A control system and method for steel casting

Abstract

The present application relates to the technical field of pouring control, and particularly relates to a control system and method based on steel casting pouring, which comprises: a protective sleeve for blocking high-temperature gas and metal liquid sprayed at a riser; a parameter acquisition module for acquiring pouring speed and pouring amount of the metal liquid at a pouring hole; a metal liquid temperature acquisition module for acquiring the temperature of the metal liquid in a cavity; a gas discharge flow rate and metal liquid spray amount acquisition module for acquiring the gas discharge flow rate and metal liquid spray amount of a cavity outer sleeve hole; a data analysis module for determining metal liquid height, gas pressure and protection mode based on parameters and feeding back and adjusting pouring speed; and a protection control module for controlling the protection angle and protection height of the protective sleeve based on the protection mode. The present application determines the gas pressure in the cavity through the metal liquid height and pouring speed, and then determines the protection mode through the metal liquid spray amount to feed back and adjust the pouring speed, so as to improve the safety protection degree for the operator by controlling the gas discharge and metal liquid spray during pouring.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of pouring control, in particular to a control system and method based on steel casting pouring. BACKGROUND

[0002] Pouring is a molding process of injecting molten metal into a mold, which is applied to the field of metal casting production and covers technical categories such as gravity filling and external force filling. Metal pouring needs to follow safety voltage detection, pouring pit operation and other specifications. This process can be traced back to the production of bronze wares in the Shang Dynasty in the field of casting. Modern technology restores the ancient pouring process through reverse modeling.

[0003] Chinese Patent Publication No. CN106255562A discloses a pouring device and a pouring method, which pours by maintaining the pouring position of molten metal from the pouring outlet portion of the ladle at a certain position, the pouring device has a ladle with a main body portion and a pouring outlet portion, and a control portion that controls the tilting angle of the ladle, the main body portion has a side portion with a cylindrical or conical inner surface, the pouring outlet portion has a pouring outlet front end that guides molten metal to the outside, is integrated with the main body portion on the side of the main body portion, guides molten metal from the main body portion to the pouring outlet front end, and pours molten metal through the pouring outlet front end, and the control portion controls the tilting angle according to the surface area of the molten metal when the ladle is tilted.

[0004] Therefore, the prior art has the following problems: due to the lack of feedback regulation of pouring speed by determining the gas pressure in the cavity through the metal liquid height and pouring speed and then determining the protection mode through the metal liquid ejection amount, the gas discharge and metal liquid ejection during pouring are difficult to protect, and the personal safety of the workers cannot be protected. SUMMARY

[0005] Therefore, the present application provides a control system and method based on steel casting pouring to overcome the problem in the prior art that the personal safety of workers cannot be protected due to the lack of feedback regulation of pouring speed by determining the gas pressure in the cavity through the metal liquid height and pouring speed and then determining the protection mode through the metal liquid ejection amount.

[0006] To achieve the above purpose, the present application provides a control system based on steel casting pouring, comprising:

[0007] A protection kit for blocking high-temperature gas and metal liquid ejected at the riser;

[0008] A pouring parameter acquisition module for acquiring the pouring speed and pouring amount of the metal liquid at the pouring port;

[0009] a cavity parameter acquisition module connected with the pouring parameter acquisition module, used for collecting the temperature of the molten metal in the cavity, wherein a plurality of temperature measuring units are arranged in the cavity parameter acquisition module, used for collecting the temperature of the molten metal at different positions in the cavity;

[0010] a riser parameter acquisition module connected with the cavity parameter acquisition module, used for collecting the gas discharge flow rate and the molten metal ejection amount of the riser arranged at the outer sleeve port of the cavity;

[0011] a data analysis module connected with the pouring parameter acquisition module, the cavity parameter acquisition module and the riser parameter acquisition module respectively, used for determining the molten metal height based on the pouring amount and the cross-sectional area of the cavity, determining the gas pressure in the cavity based on the molten metal height and the pouring speed, determining the protection mode based on the gas pressure and the molten metal ejection amount, and feeding back and adjusting the pouring speed based on the protection mode and the gas discharge flow rate;

[0012] a protection control module connected with the data analysis module, used for controlling the protection angle and the protection height of the protection kit based on the protection mode;

[0013] wherein the protection mode includes a primary protection mode, an intermediate protection mode and a high-level protection mode.

[0014] Further, the protection kit includes:

[0015] a sleeve used for connecting the riser ring to guide the high-temperature gas and the molten metal ejection;

[0016] a support column connected with the sleeve, used for supporting the inclined eaves, wherein the support column includes a support main rod and an extension rod, the support main rod is provided with a slide rail capable of sliding up and down, and the extension rod is connected with the slide rail, used for changing the height of the inclined eaves;

[0017] a protection angle adjusting mechanism connected with the support column and the bottom plate respectively, used for controlling the protection angle between the support column and the bottom plate based on a rotating adjusting shaft.

[0018] Further, the data analysis module determines three kinds of protection modes based on the gas pressure and the molten metal ejection amount, including:

[0019] a primary protection mode, which is a protection mode started when the gas pressure is less than a gas pressure threshold range, or the molten metal ejection amount is zero;

[0020] an intermediate protection mode, which is a protection mode started when the gas pressure is within a gas pressure threshold range, or the molten metal ejection amount is within a molten metal ejection threshold range;

[0021] The high-level protection mode is a protection mode that is started when the gas pressure is greater than a gas pressure threshold range or the metal liquid ejection amount is greater than a metal liquid ejection threshold range.

[0022] Further, the data analysis module comprises:

[0023] The first data analysis unit controls the support column to maintain the initial height and controls the protection angle to be the initial angle by the protection control module, the initial angle being a right angle, which is the primary protection mode;

[0024] The second data analysis unit controls the support column to reduce the height and maintain the original protection angle based on the first difference value of the metal liquid ejection amount by the protection control module, which is the intermediate protection mode;

[0025] The third data analysis unit controls the support column to reduce the height and reduce the protection angle based on the second difference value of the metal liquid ejection amount by the protection control module, which is the high-level protection mode;

[0026] The first difference value is the difference between the metal liquid ejection amount and the minimum value of the metal liquid ejection threshold range, and the second difference value is the difference between the metal liquid ejection amount and the maximum value of the metal liquid ejection threshold range.

[0027] Further, the data analysis module further comprises:

[0028] The alarm unit alarms based on the metal liquid ejection amount being in a metal liquid ejection amount early warning range;

[0029] The metal liquid ejection amount early warning range is greater than the metal liquid ejection threshold range.

[0030] Further, the data analysis module further comprises:

[0031] The basic data analysis unit is used to determine the theoretical metal liquid height according to the pouring amount and the cross-sectional area of the mold cavity, and determine the metal liquid height based on the theoretical metal liquid height and the height correction parameter;

[0032] The height correction parameter is determined based on historical data.

[0033] Further, the basic data analysis unit determines the first influence value of the metal liquid height on the gas pressure based on the comparison result of the metal liquid height and the metal liquid height threshold, and determines the gas pressure based on the first influence value and the pouring speed.

[0034] The first influence value is the additional pressure evaluation influence value generated by the mold cavity gas when the metal liquid height deviates from the metal liquid height threshold.

[0035] Further, the basic data analysis unit is based on the metal liquid height being lower than the metal liquid height threshold value, the first influence value being positively correlated with the metal liquid height, and the influence value increasing at a first rate; the metal liquid height being higher than the metal liquid height threshold value, the first influence value still being positively correlated with the metal liquid height, and the influence value increasing at a second rate.

[0036] The second rate is greater than the first rate.

[0037] Further, the protection mode is a primary protection mode, the basic data analysis unit is based on the gas discharge flow rate being greater than or equal to a preset gas flow rate threshold value, maintaining the current pouring speed; based on the gas discharge flow rate being less than the preset gas flow rate threshold value, reducing the pouring speed.

[0038] The protection mode is an intermediate protection mode, the basic data analysis unit is based on the gas discharge flow rate being less than a first interval of the preset gas flow rate threshold value to reduce the pouring speed; based on the gas discharge flow rate being less than a minimum value of the first interval of the preset gas flow rate threshold value to reduce the pouring speed.

[0039] The protection mode is a high-level protection mode, the basic data analysis unit is based on the gas discharge flow rate being less than a second interval of the preset gas flow rate threshold value to reduce the pouring speed, and triggers a phased stop pouring until the gas discharge flow rate is greater than a minimum value of a third interval of the preset gas flow rate threshold value.

[0040] The third interval is a high safety interval, the first interval is a medium safety interval, and the second interval is a safety interval.

[0041] The application also provides a control method based on steel casting pouring, comprising:

[0042] The pouring speed and pouring amount of the metal liquid at the pouring port, the metal liquid temperature in the cavity, and the gas discharge flow rate and metal liquid ejection amount at the outer sleeve port of the cavity are collected respectively.

[0043] The metal liquid height is determined based on the pouring amount and the cavity cross-sectional area, the gas pressure in the cavity is determined based on the metal liquid height and the pouring speed, the protection mode is determined based on the gas pressure and the metal liquid ejection amount, and the pouring speed is adjusted based on the protection mode and the gas discharge flow rate feedback.

[0044] The protection angle and protection height of the protection kit are controlled based on the protection mode.

[0045] Compared with the prior art, the present application has the beneficial effects that the system directly blocks the high-temperature gas and metal liquid sprayed at the riser by the protection kit, and dynamically adjusts the protection angle and protection height according to the protection mode to form a hierarchical protection mechanism in combination with the protection control module. At the same time, the alarm unit timely alarms when the metal liquid spray amount enters the early warning range, which can effectively avoid the damage of high-temperature spatter to the operators and surrounding equipment, and greatly reduce the risk of safety accidents in the casting process. The pouring speed is dynamically adjusted based on the protection mode and the gas discharge flow rate. This closed-loop control can avoid the formation of gas holes due to the gas not being discharged due to too fast pouring or the formation of insufficient pouring, cold separation and other defects due to too slow pouring, thereby significantly improving the consistency of the casting quality.

[0046] Further, the sleeve directly connects the riser ring, can direct the high-temperature gas and metal liquid sprayed at the riser to the preset path instead of disordered diffusion, avoids the random spatter of high-temperature medium to the surrounding, and the inclined eaves serves as a direct blocking component to form a first physical barrier for the sprayed material after being guided, and the two cooperate to greatly reduce the risk of accidental damage of high-temperature gas and metal liquid to operators and equipment. The height-adjustable design adapts to the spatter height of different pouring scenes, and the support column is combined by a support main rod, an extension rod and a slide rail to realize flexible adjustment of the height of the inclined eaves: when the metal liquid spray amount is small, such as the primary protection mode, the initial height can be maintained to ensure smooth gas discharge while reducing protection intervention; when the spatter amount increases, such as the intermediate and advanced protection modes, the extension rod is lowered along the slide rail to reduce the height of the inclined eaves, shorten the protection distance, enhance the blocking effect of low-altitude spatter, and improve the pertinence of protection. The protection angle adjusting mechanism controls the angle of the support column and the bottom plate through a rotating adjusting shaft to dynamically change the protection direction of the inclined eaves: for example, the primary mode keeps the right-angle inclined eaves perpendicular to the bottom plate, taking into account protection and gas discharge; the advanced mode reduces the protection angle and inclines the inclined eaves to the riser direction to expand the shielding area of the spatter, especially for the scene where the metal liquid spray amount is large and the spatter angle is inclined, which can more comprehensively cover the potential risk area and avoid side spatter.

[0047] Further, by judging the gas pressure and the metal liquid spray amount, the system can independently trigger the corresponding protection mode for any parameter risk exceeding the standard, avoiding the limitation of single parameter judgment, ensuring that the risk can be captured and responded in time, and improving the timeliness of protection. In the early stage of low risk, the primary mode provides basic protection and reduces the intervention on normal pouring; in the middle stage of medium risk, the intermediate mode moderately strengthens the protection; in the late stage of high risk, the advanced mode rapidly upgrades the protection strength, so that the protection measures fit the risk intensity at each stage and enhance the pertinence. The mode judgment threshold is determined based on process test, which not only clearly defines the safety interval but also defines the risk early warning interval, balancing safety and production reliability while ensuring safety.

[0048] Further, the three data analysis units correspond to different protection modes respectively, forming progressive control from basic to intensive. The primary protection mode maintains the initial height and right angle, reducing intervention on pouring exhaust in low-risk situations, balancing basic protection and smooth process. The intermediate protection mode adjusts the protection height based on the amplitude of the metal liquid ejection exceeding the splash-free state, without changing the angle, adapting to the directional protection needs in medium-risk situations. The advanced protection mode reduces the protection height and angle simultaneously based on the amplitude of the splash exceeding the threshold, expanding the protection range through double adjustment, and responding to high-risk splashing.

[0049] Further, the alarm unit triggers an alarm based on the pre-warning interval exceeding the metal liquid ejection threshold, providing early warning for manual intervention when the splashing risk escalates but has not reached an extreme state, leaving a buffer space for risk control and avoiding the risk of expansion. The basic data analysis unit calculates the actual metal liquid height based on the theoretical height and historical correction parameters, correcting the influence of factors such as sand deformation and metal liquid shrinkage, making the height data more accurate and providing a reliable basis for subsequent pressure calculation. By comparing the metal liquid height with the metal liquid height threshold to determine the first influence value and combining the pouring speed to derive the gas pressure, the quantitative correlation calculation of pressure is realized, avoiding the deviation of single parameter judgment and making the pressure evaluation more scientific. The first influence value increases faster when the difference between the design and the metal liquid height threshold, which can sensitively capture the pressure changes in high-risk situations. Even a small increase in metal liquid height will trigger the assessment of rapid pressure growth, making the system more sensitive to high-risk scenarios and further improving the timeliness and accuracy of protection mode determination.

[0050] Further, in the primary protection mode, the pouring speed is maintained or reduced based on whether the gas flow rate meets the standard, ensuring production efficiency in low-risk situations and preventing initial risks of poor exhaust through mild adjustment, balancing safety and efficiency. The intermediate protection mode adopts a stepwise speed reduction for different flow rate intervals, responding more subtly to exhaust changes in medium-risk situations. When the gas discharge flow rate is in the basic normal interval, the speed is reduced moderately, and when the flow rate further decreases, the adjustment amplitude is increased, effectively relieving gas accumulation and avoiding the risk of escalation to a higher level. The advanced protection mode uses a strong intervention measure of significant speed reduction and periodic pouring to directly face high-risk situations, and uses the flow rate in the high safety interval as the recovery standard to ensure that the exhaust is completely smooth before restarting pouring, thereby reducing the risk of severe splashing or casting gas hole defects caused by gas blockage. BRIEF DESCRIPTION OF DRAWINGS

[0051] Figure 1 The structure diagram of the control system based on steel casting pouring in the embodiment;

[0052] Figure 2A structure diagram of a data analysis module of a control system based on steel casting pouring in the embodiment;

[0053] Figure 3 A structure diagram of a protection kit of a control system based on steel casting pouring in the embodiment;

[0054] Figure 4 A flow chart of a control method based on steel casting pouring in the embodiment;

[0055] Figure 5 A structure diagram of a protection kit A of a control system based on steel casting pouring in the embodiment.

[0056] In the figure, 1 is a sleeve; 2 is a support column; 21 is a support main rod; 22 is an extension rod; 23 is a sliding rail; 3 is a slanted eave; 4 is a protection angle adjusting mechanism; 5 is a bottom plate; 6 is a cavity; 7 is a pouring opening. DETAILED DESCRIPTION

[0057] In order to make the objects and advantages of the present application clearer, the present application will be further described in conjunction with embodiments. It should be understood that the specific embodiments described herein merely serve the purpose of explaining the present application and are not intended to limit the present application.

[0058] The preferred embodiments of the present application will be described below with reference to the accompanying drawings. It should be understood by those skilled in the art that the embodiments are merely used to explain the technical principles of the present application and are not intended to limit the protection scope of the present application.

[0059] It should be noted that, in the description of the present application, the terms indicating the direction or positional relationship such as "upper", "lower", "left", "right", "inner", "outer" and the like are based on the direction or positional relationship shown in the drawings, which is merely for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present application.

[0060] In addition, it should also be noted that, in the description of the present application, unless otherwise explicitly specified and limited, the terms "mounting", "connection" and "connecting" should be understood in a broad sense, for example, can be fixed connection, can also be detachable connection, or integrally connected; can be mechanical connection, can also be electrical connection; can be directly connected, can also be indirectly connected through an intermediate medium, and can be the communication inside two elements. Those skilled in the art can understand the specific meaning of the above terms in the present application according to the specific circumstances.

[0061] Please refer to Figure 1 A structure diagram of a control system based on steel casting pouring in the embodiment is shown in the figure;

[0062] The embodiment of the present application is based on a steel casting pouring control system, comprising:

[0063] A protective kit for blocking high-temperature gas and metal liquid spouted at the riser;

[0064] A pouring parameter acquisition module for acquiring pouring speed and pouring amount of the metal liquid at the pouring hole;

[0065] A cavity parameter acquisition module connected with the pouring parameter acquisition module for acquiring the temperature of the metal liquid in the cavity, wherein a plurality of temperature measuring units are arranged in the cavity parameter acquisition module for acquiring the temperature of the metal liquid at different positions in the cavity;

[0066] A riser parameter acquisition module connected with the cavity parameter acquisition module for acquiring the gas discharge flow rate and the metal liquid spouting amount at the gas outlet of the sleeve outside the cavity;

[0067] A data analysis module connected with the pouring parameter acquisition module, the cavity parameter acquisition module and the riser parameter acquisition module respectively, for determining the metal liquid height based on the pouring amount and the cross-sectional area of the cavity, determining the gas pressure in the cavity based on the metal liquid height and the pouring speed, determining the protection mode based on the gas pressure and the metal liquid spouting amount, and feeding back and adjusting the pouring speed based on the protection mode and the gas discharge flow rate;

[0068] A protection control module connected with the data analysis module for controlling the protection angle and the protection height of the protective kit based on the protection mode;

[0069] The protection mode includes a primary protection mode, an intermediate protection mode and a high-level protection mode.

[0070] The protective kit is composed of a sleeve 1, a support column 2, an inclined eave 3, a protection angle adjusting mechanism 4 and a bottom plate 5.

[0071] The system directly blocks the high-temperature gas and metal liquid spouted at the riser by the protective kit, and dynamically adjusts the protection angle and the protection height according to the protection mode by the protection control module to form a hierarchical protection mechanism. At the same time, the alarm unit timely alarms when the metal liquid spouting amount enters the early warning range, which can effectively avoid the damage of high-temperature spatter to the operators and surrounding equipment, and greatly reduce the risk of safety accidents in the casting process. The pouring speed is dynamically adjusted based on the protection mode and the gas discharge flow rate. This closed-loop control can avoid the formation of gas holes due to the slow pouring speed or the formation of defects such as insufficient pouring and cold separation due to the slow pouring speed, and significantly improve the consistency of the casting quality.

[0072] Please refer to Figure 3 , which is a protective kit structure diagram of the steel casting pouring control system in the embodiment; please refer to Figure 5As shown, it is a structural schematic diagram of the protection kit A based on the control system of steel casting pouring in the embodiment;

[0073] It can be understood that Figure 3 The shape of the medium cavity is for easy understanding, which can be replaced according to the actual use scene;

[0074] Specifically, the protection kit comprises:

[0075] The sleeve 1 is used to connect the riser ring to guide the high-temperature gas and metal liquid spatter;

[0076] The support column 2 is connected with the sleeve and is used to support the inclined eave 3, the support column 2 comprises a support main rod 21 and a telescopic rod 22, the support main rod is provided with a slide rail 23 capable of sliding up and down, and the telescopic rod 22 is connected with the slide rail 23 and is used to change the height of the inclined eave 3.

[0077] The protection angle adjusting mechanism 4 is connected with the support column 2 and the bottom plate 5 respectively, and controls the protection angle between the support column 2 and the bottom plate 5 based on a rotating adjusting shaft.

[0078] The sleeve directly connects the riser ring, can direct the high-temperature gas and metal liquid spatter at the riser to the preset path instead of disordered diffusion, avoids the high-temperature medium from being randomly spattered to the periphery, the inclined eave serves as a direct blocking component and can form a first physical barrier for the spatter after being guided, and the combination of the two can greatly reduce the accidental damage risk of the high-temperature gas and metal liquid to the operators and equipment. The height-adjustable design is suitable for the spatter height of different pouring scenes, the support column realizes flexible adjustment of the height of the inclined eave through the combination of the support main rod, the telescopic rod and the slide rail: when the metal liquid spatter amount is small, such as in the primary protection mode, the initial height can be maintained to ensure the smooth discharge of the gas while reducing the protection intervention; when the spatter amount increases, such as in the intermediate and advanced protection modes, the telescopic rod is lowered along the slide rail to reduce the height of the inclined eave, the protection distance is shortened, the blocking effect on the low-altitude spatter is enhanced, and the pertinence of protection is improved. The protection angle adjusting mechanism controls the angle between the support column and the bottom plate through the rotating adjusting shaft, can dynamically change the protection direction of the inclined eave, for example, the straight-angle inclined eave is kept perpendicular to the bottom plate in the primary mode, and the protection and gas discharge are considered; the protection angle is reduced in the advanced mode, the inclined eave is inclined to the riser direction, the shielding area of the spatter is expanded, especially for the scene that the metal liquid spatter amount is large and the spatter angle is inclined, the potential risk area can be more comprehensively covered, and the side spatter is avoided.

[0079] Specifically, the data analysis module determines three protection modes based on the gas pressure and the metal liquid spatter amount, which comprises:

[0080] The primary protection mode is a protection mode started when the gas pressure is less than the gas pressure threshold range or the metal liquid spatter amount is zero;

[0081] The intermediate protection mode is a protection mode that is started when the gas pressure is in the gas pressure threshold range, or the metal liquid ejection amount is in the metal liquid ejection threshold range;

[0082] The advanced protection mode is a protection mode that is started when the gas pressure is greater than the gas pressure threshold range, or the metal liquid ejection amount is greater than the metal liquid ejection threshold range.

[0083] In the embodiment of the present application, the gas pressure threshold range is set to 0.05-0.1 MPa, which is determined based on previous process tests, and this range is a safe pressure interval in which the cavity exhaust is smooth and there is no obvious risk of splashing; the metal liquid ejection threshold range is set to 0-50 g / s, that is, the mass of metal liquid ejected from the riser sleeve per unit time, which is a range of acceptable micro-splashing that does not affect the safety of operation;

[0084] When the pouring is in the initial stage and the pouring amount is 10%-30% of the total demand, the metal liquid height in the cavity is low and does not exceed 1 / 3 of the total height of the cavity, and the gas has sufficient space to diffuse, at this time the cavity parameter acquisition module detects that the gas pressure is 0.03 MPa, which is less than the lower limit of the gas pressure threshold range 0.05 MPa; the riser parameter acquisition module detects that the metal liquid ejection amount is 0 g / s, and the metal liquid has not risen to the riser position, and there is no splashing, at this time the protection mode is the primary protection mode;

[0085] When the pouring enters the middle stage and the pouring amount is 40%-70% of the total demand,

[0086] Scenario one: the metal liquid height rises to 1 / 2 of the total height of the cavity, the cavity gas is compressed, the gas pressure rises to 0.07 MPa, which is in the gas pressure threshold range of 0.05-0.1 MPa, at this time the metal liquid ejection amount is 20 g / s, which is in the metal liquid ejection threshold range of 0-50 g / s, triggering the intermediate protection mode;

[0087] Scenario two: if the local sand mold has slightly poor permeability, the gas pressure is still 0.04 MPa, which is less than the threshold range, but the metal liquid has risen to the riser, and the ejection amount is 30 g / s, which is in the gas pressure threshold range, at this time the intermediate protection mode can be triggered;

[0088] When the pouring is close to the end stage and the pouring amount is more than 80% of the total demand,

[0089] Scenario one: the metal liquid height is close to the top of the cavity, the gas is compressed violently, the gas pressure rises sharply to 0.12 MPa, which is greater than the upper limit of the gas pressure threshold range 0.1 MPa, at this time the metal liquid ejection amount is 40 g / s, which is still in the metal liquid ejection threshold range, at this time the advanced protection mode is triggered;

[0090] Scenario two: if the pouring speed is too fast, the metal liquid forms a vortex inside the cavity, causing the metal liquid to spray out of the riser at a rate of 60g / s, which is greater than the upper limit of the metal liquid spray threshold range of 50g / s. At this time, even if the gas pressure is 0.08MPa within the gas pressure threshold range, at this time, the advanced protection mode can be triggered.

[0091] By determining the gas pressure and the metal liquid spray amount, the system can independently trigger the corresponding protection mode for any parameter risk exceeding the standard, avoiding the limitations of single parameter judgment, ensuring that risks can be captured and responded to in a timely manner, and improving the timeliness of protection. In the early stage of low risk, the primary mode provides basic protection and reduces intervention on normal pouring; in the middle stage of medium risk, the intermediate mode moderately strengthens protection; in the late stage of high risk, the advanced mode quickly upgrades the protection strength, so that the protection measures fit the risk intensity at each stage and enhance the pertinence. The mode determination threshold is determined based on process tests, which not only defines the safety interval but also defines the risk warning interval, ensuring safety while avoiding excessive protection affecting the stability of the casting process, such as smooth exhaust, balancing safety and production reliability.

[0092] Referring to Figure 2 The data analysis module of the control system based on steel casting pouring in the embodiment is shown in FIG. 1.

[0093] Specifically, the data analysis module includes:

[0094] The first data analysis unit controls the support column to maintain the initial height and controls the protection angle to be the initial angle through the protection control module, the initial angle is a right angle, which is the primary protection mode;

[0095] The second data analysis unit controls the support column to reduce the height and maintain the original protection angle based on the first difference value of the metal liquid spray amount through the protection control module, which is the intermediate protection mode;

[0096] The third data analysis unit controls the support column to reduce the height and reduce the protection angle based on the second difference value of the metal liquid spray amount through the protection control module, which is the advanced protection mode;

[0097] The first difference value is the difference between the metal liquid spray amount and the minimum value of the metal liquid spray threshold range; the second difference value is the difference between the metal liquid spray amount and the maximum value of the metal liquid spray threshold range.

[0098] In the embodiment of the application, the initial height of the support column is set to 1.2m, and the initial protection angle is 90°.

[0099] When the pouring is in the initial stage, the metal liquid ejection amount is 0 g / s, which does not reach the ejection threshold range, the first data analysis unit instructs the support column to maintain the initial height of 1.2 m through the protection control module, and controls the protection angle to maintain 90° at the same time, so that the inclined eaves are in the basic protection position, which neither affects the natural exhaust of the cavity nor deals with the potential trace spatter;

[0100] In the embodiment of the present application, the height adjustment first coefficient of the metal liquid ejection amount is set to 0.0067, when the pouring enters the middle stage, the metal liquid ejection amount is 30 g / s, which is in the metal liquid ejection threshold range of 0-50 g / s, the first difference = metal liquid ejection amount - minimum value of metal liquid ejection threshold range = 30-0 = 30 g / s, which reflects the amplitude of the metal liquid ejection amount exceeding the non-spatter state, and the height to be reduced is 30*0.0067≈0.2 m, the second data analysis unit reduces the height of the telescopic rod from 1.2 m to 1.0 m along the slide rail based on the difference through the protection control module, so as to reduce the height and enhance the block, while keeping the protection angle at 90° without the need to expand the lateral coverage;

[0101] In the embodiment of the present application, the height adjustment second coefficient of the metal liquid ejection amount is set to 0.02, and the angle adjustment coefficient of the metal liquid ejection amount is 3° / (g / s), that is, for every 1 g / s exceeding the maximum value of the metal liquid ejection threshold range, the protection angle is reduced by 3°, when the pouring approaches the end stage, the metal liquid ejection amount increases to 60 g / s, exceeding the maximum value of the metal liquid ejection threshold range of 50 g / s, the second difference = metal liquid ejection amount - maximum value of metal liquid ejection threshold range = 60 g-50 = 10 g / s, which reflects the amplitude of the spatter amount exceeding the limit, and the height to be reduced is 10*0.02≈0.2 m, the third data analysis unit further reduces the height of the support column to 0.8 m based on the difference through the protection control module, so as to reduce the height and enhance the block, while controlling the rotary adjusting shaft to reduce the protection angle from 90° to 60°, so that the inclined eaves are inclined to the riser, and the lateral coverage range is expanded, so as to deal with the larger spatter risk.

[0102] The three data analysis units correspond to different protection modes respectively, forming progressive control from basic to intensive, the primary protection mode maintains the initial height and the right angle, reduces the intervention to the pouring exhaust at low risk, and takes into account the basic protection and smooth process; the intermediate protection mode adjusts the protection height based on the amplitude of the metal liquid ejection amount exceeding the non-spatter state, only to enhance the block, without changing the angle, which is suitable for directional protection demand under medium risk; the advanced protection mode combines the amplitude of the spatter amount exceeding the limit, reduces the protection height and the protection angle at the same time, expands the protection range through double adjustment, and specifically deals with high-risk spatter.

[0103] Specifically, the data analysis module further includes:

[0104] The alarm unit triggers an alarm when the amount of molten metal ejected falls within the warning range for molten metal ejection.

[0105] The warning range for the amount of molten metal ejected is greater than the threshold range for molten metal ejection.

[0106] Specifically, the data analysis module also includes:

[0107] The basic data analysis unit is used to determine the theoretical molten metal height based on the pouring volume and the cross-sectional area of ​​the cavity, and to determine the molten metal height based on the theoretical molten metal height and the height correction parameter.

[0108] The height correction parameter is determined based on historical data.

[0109] Specifically, the basic data analysis unit determines the first influence value of the molten metal height on the gas pressure based on the comparison result between the molten metal height and the molten metal height threshold, and determines the gas pressure based on the first influence value and the pouring speed;

[0110] The first influence value is the assessment value of the additional pressure generated on the cavity gas when the molten metal height deviates from the molten metal height threshold.

[0111] Specifically, the basic data analysis unit is based on the following: when the liquid metal height is below the liquid metal height threshold, the first influence value is positively correlated with the liquid metal height, and the growth rate of the influence value is the first rate; when the liquid metal height is above the liquid metal height threshold, the first influence value is still positively correlated with the liquid metal height, and the growth rate of the influence value is the second rate.

[0112] The second rate is greater than the first rate.

[0113] As the pouring process enters its final stage, the amount of molten metal ejected gradually increases. If the amount of molten metal ejected exceeds the molten metal ejection threshold range, such as moving from the acceptable micro-splash range into the excessive splash range that requires vigilance, i.e. falling into the molten metal ejection warning range, the alarm unit will immediately activate to remind the operator to pay attention to the riser status through audible and visual alarm signals. This provides an early warning for possible manual intervention, such as temporarily adjusting the pouring speed, to prevent the risk of splashing from further escalating.

[0114] In this embodiment, the warning range for the amount of molten metal ejected is set to 50-100 g / s. If the amount exceeds the threshold but does not reach an extreme risk, a warning is required. When the amount of molten metal ejected reaches 60 g / s and falls into the 50-100 g / s range, the alarm unit triggers an audible and visual alarm.

[0115] In this embodiment, the cross-sectional area of ​​the mold cavity is set to 2m², and the height correction parameter is set to 0.01m. This setting is based on historical data and takes into account the thermal expansion of the sand mold and the shrinkage of the molten metal.

[0116] The real-time pouring volume is 0.4 m3 of metal liquid volume;

[0117] The theoretical metal liquid height = pouring volume / cross-sectional area of the mold cavity = 0.4 ÷ 2 = 0.2 m;

[0118] The actual metal liquid height = theoretical metal liquid height + height correction parameter = 0.2 + 0.01 = 0.21 m;

[0119] In this embodiment, the metal liquid height threshold value, i.e., the safety critical value, is set to 0.5 m; and the influence coefficient of pouring speed on gas pressure is set to 0.01 MPa / (m / s);

[0120] The actual metal liquid height is 0.6 m higher than the metal liquid height threshold value 0.1 m;

[0121] The first influence value 0.02 MPa is the additional pressure generated due to the height exceeding the threshold value 0.1 m;

[0122] The pouring speed is 0.3 m / s;

[0123] The gas pressure = first influence value + (pouring speed × influence coefficient) = 0.02 + (0.3 × 0.01) = 0.023 MPa.

[0124] In this embodiment, when the metal liquid height is lower than the metal liquid height threshold value, the first rate is set to 0.005 MPa / m, i.e., the first influence value increases by 0.005 MPa for each 1 m increase in the metal liquid height; for example, the metal liquid height is 0.3 m lower than the metal liquid height threshold value 0.5 m, and the first influence value = 0.3 × 0.005 = 0.0015 MPa;

[0125] When the metal liquid height is higher than the metal liquid height threshold value, the second rate is set to 0.02 MPa / m, i.e., the first influence value increases by 0.02 MPa for each 1 m increase in the metal liquid height.

[0126] The alarm unit triggers an alarm based on the pre-warning interval exceeding the metal liquid spouting amount threshold range, can prompt manual intervention in advance when the spattering risk is upgraded but not in an extreme state, reserves a buffer space for risk control, and avoids the risk from expanding. The basic data analysis unit calculates the actual metal liquid height in combination with the theoretical height and historical correction parameters, corrects the influence of factors such as sand mold deformation and metal liquid shrinkage, makes the height data more in line with the actual situation, and provides a reliable basis for subsequent pressure calculation. The first influence value is determined by comparing the metal liquid height with the metal liquid height threshold, and the gas pressure is derived in combination with the pouring speed, realizing quantitative correlation calculation of the pressure, avoiding the deviation of single parameter judgment, and making the pressure evaluation more scientific. When the increase rate difference of the first influence value is designed to be higher than the increase rate of the metal liquid height threshold, the pressure change in a high-risk state can be captured sensitively, and even a small increase will trigger the evaluation of rapid pressure growth after the metal liquid height exceeds the limit, so that the system is more sensitive to the response of high-risk scenarios, and the timeliness and accuracy of the protection mode determination are further improved.

[0127] Specifically, the protection mode is a primary protection mode, the basic data analysis unit maintains the current pouring speed based on the gas discharge flow rate being greater than or equal to a preset gas flow rate threshold; and reduces the pouring speed based on the gas discharge flow rate being less than the preset gas flow rate threshold.

[0128] The protection mode is an intermediate protection mode, the basic data analysis unit reduces the pouring speed based on the gas discharge flow rate being in a first interval of the preset gas flow rate threshold; and reduces the pouring speed based on the gas discharge flow rate being less than a minimum value of the first interval of the preset gas flow rate threshold.

[0129] The protection mode is a high-level protection mode, the basic data analysis unit reduces the pouring speed based on the gas discharge flow rate being in a second interval of the preset gas flow rate threshold, and triggers a phased stop pouring until the gas discharge flow rate is greater than a minimum value of a third interval of the preset gas flow rate threshold.

[0130] Among them, the third interval is a high safety interval, the first interval is a medium safety interval, and the second interval is a safety interval.

[0131] In the embodiment of the present application, the preset gas flow rate threshold reference value is set to 5 m / s.

[0132] Each interval is divided into,

[0133] The third interval: 6-8 m / s, a high safety interval with smooth gas discharge;

[0134] The first interval: 3-5 m / s, a medium safety interval with basically normal gas discharge;

[0135] The second interval: 0-2 m / s, a low safety interval with blocked gas discharge;

[0136] The adjustment under the primary protection mode,

[0137] When the system is in the primary protection mode,

[0138] If the gas discharge flow rate is detected by the riser parameter acquisition module to be 6 m / s ≥ the preset reference value 5 m / s, the basic data analysis unit determines that the exhaust is smooth, and the current pouring speed is maintained, such as 1.2 m³ / min;

[0139] If the gas discharge flow rate is detected to be 4 m / s < 5 m / s, it is determined that the exhaust is slightly blocked, and the pouring speed is instructed to be reduced, such as to 1.0 m³ / min, to reduce the risk of gas compression;

[0140] Adjustment in the intermediate protection mode,

[0141] When the system is in the intermediate protection mode;

[0142] If the gas discharge flow rate is 4 m / s in the first interval 3-5 m / s, the basic data analysis unit instructs to reduce the pouring speed, such as from 1.0 m³ / min to 0.8 m³ / min;

[0143] If the gas discharge flow rate drops to 2 m / s < the minimum value 3 m / s of the first interval, it is determined that the exhaust is further blocked, and the pouring speed is instructed to be further reduced, such as to 0.6 m³ / min, to alleviate gas accumulation;

[0144] Adjustment in the advanced protection mode,

[0145] When the system is in the advanced protection mode,

[0146] If the gas discharge flow rate is 1 m / s < the maximum value 2 m / s of the second interval, the basic data analysis unit instructs to greatly reduce the pouring speed, such as to 0.4 m³ / min, and triggers a phased stop pouring pause of 30 seconds;

[0147] The gas discharge flow rate is continuously monitored during the stop pouring, until the flow rate rises to 7 m / s > the minimum value 6 m / s of the third interval, it is determined that the exhaust is smooth, and the pouring is restarted and the current pouring speed is maintained.

[0148] In the primary protection mode, whether the gas flow rate meets the standard determines whether to maintain or reduce the pouring speed. In the low-risk scenario, both production efficiency and the prevention of early-stage risk of poor exhaust are ensured through slight adjustment, balancing safety and efficiency. In the intermediate protection mode, the pouring speed is reduced in stages according to different flow rate intervals, and a more detailed response is made to the exhaust changes in the medium-risk scenario. When the gas exhaust flow rate is in the basic normal interval, the speed is moderately reduced, and when the flow rate is further reduced, the adjustment amplitude is increased, effectively relieving gas accumulation and avoiding the risk of upgrading to a high level. In the high protection mode, through the strong intervention measures of large-scale speed reduction and phased pouring stop, the high-risk scenario is directly faced, and the flow rate in the high safety interval is used as the recovery standard to ensure that the exhaust is completely smooth before restarting pouring, thereby reducing the severe splashing or casting porosity defects caused by gas blockage from the root.

[0149] The working process of the protection kit is as follows: the metal liquid enters the cavity 6 through the pouring gate 7, the solidification disappears the mold plate tooling melts, and as the metal liquid enters the sleeve, high-temperature gas is sprayed out or metal liquid is sprayed out at the sleeve 1. At this time, the protection control module adjusts the length of the supporting column and the protection angle to block the sprayed metal liquid according to the high-temperature gas exhaust flow rate and the metal liquid spraying amount.

[0150] Please refer to Figure 4 The control method for steel casting pouring based on the control method flowchart shown in the embodiment;

[0151] The embodiment also provides a control method for steel casting pouring, which comprises the following steps:

[0152] In step S1, the pouring speed and pouring amount of the metal liquid at the pouring gate, the temperature of the metal liquid in the cavity, and the gas exhaust flow rate and metal liquid spraying amount at the sleeve opening outside the cavity are collected respectively.

[0153] In step S2, the metal liquid height is determined based on the pouring amount and the cross-sectional area of the cavity, the gas pressure in the cavity is determined based on the metal liquid height and the pouring speed, the protection mode is determined based on the gas pressure and the metal liquid spraying amount, and the pouring speed is adjusted based on the protection mode and the gas exhaust flow rate feedback.

[0154] In step S3, the protection angle and protection height of the protection kit are controlled based on the protection mode.

[0155] So far, the technical scheme of the present application has been described in combination with the preferred embodiments shown in the drawings, but those skilled in the art can easily understand that the protection scope of the present application is obviously not limited to these specific embodiments. Those skilled in the art can make equivalent changes or replacements to the related technical features without departing from the principles of the present application, and the technical schemes after these changes or replacements will all fall within the protection scope of the present application.

[0156] The above merely illustrates the preferred embodiments of the present application, and is not used to limit the present application; for those skilled in the art, the present application can have various modifications and changes. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A control system based on steel casting and pouring, characterized in that, include: Protective kits are used to block high-temperature gases and molten metal ejected from the riser; The pouring parameter acquisition module is used to collect the pouring speed and pouring volume of molten metal at the pouring gate; A cavity parameter acquisition module, which is connected to the casting parameter acquisition module, is used to acquire the temperature of the molten metal in the cavity. The cavity parameter acquisition module is equipped with several temperature measuring units to acquire the temperature of the molten metal at different locations in the cavity. The riser parameter acquisition module is connected to the cavity parameter acquisition module and is used to acquire the gas discharge velocity and molten metal ejection volume at the sleeve opening outside the cavity. The data analysis module is connected to the pouring parameter acquisition module, the cavity parameter acquisition module and the riser parameter acquisition module respectively. It determines the molten metal height based on the pouring volume and the cross-sectional area of ​​the cavity, determines the gas pressure in the cavity based on the molten metal height and the pouring speed, determines the protection mode based on the gas pressure and the molten metal ejection volume, and adjusts the pouring speed based on the protection mode and the gas discharge flow rate feedback. A protection control module, which is connected to the data analysis module, controls the protection angle and protection height of the protection kit based on the protection mode; The protection modes include basic protection mode, intermediate protection mode and advanced protection mode.

2. The control system based on steel casting and pouring according to claim 1, characterized in that, The protective kit includes: A bushing, used to connect riser rings to guide the ejection of high-temperature gas and molten metal; A support column, which is connected to the sleeve, is used to support the sloping eaves. The support column includes a main support rod and a telescopic rod. The main support rod is provided with a slide rail that can slide up and down. The telescopic rod is connected to the slide rail and is used to change the height of the sloping eaves. The protective angle adjustment mechanism is connected to the support column and the base plate respectively, and controls the protective angle between the support column and the base plate based on the rotation adjustment shaft.

3. The control system based on steel casting and pouring according to claim 2, characterized in that, The data analysis module determines three protection modes based on gas pressure and molten metal ejection volume, including: The primary protection mode is activated when the gas pressure is less than the gas pressure threshold range and the amount of molten metal ejected is zero. Intermediate protection mode, which is the protection mode activated when the gas pressure is within the gas pressure threshold range and the molten metal ejection volume is within the molten metal ejection threshold range, or; The protection mode is activated when the gas pressure is less than the gas pressure threshold range, the molten metal has risen to the riser, and the amount of molten metal ejected is within the molten metal ejection threshold range. Advanced protection mode is a protection mode that is activated when the gas pressure is greater than the gas pressure threshold range, or when the amount of molten metal ejected is greater than the molten metal ejection threshold range.

4. The control system based on steel casting and pouring according to claim 3, characterized in that, The data analysis module includes: The first data analysis unit controls the support column to maintain its initial height and controls the protection angle to an initial angle through the protection control module. The initial angle is a right angle, which is the primary protection mode. The second data analysis unit, based on the first difference in the amount of molten metal ejected, controls the support column to reduce its height and maintain its original protective angle through the protection control module, which is the intermediate protection mode. The third data analysis unit, based on the second difference in the amount of molten metal ejected, controls the support column to reduce its height and the protection angle through the protection control module, which is the advanced protection mode. Wherein, the first difference is the difference between the amount of molten metal ejected and the minimum value of the molten metal ejection threshold range; the second difference is the difference between the amount of molten metal ejected and the maximum value of the molten metal ejection threshold range.

5. The control system based on steel casting and pouring according to claim 4, characterized in that, The data analysis module also includes: The alarm unit triggers an alarm when the amount of molten metal ejected falls within the warning range for molten metal ejection. The warning range for the amount of molten metal ejected is greater than the threshold range for molten metal ejection.

6. The control system based on steel casting and pouring according to claim 5, characterized in that, The data analysis module also includes: The basic data analysis unit is used to determine the theoretical molten metal height based on the pouring volume and the cross-sectional area of ​​the cavity, and to determine the molten metal height based on the theoretical molten metal height and the height correction parameter. The height correction parameter is determined based on historical data.

7. The control system based on steel casting pouring according to claim 6, characterized in that, The basic data analysis unit determines the first influence value of the molten metal height on the gas pressure based on the comparison result between the molten metal height and the molten metal height threshold, and determines the gas pressure based on the first influence value and the pouring speed. The first influence value is the assessment value of the additional pressure generated on the cavity gas when the molten metal height deviates from the molten metal height threshold.

8. The control system based on steel casting and pouring according to claim 7, characterized in that, The basic data analysis unit is based on the following: when the liquid metal height is below the liquid metal height threshold, the first influence value is positively correlated with the liquid metal height, and the growth rate of the influence value is the first rate; when the liquid metal height is above the liquid metal height threshold, the first influence value is still positively correlated with the liquid metal height, and the growth rate of the influence value is the second rate. The second rate is greater than the first rate.

9. The control system based on steel casting and pouring according to claim 8, characterized in that, The protection mode is the basic protection mode. The basic data analysis unit maintains the current pouring speed based on the gas discharge flow rate being greater than or equal to the preset gas flow rate threshold. The pouring speed is reduced because the gas discharge velocity is less than the preset gas velocity threshold. The protection mode is medium protection mode. The basic data analysis unit reduces the pouring speed based on the gas discharge velocity being in the first interval of the preset gas velocity threshold; and reduces the pouring speed based on the minimum value of the first interval where the gas discharge velocity is less than the preset gas velocity threshold. The protection mode is advanced protection mode. The basic data analysis unit reduces the pouring speed based on the second interval where the gas discharge flow rate is less than the preset gas flow rate threshold, and triggers a phased stop pouring until the gas discharge flow rate is greater than the minimum value of the third interval where the gas discharge flow rate is greater than the preset gas flow rate threshold. The third interval is a high-safety interval, the first interval is a medium-safety interval, and the second interval is a safe interval.

10. A method for a control system based on steel casting pouring according to any one of claims 1-9, characterized in that, include: The pouring speed and volume of molten metal at the pouring gate, the temperature of molten metal inside the mold cavity, and the gas discharge velocity and molten metal ejection volume at the external sleeve opening of the mold cavity were collected respectively. The height of the molten metal is determined based on the pouring volume and the cross-sectional area of ​​the cavity. The gas pressure inside the cavity is determined based on the height of the molten metal and the pouring speed. The protection mode is determined based on the gas pressure and the amount of molten metal ejected. The pouring speed is adjusted based on the protection mode and the gas discharge flow rate feedback. The protection mode controls the protection angle and protection height of the protection kit.

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