the quantitative pouring situation of the straight pipe stage in real time; The straight pipe molten iron pouring amount refers to the weight of the molten iron poured into the chute from the sector in one pouring control interval, that is, the weight of the molten iron poured into the pipe type in one pouring control interval in the straight pipe stage.

[0043] It should be noted that in the collection of the straight pipe ladle pouring amount and the calculation of the straight pipe calibration displacement value, the premise is that the whole process of the ladling in the socket stage has been completed, which includes but is not limited to that the socket calibration amount is completely poured and the pouring control system completes the real-time calibration pouring control in the socket stage. After the completion of the socket stage, the first moment of the straight pipe stage can be used as the first moment of the straight pipe stage.

[0044] The straight pipe calibration displacement value refers to the horizontal displacement amplitude of the pouring equipment corresponding to the straight pipe ladle pouring amount in a pouring control interval in the straight pipe stage, so that the straight pipe calibration displacement value can be used as the amplitude value of the horizontal displacement of the pouring equipment in the straight pipe stage, and as a basis for judging whether the thickness of the straight pipe structure in the pipe type is uniform and calibrated. The calculation method of the straight pipe calibration displacement value is: In the straight pipe stage, the moment when the socket calibration amount is completely poured is recorded as the straight pipe execution moment. The pressure values of the sector at the straight pipe execution moment and after a pouring control interval are detected by the pressure sensor, which are recorded as the straight pipe start weight value and the straight pipe end weight value, respectively. The straight pipe ladle pouring amount is calculated by subtracting the straight pipe start weight value from the straight pipe end weight value. The calculation formula of the straight pipe ladle pouring amount is: ; In the formula, is the straight pipe ladle pouring amount, is the straight pipe start weight value, is the straight pipe end weight value. The second pouring ratio is calculated by dividing the straight pipe ladle pouring amount by the straight pipe calibration amount, and the straight pipe calibration displacement value is calculated by multiplying the second pouring ratio by the length of the straight pipe structure, which is obtained by querying the pipe type design drawing. The calculation formula of the straight pipe calibration displacement value is: ; In the formula, is the straight pipe calibration displacement value, is the length of the straight pipe structure, is the straight pipe calibration amount.

[0045] After the straight pipe calibration displacement value is calculated, the amplitude of the horizontal displacement of the pouring equipment corresponding to the straight pipe ladle pouring amount in a pouring control interval in the straight pipe stage can be determined. Then, the straight pipe calibration displacement value is compared with the actual amplitude of the horizontal displacement of the pouring equipment, so as to judge whether the pouring equipment has abnormal phenomena such as too large or too small horizontal displacement amplitude, and as a basis for whether to issue a pouring control warning prompt. The determination method for whether to issue a pouring control early warning prompt is: The displacement data in a pouring control interval is detected in real time by a displacement sensor on the pouring equipment, and is recorded as a straight pipe real-time displacement value; The straight pipe real-time displacement value is compared with the straight pipe calibration displacement value; When the straight pipe real-time displacement value is equal to the straight pipe calibration displacement value, it indicates that the actual horizontal displacement amplitude of the pouring equipment in the pouring control interval is consistent with the calibrated horizontal displacement amplitude, at this time, the phenomenon of different wall thicknesses of the straight pipe position of the casting pipe does not occur, and it is determined that no pouring control early warning prompt is issued; When the straight pipe real-time displacement value is not equal to the straight pipe calibration displacement value, it indicates that the actual horizontal displacement amplitude of the pouring equipment in the pouring control interval is inconsistent with the calibrated horizontal displacement amplitude, at this time, the phenomenon of different wall thicknesses of the straight pipe position of the casting pipe occurs, and it is determined that a pouring control early warning prompt is issued.

[0046] The third data acquisition unit acquires the pouring control interval of the pouring equipment in the tundish stage, combines the tundish calibration amount, calculates the tundish calibration displacement value of the pouring equipment, and determines whether to issue a pouring control early warning prompt; In the tundish stage pouring of the casting pipe, the related data of the real-time pouring process need to be acquired and analyzed, so as to acquire and analyze the quantitative pouring of the tundish stage in real time; The tundish molten iron pouring amount refers to the weight of the molten iron poured into the runner from the sector in a pouring control interval, that is, the weight of the molten iron poured into the pipe type in a pouring control interval in the tundish stage.

[0047] It should be noted that when the tundish molten iron pouring amount is acquired and the tundish calibration displacement value is calculated, the premise is that all the processes of the molten iron pouring in the straight pipe stage have been completed, at this time, the molten iron pouring processes include but are not limited to that the straight pipe calibration amount is completely poured and the pouring control system completes the real-time quantitative pouring control in the straight pipe stage, etc. After the straight pipe stage is completely executed, the first moment of the tundish stage can be regarded as the first moment of the tundish stage.

[0048] The tundish calibration displacement value refers to the horizontal displacement amplitude of the pouring equipment in a pouring control interval of the straight pipe stage corresponding to the tundish molten iron pouring amount, so that the tundish calibration displacement value can be used as the amplitude value of the horizontal displacement of the pouring equipment in the tundish stage, and as the basis for judging whether the tundish structure pouring thickness in the pipe type is uniform and quantitative; The calculation method of the tundish calibration displacement value is: In the tundish stage, the time when the straight pipe calibration quantity is all poured out is recorded as the tundish execution time, the pressure values of the sector package at the tundish execution time and after a pouring control interval are detected by the pressure sensor, and are recorded as the tundish start weight value and the tundish end weight value respectively; The tundish molten iron pouring quantity is calculated after the tundish start weight value is subtracted from the tundish end weight value; The calculation formula of the tundish molten iron pouring quantity is: ; In the formula, is the tundish molten iron pouring quantity, is the tundish start weight value, is the tundish end weight value; The third pouring ratio is calculated after the tundish molten iron pouring quantity is divided by the tundish calibration quantity, and the tundish calibration displacement value is calculated after the third pouring ratio is multiplied by the length of the tundish structure, which is obtained by querying the pipe type design drawing; The calculation formula of the tundish calibration displacement value is: ; In the formula, is the tundish calibration displacement value, is the length of the tundish structure, is the tundish calibration quantity.

[0049] After the tundish calibration displacement value is calculated, the amplitude of the horizontal displacement of the pouring equipment in a pouring control interval corresponding to the tundish molten iron pouring quantity in the tundish stage can be determined, and then the tundish calibration displacement value is compared with the actual amplitude of the horizontal displacement of the pouring equipment, so as to determine whether the pouring equipment has the abnormal phenomenon of too large or too small horizontal displacement amplitude, and to serve as the basis for whether to issue a pouring control early warning prompt; The determination method of whether to issue a pouring control early warning prompt is: The displacement data in a pouring control interval is detected by the displacement sensor on the pouring equipment, and is recorded as the tundish real-time displacement value; The tundish real-time displacement value is compared with the tundish calibration displacement value; When the tundish real-time displacement value is equal to the tundish calibration displacement value, it indicates that the actual horizontal displacement amplitude of the pouring equipment in the pouring control interval is consistent with the calibrated horizontal displacement amplitude, at this time, the phenomenon of different wall thicknesses at the tundish position of the casting pipe does not occur, and it is determined that the pouring control early warning prompt is not issued; When the tundish real-time displacement value is not equal to the tundish calibration displacement value, it indicates that the actual horizontal displacement amplitude of the pouring equipment in the pouring control interval is inconsistent with the calibrated horizontal displacement amplitude, at this time, the phenomenon of different wall thicknesses at the tundish position of the casting pipe occurs, and it is determined that the pouring control early warning prompt is issued.

[0050] The pouring control module formulates a pouring control instruction if a pouring control early warning prompt is issued, and controls the pouring equipment to execute the pouring control instruction; When the pouring control early warning prompt is issued, it indicates that the pouring equipment has a phenomenon of mismatch between the molten iron pouring amount and the horizontal transverse amplitude of the pouring equipment during the pouring process of the casting pipe at this time. At this time, timely and accurate pouring control adjustment needs to be made for the abnormal casting pipe pouring phenomenon to ensure that the pouring equipment can timely and accurately control the pouring process of the casting pipe, prevent the phenomenon of local thickness difference of the casting pipe during pouring, and also achieve the effect of quantitative molten iron pouring to reduce the weight fluctuation of the casting pipe.

[0051] The pouring control instruction is used to match the horizontal transverse amplitude of the pouring equipment with the molten iron pouring amount, so as to ensure that the pouring equipment can timely and accurately control the pouring process of the casting pipe; Specifically, the pouring control instruction includes an increase pouring equipment moving speed instruction and a decrease pouring equipment moving speed instruction. The formulation method of the increase pouring equipment moving speed instruction and the decrease pouring equipment moving speed instruction is: When the spout real-time displacement value is greater than the spout calibration displacement value, the straight pipe real-time displacement value is greater than the straight pipe calibration displacement value, or the spout real-time displacement value is greater than the spout calibration displacement value, at this time, the pouring equipment has a phenomenon of too large horizontal transverse amplitude in the spout stage, the straight pipe stage or the spout stage. Therefore, the horizontal transverse amplitude of the pouring equipment needs to be reduced, and a decrease pouring equipment moving speed instruction is formulated; When the spout real-time displacement value is less than the spout calibration displacement value, the straight pipe real-time displacement value is less than the straight pipe calibration displacement value, or the spout real-time displacement value is less than the spout calibration displacement value, at this time, the pouring equipment has a phenomenon of too small horizontal transverse amplitude in the spout stage, the straight pipe stage or the spout stage. Therefore, the horizontal transverse amplitude of the pouring equipment needs to be increased, and an increase pouring equipment moving speed instruction is formulated.

[0052] After the corresponding pouring control instruction is formulated, the pouring control instruction needs to be sent to the pouring equipment through the pouring controller to control the pouring equipment to execute the pouring control instruction, so as to achieve the purpose of increasing the moving speed of the pouring equipment or decreasing the moving speed of the pouring equipment, and finally realize the effect of matching the horizontal transverse amplitude of the pouring equipment with the molten iron pouring amount; Specifically, when executing the pouring control instruction, the driving component on the pouring equipment needs to be controlled according to the specific content of the pouring control instruction, wherein the driving component is a device that provides driving force to the moving wheel of the pouring equipment. For example, the driving component is a motor.

[0053] In the specific implementation, if the pouring control instruction is an instruction to increase the moving speed of the pouring device, the pouring controller sends information to increase the rotating speed to the driving component, the driving component increases the working power to increase the horizontal moving speed of the pouring device until the pouring control early warning prompt is not sent out. If the pouring control instruction is an instruction to decrease the moving speed of the pouring device, the pouring controller sends information to decrease the rotating speed to the driving component, the driving component decreases the working power to decrease the horizontal moving speed of the pouring device until the pouring control early warning prompt is not sent out.

[0054] The weight of the 46 pipes poured in the workshop is counted according to the control effect of the quantitative pouring control system, the predetermined pouring weight of the pipe is 230 kg, and the weight of all the pipes is collected to draw a pipe weight scatter plot as shown in Figure 3 The vertical direction of the pipe weight scatter plot represents the weight of the pipe, and the horizontal direction represents the number of pipes. Figure 3 It can be seen that the quantitative pouring control of the quantitative pouring control system can ensure that the weight of the poured pipe is as close as possible to the predetermined pouring weight of the pipe, and the weight of the pipe is kept at about 230 kg, and the final pouring weight of the pipe has a small fluctuation range.

[0055] In this embodiment, by formulating the pouring control interval, the pouring control of the pouring device can be limited in time, the effect of the pouring control approaching real-time pouring control is realized, the hysteresis of the delayed pouring control is avoided, and by dividing the pouring process into the socket stage, the straight pipe stage and the socket stage, the quantitative and independent molten iron pouring effect of different positions of the cast pipe can be realized, and the independent division effect of different pouring positions of the cast pipe is ensured. The real-time displacement amplitude of the pouring device can be calculated according to the real-time molten iron pouring amount of the sector-shaped ladle in the socket stage, the straight pipe stage and the socket stage, the pouring situation of different pouring stages can be accurately analyzed, the dynamic correlation effect between the real-time molten iron pouring amount and the horizontal moving amplitude of the pouring device is realized, and the real-time and quantitative pouring effect of the pouring device can be ensured by combining the targeted control of the pouring control instruction, which can ensure that the molten iron pouring amount of the sector-shaped ladle per unit time remains constant, achieve the effect of constant molten iron flow, avoid the dependence of the traditional ladle control on the position change of the sector-shaped ladle, and ensure the uniformity of the wall thickness of the cast pipe at different positions, reduce the quality risk of local thin wall or thick wall of the cast pipe, better control the over-weight rate of the cast pipe, greatly reduce the pouring weight fluctuation range of the cast pipe, and effectively reduce the waste of molten iron resources and the pouring manufacturing cost.

[0056] Embodiment two: please refer to Figure 4As shown, the part not described in detail in the embodiment is described in embodiment one, a new quantitative pouring control method for reducing pipe weight fluctuation is provided, which is applied to a pouring controller and realized based on a new quantitative pouring control system for reducing pipe weight fluctuation, and comprises the following steps: S1: after the starting moment, based on the dynamic balance criterion, the pouring control interval of the pouring equipment is formulated; S2: based on the segmented pouring criterion, the pouring stage is divided into the socket stage, the straight pipe stage and the socket stage, and the socket calibration quantity, the straight pipe calibration quantity and the socket calibration quantity are determined; S3: in the socket stage, the socket molten iron pouring quantity of the pouring control interval is collected, the socket calibration displacement value is calculated, and it is judged whether the pouring control early warning prompt is sent or not; S4: in the straight pipe stage, the straight pipe molten iron pouring quantity of the pouring control interval is collected, the straight pipe calibration displacement value is calculated, and it is judged whether the pouring control early warning prompt is sent or not; S5: in the socket stage, the socket molten iron pouring quantity of the pouring control interval is collected, the socket calibration displacement value is calculated, and it is judged whether the pouring control early warning prompt is sent or not; S6: if the pouring control early warning prompt is sent, the pouring control instruction is formulated, and the pouring equipment is controlled to execute the pouring control instruction.

[0057] The above is only a specific embodiment of the present application, but the protection scope of the present application is not limited to this, any person skilled in the art can easily think of changes or replacements within the technical range disclosed by the present application, which should be covered in the protection scope of the present application.

Claims

1. A novel dosing control system for reducing pipe weight fluctuation, applied to a dosing controller, characterized by, The application comprises the following steps: An interval setting module sets a pouring control interval of the pouring equipment based on a dynamic balance criterion after a starting time; A sub-stage division module divides the pouring stage into a socket stage, a straight pipe stage and a socket stage based on a segmented pouring criterion, and determines a socket calibration quantity, a straight pipe calibration quantity and a socket calibration quantity; A data acquisition module comprises a first data acquisition unit, a second data acquisition unit and a third data acquisition unit; The first data acquisition unit acquires a socket molten iron pouring quantity of the pouring control interval in the socket stage, calculates a socket calibration displacement value, and determines whether to issue a pouring control early warning prompt; The second data acquisition unit acquires a straight pipe molten iron pouring quantity of the pouring control interval in the straight pipe stage, calculates a straight pipe calibration displacement value, and determines whether to issue a pouring control early warning prompt; The third data acquisition unit acquires a socket molten iron pouring quantity of the pouring control interval in the socket stage, calculates a socket calibration displacement value, and determines whether to issue a pouring control early warning prompt; A pouring control module sets a pouring control instruction to control the pouring equipment to execute the pouring control instruction.

2. A novel dosing control system to reduce pipe weight fluctuation as claimed in claim 1, wherein, The dynamic balance criterion is that the length of a pouring control interval is the average of the maximum and minimum length of a standard angle of a sector rotating; The setting method of the pouring control interval is as follows: A 3-degree rotation is recorded as a standard angle, and the maximum and minimum length of a standard angle of a sector rotating is obtained through a pouring controller; The maximum and minimum length of a standard angle of a sector rotating is added and averaged to calculate the length of the pouring control interval; The starting time is recorded as the interval starting point, and the time after the length of a pouring control interval is recorded as the interval ending point, and the time interval between the interval starting point and the interval ending point is recorded as the pouring control interval.

3. A novel dosing control system to reduce pipe weight fluctuation as claimed in claim 2, wherein The segmented pouring criterion is that the transfer line of the pipe type is used as the pouring critical position of adjacent sub-stages; The division method of the socket stage, the straight pipe stage and the socket stage is as follows: The pipe type design drawing of the pouring equipment is obtained through the pouring controller, and the socket structure, the straight pipe structure and the socket structure are marked on the pipe type design drawing; A first transfer line is drawn along the radial direction of the pipe type at the connection between the socket structure and the straight pipe structure, and a second transfer line is drawn at the connection between the straight pipe structure and the socket structure; The part of the pouring stage before the first transfer line is recorded as the socket stage, the part of the pouring stage between the first transfer line and the second transfer line is recorded as the straight pipe stage, and the remaining part of the pouring stage is recorded as the socket stage.

4. A novel dosing control system to reduce pipe weight fluctuation as claimed in claim 3, wherein The calculation method of the socket calibration displacement value is as follows: In the socket stage, the first time and the last time of the pouring control interval are marked, and the pressure values of the sector at the first time and the last time are detected through the pressure sensor, which are recorded as the socket starting weight value and the socket ending weight value, respectively; The difference between the socket starting weight value and the socket ending weight value is calculated to obtain the socket molten iron pouring quantity; The first pouring ratio is calculated by dividing the socket molten iron pouring quantity by the socket calibration quantity, and the socket calibration displacement value is calculated by multiplying the first pouring ratio by the length of the socket structure.

5. A novel dosing control system to reduce pipe weight fluctuation as claimed in claim 4 wherein, The determination method of whether to issue a pouring control early warning prompt is as follows: The displacement data in a pouring control interval is detected in real time by a displacement sensor on the pouring equipment, and is recorded as the spout real-time displacement value; When the spout real-time displacement value is equal to the spout calibration displacement value, it is determined that no pouring control early warning prompt is issued; When the spout real-time displacement value is not equal to the spout calibration displacement value, it is determined that a pouring control early warning prompt is issued.

6. A novel dosing control system to reduce pipe weight fluctuation as claimed in claim 5, wherein, The calculation method of the straight pipe calibration displacement value is: In the straight pipe stage, the time when the spout calibration amount is completely poured is recorded as the straight pipe execution time, the pressure values of the sector pack at the straight pipe execution time and after one pouring control interval are detected by the pressure sensor, and are recorded as the straight pipe start weight value and the straight pipe end weight value, respectively; The straight pipe molten iron pouring amount is calculated by subtracting the straight pipe start weight value from the straight pipe end weight value; The second pouring ratio is calculated by dividing the straight pipe molten iron pouring amount by the straight pipe calibration amount, and the straight pipe calibration displacement value is calculated by multiplying the second pouring ratio by the length of the straight pipe structure.

7. A novel dosing control system to reduce pipe weight fluctuation as claimed in claim 6 wherein, The determination method of whether to issue a pouring control early warning prompt is: The displacement data in a pouring control interval is detected in real time by a displacement sensor on the pouring equipment, and is recorded as the straight pipe real-time displacement value; When the straight pipe real-time displacement value is equal to the straight pipe calibration displacement value, it is determined that no pouring control early warning prompt is issued; When the straight pipe real-time displacement value is not equal to the straight pipe calibration displacement value, it is determined that a pouring control early warning prompt is issued.

8. A novel dosing control system to reduce pipe weight fluctuation as claimed in claim 7, wherein, The calculation method of the spout calibration displacement value is: In the spout stage, the time when the straight pipe calibration amount is completely poured is recorded as the spout execution time, the pressure values of the sector pack at the spout execution time and after one pouring control interval are detected by the pressure sensor, and are recorded as the spout start weight value and the spout end weight value, respectively; The spout molten iron pouring amount is calculated by subtracting the spout start weight value from the spout end weight value; The third pouring ratio is calculated by dividing the spout molten iron pouring amount by the spout calibration amount, and the spout calibration displacement value is calculated by multiplying the third pouring ratio by the length of the spout structure.

9. A novel dosing control system to reduce pipe weight fluctuation as claimed in claim 8, wherein, The determination method of whether to issue a pouring control early warning prompt is: The displacement data in a pouring control interval is detected in real time by a displacement sensor on the pouring equipment, and is recorded as the spout real-time displacement value; When the spout real-time displacement value is equal to the spout calibration displacement value, it is determined that no pouring control early warning prompt is issued; When the spout real-time displacement value is not equal to the spout calibration displacement value, it is determined that a pouring control early warning prompt is issued.

10. A novel dosing control system to reduce pipe weight fluctuation as claimed in claim 9, wherein, The pouring control instruction includes an increase pouring equipment moving speed instruction and a decrease pouring equipment moving speed instruction; The formulation method of the increase pouring equipment moving speed instruction and the decrease pouring equipment moving speed instruction is: When the spout real-time displacement value is greater than the spout calibration displacement value, the straight pipe real-time displacement value is greater than the straight pipe calibration displacement value, or the spout real-time displacement value is greater than the spout calibration displacement value, the decrease pouring equipment moving speed instruction is formulated; When the spout real-time displacement value is less than the spout calibration displacement value, the straight pipe real-time displacement value is less than the straight pipe calibration displacement value, or the spout real-time displacement value is less than the spout calibration displacement value, the increase pouring equipment moving speed instruction is formulated.

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