Aluminum processing deep well casting molten aluminum leakage identification and early warning system and method

Abstract

The invention relates to the technical field of aluminum processing production safety, and provides an aluminum processing deep well casting molten aluminum leakage identification and early warning system and method.The system comprises a leakage identification subsystem, a linkage circuit is formed by arranging special aluminum wires at an outlet of a crystallizer, and instant leakage alarm and leakage point positioning are achieved; the leakage rate judgment subsystem is used for judging the leakage rate of the molten aluminum; and the control terminal is used for simultaneously receiving and processing the information of the leakage identification subsystem and the leakage rate judgment subsystem and giving an emergency processing instruction. Through double-judgment cross validation of aluminum conductor leakage triggering and temperature sensing data, the molten aluminum leakage judgment accuracy is remarkably improved, the method can stably adapt to the high-temperature, humid and high-noise environment of deep well casting, early warning lag and positioning fuzziness are effectively eradicated, the risk of explosion accidents caused when molten aluminum encounters water is practically reduced, and the service life of the molten aluminum is prolonged. And reliable support is provided for deep well casting intrinsic safety.

Description

Technical Field

[0001] This invention relates to the field of safety technology in aluminum processing production, and in particular to a system and method for identifying and warning of leaks in molten aluminum from deep well casting in aluminum processing. Background Technology

[0002] In recent years, explosions in the global aluminum processing industry have become increasingly frequent. Between 2015 and 2023, an average of 170 explosions occurred annually in the global aluminum processing industry (compared to an average of 109 incidents between 1981 and 2023). 49% of these explosions occurred during casting or mold-making processes, with the primary cause being damp or damaged (leaking) molds. These explosions not only cause significant casualties and property damage, triggering strong negative social impacts, but also seriously threaten safe production in the aluminum processing industry. Improving the inherent safety of aluminum processing (deep well casting) processes has become an urgent problem for the industry. Investigations of past accident cases have revealed that continuous aluminum leakage during the casting process is the root cause of explosions. Timely identification of aluminum leaks and effective plugging measures can significantly curb the occurrence of explosions caused by water contact with molten aluminum.

[0003] Currently, domestic and international aluminum processing deep well casting enterprises generally lack the ability to identify signs of aluminum leakage in crystallizers. The leakage of molten aluminum often relies on manual experience for judgment, which has problems such as poor judgment accuracy and untimely judgment, posing great safety hazards in the production process.

[0004] Chinese invention patent application number 202410538848.3 discloses a sound recognition and early warning system for aluminum molten aluminum leakage in a diverter plate based on a digital hydrophone. The system includes a sound acquisition device, an audio data preprocessing module, a sound recognition model, an alarm logic judgment module, and an early warning module. The system uses the distinctive "hissing" sound emitted when molten aluminum comes into contact with water as the basis for determining if there is a leak. However, this solution has limitations. Due to the influence of high temperature and humidity and ambient noise, the sound acquisition device cannot directly capture the sound of molten aluminum contacting water, resulting in low accuracy in aluminum leakage identification and an inability to pinpoint the specific location of the leak.

[0005] Chinese invention patent application number 202311522740.7 discloses a system and method for detecting aluminum molten metal leakage and cooling effect in aluminum processing, including an image acquisition device, an image analysis device, and an alarm device. This system identifies whether aluminum molten metal is leaking by real-time acquisition of thermal image characteristics of the aluminum molten metal forming at the outlet of the mold crystallizer, combined with temperature data. The shortcomings of this solution are that the infrared thermal imager cannot cover the entire crystallizer outlet, resulting in incomplete image information. Furthermore, the acquired image information suffers from recognition lag, storage difficulties, and the inability to promptly locate the leaking aluminum. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a system and method for identifying and warning of aluminum molten metal leakage in deep well casting for aluminum processing. Addressing the problems of delayed warnings, ambiguous leak location, difficulty in predicting leakage volume, and unreliability of some monitoring methods due to workshop noise and the high temperature and humidity of deep wells, this invention integrates the collaborative monitoring logic of aluminum wire fusion-type aluminum leakage identification and temperature-sensing leakage detection systems to construct an integrated technical solution that enables real-time leakage identification, precise leak location, and leakage volume prediction. This fills the technological gap in efficient aluminum molten metal leakage monitoring in deep well casting scenarios.

[0007] The present invention adopts the following technical solution: On one hand, the present invention provides an aluminum processing deep well casting aluminum molten metal leakage identification and early warning system, comprising: The leakage identification subsystem is used to identify whether there is a leak in the aluminum liquid in the deep well casting process of aluminum processing in real time, and to determine the location of the leak when there is a leak in the aluminum liquid. The leakage assessment subsystem is used to determine the magnitude of aluminum molten metal leakage. The control terminal is used to simultaneously receive and process information from the leakage identification subsystem and the leakage amount determination subsystem, and to issue emergency handling instructions.

[0008] In addition to any of the possible implementations described above, another implementation is provided, wherein the leakage identification subsystem includes: an aluminum wire, a first circuit power supply, a second circuit power supply, an electromagnetic relay, an armature, a first spring, a second spring, a support column, a first contact, a second contact, a working indicator light, an alarm light, and a circuit locator. The melting point of the aluminum wire is lower than the temperature of the molten aluminum in deep well casting. The aluminum wire is set at the outlet of the crystallizer and arranged in a circle along the outlet of the crystallizer to cover all possible aluminum leakage paths. The support column supports the armature, which can rotate around the support point of the support column. A first spring and a second spring are respectively provided on both sides of the support column. The first spring is located at the first end of the armature, and the second spring is located at the second end of the armature. Both the first spring and the second spring are connected to the armature to provide elastic force for the rotation of the armature. A first contact is provided above the second end of the armature, and a second contact is provided below the second end of the armature. The electromagnetic relay is located below the second end of the armature. The aluminum wire, the first circuit power supply, and the electromagnetic relay are connected in series to form the first circuit. The second circuit power supply, the second spring, the second contact, and the working indicator light are connected in series to form the second circuit; The second circuit power supply, the second spring, the first contact, the alarm light, and the circuit locator are connected in series to form the third circuit; When there is no aluminum leakage, the aluminum wire is intact, and the first circuit is connected; the electromagnetic relay generates electromagnetic force, attracting the second end of the armature to move downward and contact the second contact; at this time, the second circuit is connected, the working indicator light is on, indicating that the operation is normal; When molten aluminum leaks, the aluminum wire melts, the first circuit is de-energized, the electromagnetic force of the electromagnetic relay disappears, and the second end of the armature moves upward under the action of the first and second springs, disengaging from the second contact and making contact with the first contact. At this time, the second circuit is de-energized, the third circuit is connected, the alarm light illuminates and an alarm sounds, indicating that molten aluminum has leaked. The circuit locator sends a positioning signal to the control terminal to determine the location of the leak.

[0009] In addition to any of the possible implementations described above, another implementation is provided in which the aluminum conductor includes an inner core and an insulation layer, the inner core being a pure aluminum or aluminum alloy conductor with a diameter of 0.5~1mm, and the outer layer covering the insulation layer; the melting point of the aluminum conductor is 560-620℃, and the temperature of the molten aluminum liquid in deep well casting is about 700℃.

[0010] In addition to any of the possible implementations described above, another implementation is provided in which there are multiple leakage identification subsystems, the number of which is consistent with the number of crystallizers, and each leakage identification subsystem corresponds to one crystallizer.

[0011] In addition to any of the possible implementations described above, another implementation is provided in which the leakage determination subsystem includes a temperature sensor and a temperature-sensing leakage detection unit; The temperature sensors are multiple and are evenly distributed in the deep well water; The temperature sensor leakage detection unit is used to collect and process the temperature data of the temperature sensor. It collects all temperature sensor data once at a preset time interval, calculates the average temperature and instantaneous temperature change rate, and compares them with a preset temperature rise limit threshold. When the instantaneous temperature change rate exceeds the preset temperature rise limit threshold, it determines that aluminum liquid leakage has occurred, and classifies the leakage amount into levels based on the empirical value of the instantaneous temperature change rate.

[0012] In addition to any of the possible implementations described above, another implementation is provided in which the temperature sensor is encapsulated in a waterproof heat-shrink tubing, uses a single-bus protocol, and all temperature sensor pins share a single signal line.

[0013] In addition to any of the possible implementations described above, another implementation is provided in which the preset acquisition time interval of the temperature sensing leakage detection unit is 5 seconds, and the temperature rise limit threshold is obtained from on-site casting experience or experiments.

[0014] In addition to any of the possible implementations described above, another implementation is provided in which the leakage level is divided into light leakage, moderate leakage, and heavy leakage; the empirical values ​​of the instantaneous temperature change rate corresponding to the light leakage, moderate leakage, and heavy leakage are derived from the data of aluminum molten metal explosion accidents when it comes into contact with water in aluminum processing deep well casting enterprises.

[0015] In addition to any of the possible implementations described above, a further implementation is provided in which, when the leakage identification subsystem identifies an aluminum melt leak and provides the specific leak location, and the leakage amount determination subsystem simultaneously provides the leakage amount level, the control terminal provides an emergency handling instruction. The emergency response instructions include: for minor leaks, sealing the corresponding crystallizer holes according to the leak location; for moderate leaks, cutting off the relevant production links; and for severe leaks, instructing workers to evacuate.

[0016] On the other hand, the present invention also provides a method for identifying and warning of aluminum molten metal leakage in deep well casting for aluminum processing. The method is implemented using the aforementioned system and includes: Normal working condition judgment: When there is no aluminum liquid leakage, the aluminum wire is intact, and the first circuit, which consists of the aluminum wire, the first circuit power supply, and the electromagnetic relay connected in series, is conducting; the electromagnetic relay generates electromagnetic force, attracting the second end of the armature to move downward and contact the second contact; at this time, the second circuit, which consists of the second circuit power supply, the second spring, the second contact, and the working indicator light connected in series, is conducting, the working indicator light is on, indicating normal operation.

[0017] Aluminum molten metal leakage detection: When aluminum molten metal leaks, the aluminum wire melts, the first circuit is de-energized, the electromagnetic force of the electromagnetic relay disappears, and the second end of the armature moves upward under the action of the first and second springs, disengaging from the second contact and making contact with the first contact; at this time, the second circuit is de-energized, and the third circuit, composed of the second circuit power supply, the second spring, the first contact, the alarm light, and the circuit locator connected in series, is connected. The alarm light illuminates and sounds an alarm, indicating aluminum molten metal leakage; the circuit locator displays the location of the leak. Aluminum molten metal leakage assessment: Multiple temperature sensors are evenly distributed in the deep well water. Data from all temperature sensors are collected at preset intervals. The average temperature and instantaneous temperature change rate are calculated and compared with a preset temperature rise limit threshold. When the instantaneous temperature change rate exceeds the preset temperature rise limit threshold, aluminum molten metal leakage is determined to have occurred. Based on the empirical value of the instantaneous temperature change rate, the leakage amount is classified into levels. Emergency handling command output: When the leakage identification subsystem identifies an aluminum liquid leak and provides the specific leak location, and the leakage amount judgment subsystem simultaneously provides the leakage amount level, an emergency handling command is output.

[0018] The beneficial effects of this invention are as follows: This invention employs a convenient and reliable method for identifying and locating aluminum leaks, combined with a temperature-sensing leak detection system. It can issue an early warning alarm and locate the leak at the first sign of an aluminum molten metal leak, while simultaneously determining the leakage volume. Early warning allows for proactive intervention in leak response, preventing the cumulative leakage from escalating into serious accidents such as equipment meltdown or explosions upon contact with water. Precise leak location enables staff to quickly pinpoint the risk area and take targeted measures. Leak volume prediction allows for the early initiation of tiered preventative measures—immediate sealing of small leaks and proactive shutdown of related production lines and evacuation of personnel for large leaks, mitigating the risk of escalation from the source. The system uses low-cost, readily available components, is easy to install, and can be quickly integrated with existing production line control terminals without complex modifications. It exhibits strong anti-interference capabilities in the high-temperature and humid environment of deep wells, providing continuous and stable monitoring and preventing delays in response due to false alarms or missed alarms. This comprehensive approach builds a proactive prevention barrier for aluminum molten metal leaks, enhancing the inherent safety of deep-well casting in aluminum processing. Attached Figure Description

[0019] Figure 1 The diagram shown is a structural schematic of an aluminum processing deep well casting aluminum liquid leakage identification and early warning system according to an embodiment of the present invention.

[0020] Figure 2 The diagram shown is a schematic diagram for determining the amount / degree of aluminum molten leakage in the embodiment.

[0021] Figure 3 The diagram shown is a flowchart illustrating the linkage between the leakage identification subsystem and the leakage amount determination subsystem in this embodiment.

[0022] In the diagram: 1-molten aluminum liquid; 2-casting mold; 3-crystallizer; 4-aluminum billet; 5-traction device; 6-deep well water; 7-aluminum wire; 8-temperature sensor; 91-first spring; 92-second spring; 10-armature; 11-support column; 12-electromagnetic relay; 131-first contact; 132-second contact; 14-operation indicator light; 15-alarm light; 16-circuit locator; 171-first circuit power supply; 172-second circuit power supply; 18-temperature leakage detection unit; 19-control terminal. Detailed Implementation

[0023] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be noted that the technical features or combinations of technical features described in the following embodiments should not be considered in isolation, but can be combined with each other to achieve better technical effects.

[0024] This invention discloses an aluminum processing deep-well casting aluminum molten metal leakage identification and early warning system, characterized in that the system comprises: The leakage identification subsystem is used to identify whether aluminum liquid 1 is leaking in real time during the deep well casting process of aluminum processing, and to determine the location of the leak when aluminum liquid 1 is leaking. The leakage assessment subsystem is used to determine the amount of leakage from molten aluminum 1. The control terminal is used to simultaneously receive and process information from the leakage identification subsystem and the leakage amount determination subsystem, and to issue emergency handling instructions.

[0025] In one specific embodiment, such as Figure 1 As shown, the leakage identification subsystem includes: aluminum wire 7, first circuit power supply 171, second circuit power supply 172, electromagnetic relay 12, armature 10, first spring 91, second spring 92, support column 11, first contact 131, second contact 132, working indicator light 14, alarm light 15 and circuit locator 16. The aluminum wire 7 is the core component for judging the leakage of molten aluminum 1. The melting point of the aluminum wire 7 is between 560-620℃, while the temperature of molten aluminum 1 is usually around 700℃. When molten aluminum 1 leaks, the special aluminum wire 7 can be melted instantly. Circuit power supplies 171 and 172 are used to provide power to the circuit of the aluminum liquid 1 leakage identification and early warning positioning system. Electromagnetic relay 12 is used to generate a magnetic field when energized; The armature 10 interacts with the electromagnetic relay 12 to form a closed magnetic circuit, which is used to control the connection and disconnection of the circuit. The magnetic field generated by the electromagnetic relay 12 after it is energized can attract the armature 10. Springs 91 and 92, through deformation, serve to pull armature 10, and springs 91 and 92 are conductive; Support column 11 is used to support armature 10; The armature 10 can swing within a certain range under the traction of springs 91 and 92 and the magnetic field of electromagnetic relay 12, so as to realize the connection and disconnection of the circuit. Contacts 131 and 132 are connecting elements of the circuit, facilitating circuit connection; The working indicator light 14 is used to indicate whether the aluminum liquid leakage detection circuit 1 is working properly; the working indicator light 14 emits green light when the second circuit is turned on, indicating that the aluminum liquid leakage detection circuit (second circuit) is working properly. The alarm light 15 is used to emit a continuous, sharp warning sound when molten aluminum 1 leaks; the alarm light 15 will immediately sound an alarm and flash red light when the third circuit is turned on. The circuit locator 16 is used to display the position coordinates after being powered on; the circuit locator 16 and the alarm light 15 are in the same circuit, and when the circuit is connected, it will emit an alarm sound and provide the position coordinates. The melting point of the aluminum wire 7 is lower than the temperature of the molten aluminum liquid 1 in deep well casting. The aluminum wire 7 is set at the outlet of the crystallizer 3 and arranged in a circle along the outlet of the crystallizer 3 to cover all possible leakage paths of the molten aluminum liquid 1. The support column 11 supports the armature 10, which can rotate around the support point of the support column 11. A first spring 91 and a second spring 92 are respectively provided on both sides of the support column 11. The first spring 91 is located at the first end of the armature 10, and the second spring 92 is located at the second end of the armature 10. Both the first spring 91 and the second spring 92 are connected to the armature 10 to provide elastic force for the rotation of the armature 10. A first contact 131 is provided above the second end of the armature 10, and a second contact 132 is provided below the second end of the armature 10. The electromagnetic relay 12 is located below the second end of the armature 10. The aluminum wire 7, the first circuit power supply 171, and the electromagnetic relay 12 are connected in series to form the first circuit. The second circuit consists of power supply 172, second spring 92, second contact 132, and working indicator light 14 connected in series to form the second circuit. The second circuit power supply 172, the second spring 92, the first contact 131, the alarm light 15, and the circuit locator 16 are connected in series to form the third circuit; When there is no aluminum leakage, the aluminum wire 7 is intact and the first circuit is connected; the electromagnetic relay 12 generates electromagnetic force, attracting the second end of the armature 10 to move downward and contact the second contact 132; at this time, the second circuit is connected, the working indicator light 14 lights up, indicating that the operation is normal. When molten aluminum leaks, the aluminum wire 7 melts, the first circuit is de-energized, the electromagnetic force of the electromagnetic relay 12 disappears, and the second end of the armature 10 moves upward under the elastic force of the first spring 91 and the second spring 92, disengaging from the second contact 132 and contacting the first contact 131; at this time, the second circuit is de-energized, the third circuit is connected, the alarm light 15 illuminates and alarms, indicating that molten aluminum is leaking; the circuit locator 16 displays the location of the leak.

[0026] In one specific embodiment, the aluminum wire 7 is fixed to the metal frame at the outlet of the crystallizer 3 by a ceramic support and is arranged circumferentially along the crystallizer outlet to cover all possible aluminum melt leakage paths. It should be noted that the arrangement of the aluminum wire 7 below the crystallizer 3 is not limited to a circular shape; it can be rectangular, square, or other possible shapes, depending on the outlet shape (cast billet shape) of the crystallizer 3. The perimeter of the aluminum wire 7 is not fixed and varies with the shape and size of the crystallizer 3 outlet.

[0027] In one specific embodiment, the aluminum conductor 7 includes an inner core and an insulation layer. The inner core is a pure aluminum or aluminum alloy conductor with a diameter of 0.5~1mm, and the outer layer is covered by the insulation layer.

[0028] In one specific embodiment, there are multiple leakage identification subsystems, the number of which is consistent with the number of crystallizers 3, and each leakage identification subsystem corresponds to one crystallizer 3.

[0029] In one specific embodiment, the first spring 91 provides a pulling force for the rotation of the armature 10, and the second spring 92 provides a pushing force for the rotation of the armature 10; or at least one of the first spring 91 and the second spring 92 acts on the rotation of the armature 10, and both the first spring 91 and the second spring 92 are conductive.

[0030] In one specific embodiment, the leakage determination subsystem includes a temperature sensor 8 and a temperature-sensing leakage detection unit 18; The temperature sensors 8 are multiple and are evenly arranged in the deep well water; The temperature sensing leakage detection unit 18 is used to collect and process the temperature data of the temperature sensor 8. It collects data from all temperature sensors 8 at preset intervals, calculates the average temperature and instantaneous temperature change rate, and compares them with a preset temperature rise limit threshold. When the instantaneous temperature change rate exceeds the preset temperature rise limit threshold, it determines that aluminum liquid leakage has occurred, and classifies the leakage amount into levels based on the empirical value of the instantaneous temperature change rate.

[0031] In one specific embodiment, the temperature sensor 8 is encapsulated with waterproof heat shrink tubing to extend measurement accuracy and service life; a single-bus protocol is adopted and all pins of the temperature sensor 8 share a single signal line, reducing wiring requirements.

[0032] In one specific embodiment, the preset acquisition time interval of the temperature sensing leakage detection unit 18 is 5 seconds, and the temperature rise limit threshold is obtained from on-site casting experience or experiments.

[0033] Under normal casting conditions (no aluminum molten metal leakage), after the secondary cooling zone spray system cools the aluminum billet with water, the water temperature will gradually rise. However, the instantaneous rate of temperature increase is always below the limit threshold, indicating a leak-free operating condition. See [link / reference]. Figure 2 .

[0034] In the actual casting process, when molten aluminum liquid 1 leaks into the deep well, the water temperature in the deep well will rise rapidly. At this time, the instantaneous rate of temperature rise will be much higher than the limit threshold. At this time, the leakage amount judgment subsystem will determine that the molten aluminum liquid has leaked into the deep well.

[0035] In one specific embodiment, the leakage level is divided into minor leakage (Level 1), moderate leakage (Level 2), and severe leakage (Level 3); the empirical values ​​of the instantaneous temperature change rate corresponding to the minor leakage, moderate leakage, and severe leakage are derived from the data of aluminum molten metal explosion accidents when it comes into contact with water in aluminum processing deep well casting enterprises. Figure 2 A specific example is given.

[0036] In one specific embodiment, when the leakage identification subsystem identifies an aluminum liquid leak and provides the specific leak location, and the leakage amount judgment subsystem simultaneously provides the leakage amount level, the control terminal 19 issues an emergency handling command. The emergency response instructions include: for minor leaks, sealing the corresponding three holes of the crystallizer according to the leak location; for moderate leaks, cutting off the relevant production links; and for severe leaks, instructing workers to evacuate.

[0037] This invention provides a method for identifying and warning of aluminum molten metal leakage in deep well casting during aluminum processing. The method is implemented using the aforementioned system and includes: Normal working condition judgment: When there is no aluminum liquid leakage, the aluminum wire 7 is intact, and the first circuit consisting of the aluminum wire 7, the first circuit power supply 171, and the electromagnetic relay 12 connected in series is connected; the electromagnetic relay 12 generates electromagnetic force, attracting the second end of the armature 10 to move downward and contact the second contact 132; at this time, the second circuit consisting of the second circuit power supply 172, the second spring 92, the second contact 132, and the working indicator light 14 connected in series is connected, and the working indicator light 14 lights up, indicating normal operation.

[0038] Aluminum molten metal leakage detection: When aluminum molten metal 1 leaks, aluminum wire 7 melts, the first circuit is de-energized, the electromagnetic force of electromagnetic relay 12 disappears, and the second end of armature 10 moves upward under the elastic force of the first spring 91 and the second spring 92, disengaging from the second contact 132 and contacting the first contact 131; at this time, the second circuit is de-energized, and the third circuit, composed of the second circuit power supply 172, the second spring 92, the first contact 131, the alarm light 15, and the circuit locator 16 connected in series, is connected. The alarm light 15 lights up and alarms, indicating that aluminum molten metal 1 is leaking; the circuit locator 16 displays the leak location; Aluminum liquid leakage assessment: Multiple temperature sensors 8 are evenly distributed in the deep well water. Data from all temperature sensors 8 are collected at preset intervals. The average temperature and instantaneous temperature change rate are calculated and compared with a preset temperature rise limit threshold. When the instantaneous temperature change rate exceeds the preset temperature rise limit threshold, aluminum liquid leakage is determined to have occurred. Based on the empirical value of the instantaneous temperature change rate, the leakage amount is classified into levels. Emergency handling command output: When the leakage identification subsystem identifies an aluminum liquid leak and provides the specific leak location, and the leakage amount judgment subsystem simultaneously provides the leakage amount level, an emergency handling command is output.

[0039] The specific process is as follows: Figure 3 As shown.

[0040] During the actual casting process, after the aluminum liquid leakage identification and early warning positioning system is set up, the system working indicator light 14 should be constantly green, indicating that the aluminum liquid leakage identification and early warning positioning system is working normally and no aluminum liquid leakage has occurred. When the green working indicator light 14 goes out and the alarm light 15 emits a sharp warning sound and flashes red light, it indicates that the system has determined that an aluminum liquid leakage has occurred, and corresponding emergency measures should be taken immediately according to the location coordinates provided by the circuit locator 16.

[0041] This invention significantly improves the accuracy of aluminum liquid leakage detection through dual cross-verification of aluminum wire 7 leakage trigger and temperature sensing data. It can also be stably adapted to the high temperature, humidity and high noise environment of deep well casting, effectively eliminate early warning lag and positioning ambiguity, and effectively reduce the risk of aluminum liquid explosion when it comes into contact with water, providing reliable support for the inherent safety of deep well casting.

[0042] While several embodiments of the present invention have been provided herein, those skilled in the art should understand that modifications can be made to these embodiments without departing from the spirit of the invention. The above embodiments are merely exemplary and should not be construed as limiting the scope of the invention.

Claims

1. A deep well casting molten aluminum leakage identification and early warning system for aluminum processing, characterized in that, The system comprises: a leakage identification subsystem for identifying whether there is leakage of molten aluminum in real time in the aluminum processing deep well casting process and determining the leakage position when there is leakage of molten aluminum; a leakage amount judgment subsystem for judging the size of the leakage amount of molten aluminum; a control terminal for simultaneously receiving and processing information of the leakage identification subsystem and the leakage amount judgment subsystem and giving emergency treatment instructions.

2. The aluminum processing deep well molten aluminum leakage identification and early warning system of claim 1, wherein, The leakage identification subsystem comprises an aluminum wire, a first circuit power supply, a second circuit power supply, an electromagnetic relay, an armature, a first spring, a second spring, a support column, a first contact, a second contact, a working indicator lamp, an alarm lamp and a circuit locator. The melting point of the aluminum wire is lower than the temperature of molten aluminum in deep well casting, the aluminum wire is arranged at the outlet of the crystallizer and is arranged in a circle along the outlet of the crystallizer to cover all possible leakage paths of molten aluminum. The support column is used for supporting the armature, the armature can rotate around the support point of the support column, the first spring and the second spring are arranged on the two sides of the support column respectively, the first spring is located at the first end of the armature, the second spring is located at the second end of the armature, and the first spring and the second spring are connected with the armature to provide elastic force for the rotation of the armature, the first contact is arranged above the second end of the armature and the second contact is arranged below the second end of the armature, and the electromagnetic relay is arranged below the second end of the armature. The aluminum wire, the first circuit power supply and the electromagnetic relay are connected in series to form a first circuit. The second circuit power supply, the second spring, the second contact and the working indicator lamp are connected in series to form a second circuit. The second circuit power supply, the second spring, the first contact, the alarm lamp and the circuit locator are connected in series to form a third circuit. When there is no leakage of molten aluminum, the aluminum wire is intact, the first circuit is conducted, the electromagnetic relay generates electromagnetic force, the second end of the armature is attracted to move downward and contacts the second contact, at this time, the second circuit is conducted, the working indicator lamp is on and shows that the work is normal. When there is leakage of molten aluminum, the aluminum wire is melted, the first circuit is powered off, the electromagnetic force of the electromagnetic relay disappears, the second end of the armature moves upward under the action of the elastic force of the first spring and the second spring, separates from the second contact and contacts the first contact, at this time, the second circuit is powered off, the third circuit is connected, the alarm lamp is on and alarms, and shows that there is leakage of molten aluminum, and the circuit locator sends a positioning signal to the control terminal to determine the leakage position.

3. The aluminum processing deep well molten aluminum leakage identification and early warning system of claim 2, wherein, The aluminum wire comprises an inner core and an insulation layer, the inner core is a pure aluminum or aluminum alloy wire with a diameter of 0.5-1 mm, and the outer layer is coated with the insulation layer, the melting point of the aluminum wire is 560-620℃, and the temperature of molten aluminum in deep well casting is about 700℃.

4. The molten aluminum leakage identification and warning system for aluminum processing deep well casting of claim 2, wherein, The leakage identification subsystems are multiple and consistent with the number of crystallizers, each leakage identification subsystem corresponds to a crystallizer.

5. The aluminum processing deep well molten aluminum leakage identification and early warning system of claim 1, wherein, The leakage amount judgment subsystem comprises a temperature sensor and a temperature sensing leakage judgment unit. The temperature sensor is multiple and uniformly arranged in the deep well water. The temperature sensing leakage judgment unit is used for collecting and processing temperature data of the temperature sensors, collecting all temperature sensor data once every preset time interval, calculating average temperature and instantaneous temperature change rate, and comparing the average temperature and the instantaneous temperature change rate with a preset temperature rise limit threshold; when the instantaneous temperature change rate exceeds the preset temperature rise limit threshold, it is determined that aluminum liquid leakage occurs, and the leakage amount is divided into grades according to empirical values of the instantaneous temperature change rate.

6. The aluminum processing deep well molten aluminum leakage identification and early warning system of claim 5, wherein, The temperature sensors are packaged by waterproof heat-shrinkable tubes, adopt a single bus protocol, and all temperature sensor pins share a signal line.

7. The aluminum processing deep well molten aluminum leakage identification and early warning system of claim 5, wherein, The preset collection time interval of the temperature sensing leakage judgment unit is 5 seconds, and the temperature rise limit threshold is obtained from field casting experience or tests.

8. The molten aluminum leakage identification and warning system for aluminum processing deep well casting of claim 5, wherein, The leakage amount grades are divided into mild leakage, moderate leakage and severe leakage; and the empirical values of the instantaneous temperature change rate corresponding to the mild leakage, the moderate leakage and the severe leakage are obtained from aluminum liquid water explosion accident data of aluminum processing deep well casting enterprises.

9. The aluminum liquid leakage identification and early warning system for deep well casting of aluminum processing according to claim 1, wherein, when the leakage identification subsystem identifies aluminum liquid leakage and gives a specific leakage position, and the leakage amount judgment subsystem synchronously gives a leakage amount grade, the control terminal gives an emergency treatment instruction; the emergency treatment instruction includes: for mild leakage, plugging the corresponding crystallizer hole according to the leakage position; for moderate leakage, cutting off the related production link; and for severe leakage, instructing the operator to evacuate.

10. A method for identifying and warning of leakage of molten aluminum in deep well casting of aluminum processing, characterized in that, The method is implemented by using the system according to any one of claims 1-9, and the method comprises: normal working state judgment: when there is no aluminum liquid leakage, the aluminum wire is intact, and a first circuit composed of the aluminum wire, a first circuit power supply and an electromagnetic relay is turned on; the electromagnetic relay generates an electromagnetic force, the second end of the armature is attracted to move downward and contact the second contact; at this time, a second circuit composed of a second circuit power supply, a second spring, the second contact and a working indicator lamp is turned on, the working indicator lamp is on, and normal working is displayed; aluminum liquid leakage judgment: when there is aluminum liquid leakage, the aluminum wire is melted, the first circuit is powered off, the electromagnetic force of the electromagnetic relay disappears, the second end of the armature moves upward under the action of the first spring and the second spring, and is separated from the second contact and contacts the first contact; at this time, a third circuit composed of the second circuit power supply, the second spring, the first contact, an alarm lamp and a circuit locator is turned on, the alarm lamp is on and alarms, and aluminum liquid leakage is displayed; the circuit locator sends a positioning signal to the control terminal, so as to determine the leakage position; aluminum liquid leakage amount judgment: a plurality of temperature sensors are uniformly arranged in the deep well water, all temperature sensor data are collected once every preset time interval, average temperature and instantaneous temperature change rate are calculated, and the average temperature and the instantaneous temperature change rate are compared with a preset temperature rise limit threshold; when the instantaneous temperature change rate exceeds the preset temperature rise limit threshold, it is determined that aluminum liquid leakage occurs, and the leakage amount is divided into grades according to empirical values of the instantaneous temperature change rate; emergency treatment instruction output: when the leakage identification subsystem identifies aluminum liquid leakage and gives a specific leakage position, and the leakage amount judgment subsystem synchronously gives a leakage amount grade, an emergency treatment instruction is output.

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