Automatic flow control and furnace eye blocking device and method for smelting furnace

Abstract

The invention relates to the technical field of smelting furnace automation, in particular to an automatic flow control and furnace eye blocking device and method for a smelting furnace, and the automatic flow control and furnace eye blocking device comprises the steps that the actual liquid level height value and the actual eye blocking pressure value of the smelting furnace are detected; if the liquid level deviation absolute value of the actual liquid level height value and the target liquid level value is larger than the preset trigger liquid level threshold value, an execution unit is driven according to the flow control valve element opening degree adjusting instruction so as to adjust the melt outflow amount of the smelting furnace; and if the absolute value of the liquid level deviation between the actual liquid level height value and the target liquid level value is smaller than or equal to the preset triggering liquid level threshold value, an execution unit is driven according to the hole plugging plug lifting instruction to plug the furnace hole until the actual hole plugging pressure value is equal to the target hole plugging pressure value, and furnace hole plugging is completed. According to the scheme, flow control adjustment can be automatically triggered, flow fluctuation caused by manual reaction delay is avoided, furnace hole plugging is completed through automatic lifting of the hole plugging plug, the pressure value serves as closed-loop feedback, tight plugging is ensured, melt leakage is avoided, and energy consumption and maintenance cost are reduced.

Description

Technical Field

[0001] This application relates to the field of smelting furnace automation technology, specifically to an automatic flow control and furnace eye blocking device and method for a smelting furnace. Background Technology

[0002] As a key piece of equipment in the metal smelting industry, the smelting furnace is widely used in the smelting and heat preservation processes of various metals such as iron, copper, and aluminum. Its core operation process covers three closely related and crucial steps: "melt discharge - liquid level control - furnace hole sealing".

[0003] Currently, in the metal smelting process of a melting furnace, flow control and plugging are usually performed as two separate steps. Specifically, the operator first manually operates a gate-type flow control device to control the flow rate of the melt at the furnace bore by adjusting its opening. After the melt discharge is completed, the flow control device needs to be removed, and then the operator manually plugs the furnace bore with refractory clay plugs.

[0004] The aforementioned adjustment process is not only cumbersome and time-consuming, but manual adjustment often fails to achieve the desired flow control effect, easily leading to large fluctuations in the melt outflow. In addition, manual operation near the high-temperature furnace opening is prone to scalding from splashes, and manual plugging relies on experience; inadequate sealing can easily lead to melt leakage during subsequent smelting, further increasing energy consumption and cleanup costs. Summary of the Invention

[0005] In view of this, this application provides an automatic flow control and furnace hole plugging device and method for a smelting furnace. The main purpose is to solve the technical problems of the current manual adjustment of melt flow rate, which is not only cumbersome and time-consuming, but also often fails to achieve the ideal flow control effect, which easily leads to large fluctuations in melt outflow. Furthermore, manual use of refractory plugs to seal the furnace hole is prone to splashing and burns, and manual plugging relies on experience, which can easily lead to melt leakage during subsequent smelting, thus increasing energy consumption and cleaning costs.

[0006] According to the first aspect of this application, an automatic flow control and furnace hole blocking device for a smelting furnace is provided. The system includes: a detection unit, an execution unit, and a control unit. The detection unit is used to detect the actual liquid level height and the actual plugging pressure of the smelting furnace in real time. The execution unit is installed at the central axis of the molten metal outlet of the smelting furnace. The execution unit is used to adjust the molten metal outflow rate of the smelting furnace and to seal the furnace bore. The control unit is connected to the detection unit and the execution unit respectively. The control unit is used to receive the actual liquid level height value and the actual plugging pressure value from the detection unit. The actual liquid level height value is compared with the target liquid level value. If the absolute value of the liquid level deviation between the actual liquid level height value and the target liquid level value is greater than the preset trigger liquid level threshold, the flow control valve core opening adjustment command is calculated by the PID algorithm, and the execution unit is driven according to the flow control valve core opening adjustment command to adjust the melt outflow of the smelting furnace. If the absolute value of the liquid level deviation between the actual liquid level height and the target liquid level is less than or equal to the preset trigger liquid level threshold, then the plugging head lifting command is calculated by the PID algorithm, and the execution unit is driven according to the plugging head lifting command to seal the furnace hole until the actual plugging pressure value is equal to the target plugging pressure value, thus completing the furnace hole sealing.

[0007] According to a second aspect of this application, an automatic flow control and furnace hole blocking method for a smelting furnace is provided, the method comprising: Real-time monitoring of the actual liquid level height and actual plugging pressure in the smelting furnace; The actual liquid level height value is compared with the target liquid level value. If the absolute value of the liquid level deviation between the actual liquid level height value and the target liquid level value is greater than the preset trigger liquid level threshold, the flow control valve core opening adjustment command is calculated by the PID algorithm, and the melt outflow of the smelting furnace is adjusted according to the flow control valve core opening adjustment command. If the absolute value of the liquid level deviation between the actual liquid level height and the target liquid level is less than or equal to the preset trigger liquid level threshold, then the plug lifting command is calculated by the PID algorithm, and the furnace hole is sealed according to the plug lifting command until the actual plug pressure value is equal to the target plug pressure value, thus completing the furnace hole sealing.

[0008] By means of the above technical solution, this application provides an automatic flow control and furnace hole blocking device and method for a smelting furnace. Compared with the prior art, the detection unit in this application is used to detect the actual liquid level height and actual plugging pressure of the smelting furnace in real time; the execution unit is installed at the central axis of the smelting furnace outlet, and the execution unit is used to adjust the melt flow rate of the smelting furnace and block the furnace hole; the control unit is connected to the detection unit and the execution unit respectively, and the control unit is used to receive the actual liquid level height and actual plugging pressure from the detection unit; and the actual liquid level height is compared with the target liquid level value. If the absolute value of the deviation between the actual liquid level and the target liquid level is greater than the preset trigger liquid level threshold, the PID algorithm calculates the control valve core opening adjustment command, and drives the execution unit according to the control valve core opening adjustment command to adjust the melt outflow of the smelting furnace; if the absolute value of the deviation between the actual liquid level and the target liquid level is less than or equal to the preset trigger liquid level threshold, the PID algorithm calculates the plug head lifting and lowering command, and drives the execution unit according to the plug head lifting and lowering command to seal the furnace hole until the actual plug pressure value equals the target plug pressure value, thus completing the furnace hole sealing.

[0009] The solution described in this application firstly involves a detection unit that monitors the liquid level in the smelting furnace in real time using sensors, eliminating errors caused by manual visual inspection or experience-based judgment. The system compares the actual liquid level with the target value; when the deviation exceeds a threshold, it automatically triggers flow control adjustment, avoiding flow fluctuations caused by delayed manual response. The control unit calculates the flow control valve core opening adjustment command based on a PID algorithm, dynamically adjusting the melt outflow. Compared to manual valve opening adjustment, the PID algorithm quickly eliminates steady-state errors through proportional, integral, and derivative steps, resulting in more precise flow control, faster response, and significantly reduced flow fluctuations. The execution unit is installed on the central axis of the outlet and directly adjusts the valve core opening via a mechanical structure, avoiding flow control failures caused by uneven force or slow response during manual operation. The system automatically completes the adjustment according to the algorithm command, simplifying the process and improving efficiency.

[0010] Secondly, this application achieves sealing by automatically raising and lowering the plug head of the execution unit, keeping operators away from high-temperature areas and significantly reducing safety risks. The detection unit monitors the plug pressure value in real time, and the control unit calculates the plug raising and lowering command through a PID algorithm until the actual pressure equals the target value. Compared to manual judgment of sealing effectiveness based on experience, the system uses pressure data as a closed-loop feedback to ensure a tight seal and prevent melt leakage. Furthermore, incomplete sealing by manual plugging can lead to melt leakage, requiring additional energy to heat and replenish the melt, and increasing the cost of cleaning up leaks. This application achieves a one-time seal through precise pressure control, reducing the risk of leakage and thus lowering energy consumption and maintenance costs.

[0011] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application. Attached Figure Description

[0012] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0013] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0014] Figure 1 This illustration shows an overall structural diagram of an automatic flow control and furnace eye blocking device for a smelting furnace according to an embodiment of this application; Figure 2 The illustration shows an effect diagram of an accessory for an automatic flow control and furnace hole blocking device for a smelting furnace according to an embodiment of this application; Figure 3 The diagram shows a flow chart of an automatic flow control and furnace hole blocking method for a smelting furnace provided in an embodiment of this application. Detailed Implementation

[0015] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0016] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0017] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0018] To better understand the above-mentioned objectives, features, and advantages of this application, the solution of this application will be further described below. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0019] To address the technical problems of manual adjustment of melt flow rate, which is cumbersome, time-consuming, and often fails to achieve ideal flow control, leading to large fluctuations in melt output, as well as the risks of scalding from splashing when manually sealing the furnace bore with refractory plugs, and the reliance on experience for manual sealing resulting in leakage during subsequent smelting, thus increasing energy consumption and cleaning costs, this application provides an automatic flow control and furnace bore sealing device for a smelting furnace.

[0020] like Figure 1 As shown, an embodiment of this application provides an automatic flow control and furnace hole blocking device for a smelting furnace, which may include: a detection unit, an execution unit, and a control unit; The detection unit can be used to detect the actual liquid level height and actual plugging pressure in the smelting furnace in real time. The actuator is installed at the central axis of the molten metal outlet of the smelting furnace. The actuator can be used to adjust the flow rate of the molten metal from the smelting furnace and to seal the furnace bore. The control unit is connected to the detection unit and the execution unit respectively. The control unit can be used to receive the actual liquid level height value and the actual plugging pressure value from the detection unit. The actual liquid level height is compared with the target liquid level. If the absolute value of the liquid level deviation between the actual liquid level height and the target liquid level is greater than the preset trigger liquid level threshold, the flow control valve core opening adjustment command is calculated by the PID algorithm. The execution unit is driven according to the flow control valve core opening adjustment command to adjust the melt outflow of the smelting furnace. If the absolute value of the liquid level deviation between the actual liquid level and the target liquid level is less than or equal to the preset trigger liquid level threshold, the PID algorithm calculates the plug lifting command and drives the execution unit according to the plug lifting command to seal the furnace hole until the actual plug pressure value equals the target plug pressure value, thus completing the furnace hole sealing.

[0021] The detection unit is also used to detect the actual melt temperature value in the smelting furnace in real time; The control unit receives the actual melt temperature value from the detection unit, compares the actual melt temperature value with the target temperature range value, and if the actual melt temperature value is not within the target temperature range value, adjusts the actual melt temperature value using the viscosity compensation coefficient until the actual melt temperature value is within the target temperature range value.

[0022] In the embodiments of this application, the detection unit may include: a temperature sensor, a pressure sensor, and an aluminum liquid level sensor.

[0023] The temperature sensor can be positioned directly above the outlet of the molten aluminum in the smelting furnace (e.g., at a height of 500 mm and 100 mm from the furnace wall) to monitor the actual molten aluminum temperature (Tactual) flowing out of the furnace in real time. In this embodiment, a non-contact infrared thermometer can be used as the temperature sensor, which has a fast response speed and avoids direct contact with the high-temperature molten aluminum.

[0024] The pressure sensor can be a PT124G-210 model, fixed inside the slide table by a bracket. The probe is aligned with the contact area of ​​the plugging head. It can be installed on the automatic plugging actuator outside the furnace eye of the smelting furnace, and can be used to monitor the actual plugging pressure (Pactual) in real time during the plugging process. In this embodiment, the pressure sensor's measurement range is 0-2 MPa, with an accuracy of ±0.5%FS, ensuring accurate plugging pressure control.

[0025] The aluminum liquid level sensor can be installed at the end of the outlet chute of the smelting furnace. In this embodiment, the aluminum liquid level sensor can be a non-contact radar level sensor. The radar level sensor is installed at a height of 1000mm and 500mm from the furnace wall. It can be used to detect the actual liquid level height (Hactual) of the aluminum liquid in the chute in real time. Its response time is less than or equal to 0.01s, and it can provide a liquid level feedback signal quickly and accurately.

[0026] In addition, a liquid level protection probe is installed on the side wall of the chute as a hardware protection for extreme situations. It can be a double metal probe, installed directly above the chute, 180mm from the bottom of the chute. When the liquid level rises abnormally and touches the probe, it can immediately trigger an emergency stop signal to the PLC system to prevent aluminum liquid from overflowing.

[0027] In the embodiments of this application, the execution unit may include: a flow control valve core, an annular plug, a slide table device, a servo motor, and a lifting rod; The flow control valve core can be fixed to the lowest end of the lifting rod. The end of the flow control valve core forms a drill bit, which can be used to adjust the cross-sectional area of ​​the aluminum liquid flow by changing the position of the drill bit in the furnace hole, thereby controlling the flow rate. In this embodiment, the flow control valve core can be a conical structure with a taper of 1:10 and a maximum diameter of 80mm, which can achieve linear adjustment of the flow rate; it can be made of 310S heat-resistant steel and coated with an Al2O3 ceramic coating to enhance corrosion resistance and wear resistance. The annular plug can be fitted onto the outside of the flow control valve core. When plugging is required, the lifting rod can lower the entire annular plug assembly, allowing the plug to contact and seal the furnace bore. In this embodiment, the annular plug is made of high-alumina refractory material, with a diameter of 85mm (5-8mm larger than the inner diameter of the furnace bore) and a thickness of 40mm (within the range of 30-50mm). It is fitted onto the outside of the flow control valve core using high-temperature resistant bolts. A 5mm thick refractory fiber sealing ring with a temperature resistance of ≥1200℃ is also attached to the outside of the plug, ensuring good sealing effect and structural strength. The slide mechanism can be connected to a servo motor to convert the rotary motion of the servo motor into linear motion. The slide mechanism may include a ball screw (5mm lead), a nut, and a slider-type slide with dual guide shafts to ensure smooth lifting without shaking and high positioning accuracy. The lifting rod can be used to connect the slide device to the lower flow control valve core and annular plug. In this embodiment, the lifting rod can adopt a segmented structure. The upper section of the lifting rod can be made of 304 stainless steel with a diameter of 20mm and a length of 200mm, and the lower section can be made of silicon carbide with a diameter of 15mm and a length of 150mm. The two sections can be connected by a high-temperature resistant coupling (such as an Inconel 625 coupling). This design can ensure the structural strength of the upper part and effectively resist the conduction of high temperatures above 1200℃ at the furnace opening, protecting the upper motor and slide. The total stroke of the lifting rod is 0-300mm, and the positioning accuracy can reach ±1mm. A servo motor can serve as a power source, providing high-precision rotary motion. In this embodiment, a servo motor of model 110HS20 with a torque of 4.5 N·m is used. It is fixed to the top support of the furnace body and drives the lifting rod through a ball screw (5 mm lead), providing stable and precise power output. The servo motor can drive the slide device, which in turn moves the lifting rod and the flow control valve core up and down. The flow rate of the melt is adjusted by changing the gap between the drill bit and the furnace eye. The servo motor also drives the slide device, which lowers the lifting rod and the annular plug fitted on the outside of the flow control valve core until the annular plug is in close contact with the furnace eye.

[0028] The control unit can be housed in an embedded control cabinet with dimensions of 400mm × 300mm × 150mm, fixed to a wall bracket 1.5m above the ground, and incorporates a high-performance STM32H743 microcontroller. The control unit can be electrically connected to both the detection and execution units via cables (such as RS485 bus). The control unit contains a built-in linkage control algorithm and connects to the deep-well casting PLC control system of the smelting furnace via an industrial bus (such as PROFINET). On one hand, it receives signals such as temperature, liquid level, and pressure from the detection units via the PLC; on the other hand, it sends calculated valve core opening adjustment commands and plug lifting commands to the servo motor driver of the execution unit. Simultaneously, the control unit supports data interaction with the smelting furnace main control system via Siemens communication protocols (such as S7 Communication) to achieve parameter setting and status monitoring.

[0029] To ensure the long-term stable operation of the equipment in harsh high-temperature and dusty environments, the automatic flow control and furnace hole blocking device of the smelting furnace is also equipped with auxiliary components, which may include: air cooling device, refractory fiber sealing ring and heat insulation cover. The air cooling device is a laser sensor air cooling device (can be made of 304 stainless steel, 120mm long and 50mm wide). It surrounds the air outlet channel, and the air inlet pipe (Φ15mm) is connected to the workshop compressed air pipeline system. The air outlet pipe is equipped with a silencer. It can be used to cool precision instruments such as temperature sensors. It can quickly and efficiently reduce the temperature of compressed air, protect the instruments from high temperature damage, and extend their service life. The refractory fiber sealing ring is set on the outside of the annular plug head, with a thickness of 5mm and a temperature resistance greater than or equal to 1200℃. The refractory fiber sealing ring is used to further fill the tiny gap between the plug head and the furnace hole wall when plugging the hole, and to enhance the sealing between the annular plug head and the furnace hole. The heat shield is wrapped around the servo motor and slide device. The heat shield can be made of 20mm thick aluminum silicate fiber, which can effectively isolate the heat radiation from the melting furnace and protect electrical components such as the servo motor.

[0030] Based on the above-mentioned automatic flow control and furnace hole blocking device structure of the smelting furnace, such as Figure 3 As shown, embodiments of this application provide an automatic flow control and furnace hole blocking method for a smelting furnace, which may include the following steps: Real-time monitoring of the actual liquid level height and actual plugging pressure in the smelting furnace; The actual liquid level height is compared with the target liquid level. If the absolute value of the liquid level deviation between the actual liquid level height and the target liquid level is greater than the preset trigger liquid level threshold, the flow control valve core opening adjustment command is calculated by the PID algorithm, and the melt outflow of the smelting furnace is adjusted according to the flow control valve core opening adjustment command. If the absolute value of the liquid level deviation between the actual liquid level and the target liquid level is less than or equal to the preset trigger liquid level threshold, the PID algorithm is used to calculate the plug lifting command. The furnace hole is then sealed according to the plug lifting command until the actual plug pressure value equals the target plug pressure value, thus completing the furnace hole sealing.

[0031] First, before starting a new smelting cycle, the operator can input initial parameters to the control unit through the human-machine interface (which can be integrated with the PLC system). These parameters may include: the target liquid level value H0 of the sluice (e.g., H0=100mm), the target temperature range of the melt [T1, T2], where the upper temperature limit T1=720℃ and the lower temperature limit T2=740℃, the preset trigger liquid level threshold H1 for plugging, H1=5mm (i.e., 5% of H0), the target plugging pressure value P1 (0.8MPa-1.2MPa), and the set PID flow control parameters (e.g., Kp=6.0, Ti=10s, Td=2s). Secondly, when the smelting furnace is ready to discharge liquid, the operator issues a command to begin casting. After receiving the command, the control unit first drives the lifting rod to descend, so that the flow control valve core is in a preset initial opening position (e.g., 50% opening), and the molten aluminum begins to flow out.

[0032] The temperature sensor and radar level sensor can collect the actual melt temperature (Tactual) and actual liquid level height (Hactual) in real time, and transmit the collected Tactual and Hactual to the control unit every 0.1 seconds.

[0033] The control unit continuously calculates the absolute value of the liquid level deviation ΔH = |Hactual - H0|.

[0034] If ΔH > 3% × H0 (i.e., 3mm), the control unit can activate the PID algorithm to calculate the required opening value of the flow control valve core based on the magnitude and trend of ΔH, and generate a corresponding lifting command to send to the servo motor. The servo motor drives the lifting rod to move precisely, changing the valve core position, thereby correcting the flow rate and making Hactual quickly stabilize near H0.

[0035] During the flow control process, the control unit can simultaneously determine whether the actual temperature T is within the target temperature range [720℃, 740℃].

[0036] If the actual temperature (Tactual) is less than 720℃ (e.g., Tactual = 710℃), it indicates that the viscosity of the molten aluminum is too high, resulting in poor fluidity. The control unit can introduce a viscosity compensation coefficient (which can be set to [1.1-1.3]) to positively correct the output of the PID algorithm, that is, to appropriately increase the valve core opening to compensate for the decrease in flow rate caused by the increase in viscosity.

[0037] If the actual temperature (Tactual) is greater than 740℃ (e.g., Tactual = 760℃), it indicates that the viscosity of the molten aluminum is too low and its fluidity is too good. The control unit can introduce a viscosity compensation coefficient (the viscosity compensation coefficient can be [0.9-1.0]) to negatively correct the output of the PID algorithm, that is, to appropriately reduce the valve core opening to prevent excessive flow.

[0038] If T is within the target temperature range [720℃, 740℃], the viscosity compensation coefficient can be taken as 1.0, and no compensation is required.

[0039] The control unit can monitor the liquid level signal in real time and determine that the furnace borehole blocking operation needs to be performed when any of the following conditions are met: Condition 1: The radar level sensor detects a state where ΔH is less than or equal to H1 for 5 seconds.

[0040] Condition 2: The liquid level signal from the liquid level sensor completely disappears, indicating that there is no melt in the flow channel.

[0041] Once it is determined that the hole needs to be plugged, the control unit can first issue a command to fully open the flow control valve core, drive the lifting rod to rise, so that the valve core is completely removed from the furnace hole, leaving an unobstructed passage for the subsequent descent of the plugging head.

[0042] The control unit drives the servo motor to reverse, causing the lifting rod to descend rapidly, and the annular plug head to move towards the furnace hole.

[0043] The pressure sensor monitors the actual plugging pressure (Pactual) between the plug head and the borehole in real time and feeds back Pactual to the control unit.

[0044] When Pactual equals the target plugging pressure value P1 (e.g., 1.0 MPa), the control unit can immediately stop the lowering action of the lifting rod and instruct the servo motor to maintain the current position, apply a constant holding force, and continue for 30 seconds to ensure that the refractory fiber sealing ring is fully compressed to form a reliable seal.

[0045] During the descent, if the pressure sensor detects that Pactual is greater than P1, i.e., Pactual > 1.5 × P1 (i.e., 1.5 MPa), the control unit can determine that it is over-compression and may damage the furnace bore. At this time, the control unit can immediately and automatically send a command to raise or lower the plug head. Based on the command, the servo motor drives the slide device to raise the lifting rod and the annular plug head sleeved on the outside of the flow control valve core by 2 mm, so that Pactual drops to equal P1.

[0046] If, after the plug head contacts the furnace eye, P_actual_pressure cannot reach P1 (i.e., the actual plugging pressure value is less than the target plugging pressure value), and this state continues for 10 seconds, the control unit can trigger an alarm and display the message "Insufficient plugging pressure, please check the wear of the plug head or the furnace eye abnormality" on the human-machine interface, reminding the operator to intervene manually.

[0047] After the 30-second pressure holding period ends, the control unit can record the completion signal of the plugging process and upload this status to the PLC system.

[0048] After the plugging is completed, the control unit can control the servo motor to rotate forward, driving the lifting rod to rise at a speed of 10mm / s, so that the plug and the flow control valve core are reset to the initial standby position (for example, 150mm away from the furnace hole). The control unit stores the operation data (flow control curve, plugging pressure change). At this time, the entire automatic flow control and furnace hole plugging device enters the standby state, waiting for the start of the next melting cycle.

[0049] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the term "comprising" or any other variations thereof is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0050] Obviously, those skilled in the art should understand that the modules or steps of this application described above can be implemented using general-purpose computing devices. They can be centralized on a single computing device or distributed across a network of multiple computing devices. Optionally, they can be implemented using computer-executable program code, thereby storing them in a storage device for execution by the computing device. In some cases, the steps shown or described can be performed in a different order than those described herein, or they can be fabricated as separate integrated circuit modules, or multiple modules or steps can be fabricated as a single integrated circuit module. Thus, this application is not limited to any particular hardware and software combination. The above are merely preferred embodiments of this application and are not intended to limit this application. For those skilled in the art, this application can have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A device for automatic control of flow and plugging of tuyere of a smelting furnace, characterized in that, The application relates to a molten metal level control system for a smelting furnace. The system comprises a detection unit, an execution unit and a control unit. The detection unit is used for detecting the actual liquid level height value and the actual plugging pressure value of the smelting furnace in real time. The execution unit is installed at the central axis of the liquid outlet of the smelting furnace, and is used for adjusting the melt outflow amount and plugging the furnace eye of the smelting furnace. The control unit is connected with the detection unit and the execution unit respectively, and is used for receiving the actual liquid level height value and the actual plugging pressure value from the detection unit. The actual liquid level height value is compared with a target liquid level value, if the absolute value of the liquid level deviation between the actual liquid level height value and the target liquid level value is greater than a preset trigger liquid level threshold value, a PID algorithm is used to calculate a control flow valve core opening degree adjustment instruction, and the execution unit is driven according to the control flow valve core opening degree adjustment instruction, so as to adjust the melt outflow amount of the smelting furnace. If the absolute value of the liquid level deviation between the actual liquid level height value and the target liquid level value is less than or equal to the preset trigger liquid level threshold value, a PID algorithm is used to calculate a plugging plug head lifting instruction, and the execution unit is driven according to the plugging plug head lifting instruction, so as to plug the furnace eye until the actual plugging pressure value is equal to a target plugging pressure value, and the furnace eye plugging is completed.

2. The automatic flow control and hole blocking device of the smelting furnace according to claim 1, characterized in that, The detection unit is also used for detecting the actual melt temperature value of the smelting furnace in real time. The control unit is used for receiving the actual melt temperature value from the detection unit, comparing the actual melt temperature value with a target temperature range value, and adjusting the actual melt temperature value by using a viscosity compensation coefficient until the actual melt temperature value is in the target temperature range value if the actual melt temperature value is not in the target temperature range value.

3. The automatic flow control and hole blocking device of the smelting furnace according to claim 2, characterized in that, The detection unit comprises a temperature sensor, a pressure sensor and an aluminum liquid level sensor. The temperature sensor is arranged at the liquid outlet of the smelting furnace, and is used for monitoring the actual melt temperature value of the smelting furnace. The pressure sensor is arranged on an automatic furnace eye plugging execution device outside the furnace eye of the smelting furnace, and is used for monitoring the actual plugging pressure value of the smelting furnace. The aluminum liquid level sensor is arranged at the end of a chute outside the furnace eye outlet of the smelting furnace, and is used for monitoring the actual liquid level height value of the smelting furnace.

4. The automatic flow control and hole blocking device of the smelting furnace according to claim 3, characterized in that, The execution unit comprises a control flow valve core, an annular furnace eye plugging plug head, a sliding table device, a servo motor and a lifting rod. The control flow valve core is fixed to the lower end of the lifting rod, and the tail end of the control flow valve core constitutes a drill bit. The annular furnace eye plugging plug head is sleeved outside the control flow valve core, and is used for plugging the furnace eye. The sliding table device is connected with the servo motor, and is used for converting the rotary motion of the servo motor into linear motion. The servo motor is used to drive the sliding table device, drive the lifting rod and the flow control valve core to lift, adjust the melt outflow by changing the gap between the torch head and the furnace eye, and the servo motor is used to drive the sliding table device, drive the lifting rod and the annular eye plugging head sleeved outside the flow control valve core to descend as a whole until the annular eye plugging head is in close contact with the furnace eye.

5. The automatic flow control and hole blocking device of the smelting furnace according to claim 4, characterized in that, The sliding table device comprises a ball screw, a nut and a slider type sliding table of double guide shafts.

6. The automatic flow control and hole blocking device of the smelting furnace according to claim 4, characterized in that, The lifting rod is of sectional structure and comprises an upper segment lifting rod and a lower segment lifting rod, the upper segment lifting rod is made of stainless steel, the lower segment lifting rod is made of silicon carbide, and the upper segment lifting rod and the lower segment lifting rod are connected through a high-temperature resistant coupling.

7. The automatic flow control and hole blocking device of the smelting furnace according to claim 4, characterized in that, If the actual eye plugging pressure value is greater than the target eye plugging pressure value, the control unit is used to send a lifting rod lifting instruction to drive the sliding table device through the servo motor according to the eye plugging head lifting instruction, drive the lifting rod and the annular eye plugging head sleeved outside the flow control valve core to lift as a whole; If the actual eye plugging pressure value is less than the target eye plugging pressure value, the control unit is used to trigger an alarm and prompt to check the wear condition of the annular eye plugging head.

8. The automatic flow control and hole blocking device of the smelting furnace according to claim 7, characterized in that, After the eye plugging is completed, the servo motor is used to drive the lifting rod to lift, drive the annular eye plugging head and the flow control valve core to reset to the initial standby position, and the automatic flow control and eye plugging device enters the standby state.

9. The automatic flow control and hole blocking device of the smelting furnace according to any one of claims 4-8, characterized in that, The auxiliary assembly comprises an air cooling device, a refractory fiber sealing ring and a heat shield. The air cooling device is used to cool the temperature sensor. The refractory fiber sealing ring is arranged outside the annular eye plugging head, and the refractory fiber sealing ring is used to enhance the sealing property between the annular eye plugging head and the furnace eye during eye plugging. The heat shield is arranged outside the servo motor, and the heat shield is used to isolate the heat radiation from the smelting furnace and protect the servo motor.

10. A method for automatically controlling the flow and plugging the tuyere of a smelting furnace, characterized in that, The method comprises the following steps: Real-time detection of the actual liquid level height value and the actual eye plugging pressure value of the smelting furnace; Comparison of the actual liquid level height value and the target liquid level value, if the liquid level deviation absolute value of the actual liquid level height value and the target liquid level value is greater than a preset trigger liquid level threshold value, the eye plugging head lifting instruction is calculated through the PID algorithm, and the melt outflow of the smelting furnace is adjusted according to the eye plugging head lifting instruction; If the liquid level deviation absolute value of the actual liquid level height value and the target liquid level value is less than or equal to the preset trigger liquid level threshold value, the eye plugging head lifting instruction is calculated through the PID algorithm, the furnace eye is blocked according to the eye plugging head lifting instruction until the actual eye plugging pressure value is equal to the target eye plugging pressure value, and the furnace eye blocking is completed.

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