Automatic control method and system for liquid level of regenerated copper melt

Abstract

The invention discloses a secondary copper melt liquid level automatic control method and system, and relates to the technical field of secondary copper smelting, the secondary copper melt liquid level automatic control system comprises a furnace body, a vertical rod is arranged at the top end of the furnace body, a fixed sleeve is fixedly connected to the bottom end of the vertical rod, and movable rods are slidably arranged at the two ends of the fixed sleeve; the end, away from the fixed sleeve, of the movable rod is fixedly connected with a bent sleeve, a sensor is installed at the bottom end of the bent sleeve, an air outlet channel is formed in the movable rod, and the fixed sleeve communicates with the bent sleeve through the air outlet channel. According to the automatic control method and system for the liquid level of the regenerated copper melt, through the laser radar, the infrared dual-mode sensor and self-adaptive PID adjustment, the liquid level control deviation is small, the situation that the liquid level is too high to overflow or too low to damage a furnace is effectively avoided, meanwhile, the manual inspection and sensor maintenance frequency is reduced, and the problems that traditional control is low in precision and poor in interference resistance are solved; the device can adapt to a high-temperature and high-dust environment, improves smelting stability, reduces energy consumption and labor cost, and can be widely applied to a regenerated copper smelting production line.

Description

Technical Field

[0001] This invention relates to the field of recycled copper smelting technology, and in particular to an automatic control method and system for the liquid level of recycled copper melt. Background Technology

[0002] In the process of recycled copper smelting, stable control of the melt level is a key link to ensure production efficiency, product quality and production safety. If the melt level is too high, it will easily cause melt overflow, leading to safety accidents and waste of raw materials. If the melt level is too low, it will cause uneven heating of the furnace body, shorten the service life of the furnace lining, and affect the smelting reaction and reduce the purity of the product.

[0003] Currently, the main shortcomings of the methods for controlling the liquid level of recycled copper melt are as follows: Manual control is a common method used by traditional small and medium-sized recycled copper enterprises. It relies on operators to judge the liquid level by observing the furnace opening or sight glass and manually adjust the feed valve or feeder based on experience. This method is greatly affected by human factors, has low control accuracy, and has a slow response. The contact liquid level detection and control method uses contact sensors such as floats, thermocouples, or electrodes to directly insert into the melt or close to the liquid surface for detection. Float sensors are easily shaken by the impact of melt flow, resulting in low detection accuracy. In addition, the high temperature of the melt can easily corrode the float material, leading to a short sensor life.

[0004] Therefore, it is necessary to propose an automatic control method and system for the liquid level of recycled copper melt to solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide an automatic control method and system for the liquid level of recycled copper molten metal, in order to solve the problem that manual control is a common method used by traditional small and medium-sized recycled copper enterprises. This method relies on operators to judge the liquid level by observing the furnace opening or sight glass and manually adjusting the feed valve or feeder based on experience. This method is greatly affected by human factors, has low control accuracy, and has a slow response. The contact liquid level detection and control method uses contact sensors such as floats, thermocouples, or electrodes to directly insert into the melt or close to the liquid surface for detection. Float sensors are easily shaken by the impact of melt flow, resulting in low detection accuracy. In addition, the high temperature of the melt can easily corrode the float material, leading to a short sensor life.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an automatic control method for the liquid level of recycled copper melt, comprising the following operational steps:

[0007] S1. Initialize and set the target liquid level H0, with a range of 400-800 mm, and set the allowable deviation threshold ΔHmax = ±10 mm;

[0008] S2. The melt level is detected in real time using a dual-mode sensor of lidar and infrared, with a detection frequency of 5-10Hz.

[0009] S3. Filter the detection data by using a moving average filter combined with a wavelet denoising algorithm to remove outliers.

[0010] S4. Calculate the deviation ΔH between the actual liquid level H and the target liquid level H0, and make adjustments when |ΔH| > ΔHmax.

[0011] S5. The control module uses an adaptive PID algorithm to output an adjustment signal based on ΔH and the liquid level change rate dH / dt. The PID parameters are dynamically adjusted according to the working conditions.

[0012] S6. Adjust the feed flow rate or discharge flow rate according to the adjustment signal. The feed adjustment range is 0-50L / min, and the discharge adjustment range is 0-30L / min. The response time is ≤2s until |ΔH|≤ΔHmax.

[0013] This invention also discloses an automatic control system for the liquid level of recycled copper melt, applied to the aforementioned automatic control method for the liquid level of recycled copper melt. The system further includes a furnace body, with a vertical rod at the top and a fixed sleeve fixedly connected to the bottom of the vertical rod. Both ends of the fixed sleeve are slidably connected to movable rods. A bent sleeve is fixedly connected to the end of the movable rod away from the fixed sleeve, and a sensor is installed at the bottom of the bent sleeve. An air outlet is provided on the movable rod, and the fixed sleeve communicates with the bent sleeve through the air outlet. An air hole is provided at the bottom of the bent sleeve, close to the sensor. An air inlet is provided on the vertical rod, with its bottom end communicating with the fixed sleeve. The top end of the air inlet penetrates the outer wall of the top of the vertical rod. A first one-way valve is installed in the air outlet, and a second one-way valve is installed in the air inlet.

[0014] Preferably, two bent rods are provided between the two bent sleeves, and the ends of the bent rods are slidably disposed within the corresponding bent sleeves.

[0015] Preferably, both ends of the bend are provided with bends, and a circular block is slidably disposed inside the bend, the circular block being fixedly connected to the corresponding bend rod.

[0016] Preferably, a slip ring is slidably provided on the vertical rod, and upper ear seats are fixedly connected to both sides of the slip ring. A connecting plate is rotatably provided on the upper ear seat, and a lower ear seat is rotatably provided at the end of the connecting plate away from the upper ear seat. The lower ear seat is fixedly connected to the corresponding bent sleeve.

[0017] Preferably, a first electric push rod is fixedly connected to the outer wall of the vertical rod, and the slip ring is fixedly connected to the telescopic end of the first electric push rod.

[0018] Preferably, an outer ring is fixedly connected to the outer wall of the furnace body, a support plate is fixedly connected to the outer ring, a vertical box is fixedly connected to the top of the support plate, a vertical plate is slidably arranged inside the vertical box, and the vertical plate passes through the top of the vertical box, a top plate is fixedly connected to the top of the vertical plate, and the vertical rod is rotatably arranged on the vertical plate.

[0019] Preferably, a motor is fixedly connected to the top plate, a first gear is fixedly connected to the drive shaft of the motor, and a second gear is fixedly connected to the vertical rod, with the first gear and the second gear meshing together.

[0020] Preferably, a second electric push rod is fixedly connected to the support plate, and the top plate is fixedly connected to the telescopic end of the second electric push rod.

[0021] Preferably, multiple sensors are provided.

[0022] The technical effects and advantages of this invention are as follows:

[0023] 1. This invention uses lidar, infrared dual-mode sensors and adaptive PID control to achieve small liquid level control deviation, effectively avoiding overflow due to excessively high liquid level or damage to the furnace due to excessively low liquid level. At the same time, it reduces the frequency of manual inspection and sensor maintenance, solves the problems of low control accuracy and poor anti-interference in traditional control, can adapt to high temperature and high dust environment, improve smelting stability, reduce energy consumption and labor costs, and can be widely used in recycled copper smelting production lines.

[0024] 2. By setting up structures such as vertical rods, bends, and top plates, the position of the sensor can be flexibly adjusted in the axial and radial directions of the furnace body to ensure the accuracy of detection;

[0025] 3. By setting up structures such as air outlet and air inlet, the movement of the moving rod can automatically clean the dust remaining on the outside of the sensor, improving the efficiency of use. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the automatic control method for the level of recycled copper melt according to the present invention.

[0027] Figure 2 This is a schematic diagram of the furnace body and vertical rod structure of the present invention.

[0028] Figure 3 For the present invention Figure 2 Enlarged schematic diagram of the structure at point A in the middle.

[0029] Figure 4 This is a schematic diagram of the vertical box and vertical plate structure of the present invention.

[0030] Figure 5 For the present invention Figure 4 Enlarged schematic diagram of the structure at point B.

[0031] Figure 6 For the present invention Figure 4 Enlarged schematic diagram of the structure at point C.

[0032] Figure 7 For the present invention Figure 4Enlarged schematic diagram of the structure at point D.

[0033] Figure 8 For the present invention Figure 4 Enlarged schematic diagram of the structure at point E in the middle.

[0034] Figure 9 This is a schematic diagram of the bending sleeve and bending rod structure of the present invention.

[0035] In the diagram: 1. Furnace body; 2. Vertical rod; 3. Bend sleeve; 4. Bend rod; 5. Bend; 6. Circular block; 7. Fixed sleeve; 8. Moving rod; 9. Air outlet; 10. Sensor; 11. Air hole; 12. First one-way valve; 13. Lower ear seat; 14. Slip ring; 15. Upper ear seat; 16. Connecting plate; 17. First electric push rod; 18. Air inlet; 19. Second one-way valve; 20. Outer ring; 21. Support plate; 22. Vertical box; 23. Vertical plate; 24. Second electric push rod; 25. Top plate; 26. Motor; 27. First gear; 28. Second gear. Detailed Implementation

[0036] This invention provides, for example Figures 1-9 The method for automatic control of the level of recycled copper melt shown includes the following steps:

[0037] S1. Initialize and set the target liquid level H0, with a range of 400-800 mm, and set the allowable deviation threshold ΔHmax = ±10 mm;

[0038] S2. The melt level is detected in real time using a dual-mode sensor of lidar and infrared, with a detection frequency of 5-10Hz.

[0039] S3. Filter the detection data by using a moving average filter combined with a wavelet denoising algorithm to remove outliers.

[0040] S4. Calculate the deviation ΔH between the actual liquid level H and the target liquid level H0, and make adjustments when |ΔH| > ΔHmax.

[0041] S5. The control module uses an adaptive PID algorithm to output an adjustment signal based on ΔH and the liquid level change rate dH / dt. The PID parameters are dynamically adjusted according to the working conditions.

[0042] Adaptive PID algorithm: The proportional coefficient Kp (5-20), integral coefficient Ki (0.1-1.0), and derivative coefficient Kd (0.05-0.5) are dynamically adjusted with dH / dt. When the dH / dt changes rapidly, Kp and Kd are increased to suppress fluctuations.

[0043] Adaptive PID algorithm is a common existing technology, and will not be elaborated here.

[0044] S6. Adjust the feed flow rate or discharge flow rate according to the adjustment signal, using an electric regulating valve, etc. The feed adjustment range is 0-50L / min, the discharge adjustment range is 0-30L / min, and the response time is ≤2s, until |ΔH|≤ΔHmax.

[0045] This invention utilizes lidar, infrared dual-mode sensors, and adaptive PID control to achieve minimal liquid level control deviation, effectively preventing overflow from excessively high levels or damage to the furnace from excessively low levels. It also reduces the frequency of manual inspections and sensor maintenance, solving the problems of low control accuracy and poor anti-interference in traditional systems. It can adapt to high-temperature and high-dust environments, improve smelting stability, and reduce energy consumption and labor costs. It can be widely applied to recycled copper smelting production lines.

[0046] The present invention also discloses an automatic control system for the liquid level of recycled copper melt, which is applied to the above-mentioned automatic control method for the liquid level of recycled copper melt. It also includes a furnace body 1, and a vertical rod 2 is provided at the top of the furnace body 1. The vertical rod 2 is concentrically arranged with the furnace body 1. The vertical rod 2 can move up and down along the axial direction of the furnace body 1, and the vertical rod 2 can also rotate.

[0047] An outer ring 20 is fixedly connected to the outer wall of the furnace body 1. A support plate 21 is fixedly connected to the outer ring 20. A vertical box 22 is fixedly connected to the top of the support plate 21. A vertical plate 23 is slidably arranged inside the vertical box 22 and passes through the top of the vertical box 22. The vertical plate 23 can move up and down inside the vertical box 22. A top plate 25 is fixedly connected to the top of the vertical plate 23. A vertical rod 2 is rotatably arranged on the vertical plate 23.

[0048] A motor 26 is fixedly connected to the top plate 25. A first gear 27 is fixedly connected to the drive shaft of the motor 26, and a second gear 28 is fixedly connected to the vertical rod 2. The first gear 27 and the second gear 28 are meshed together. The motor 26 is connected to the factory's power supply. The motor 26 drives the first gear 27 to rotate. Because the first gear 27 and the second gear 28 are meshed together, the second gear 28 drives the vertical rod 2 to rotate.

[0049] A second electric push rod 24 is fixedly connected to the support plate 21, and the top plate 25 is fixedly connected to the telescopic end of the second electric push rod 24. The second electric push rod 24 is connected to the factory's power supply, and the top plate 25 and the vertical rod 2 are moved up and down by the second electric push rod 24.

[0050] The bottom end of the vertical rod 2 is fixedly connected to a fixed sleeve 7. Both ends of the fixed sleeve 7 are slidably provided with moving rods 8, and the inner wall of the fixed sleeve 7 is provided with rubber sealing gaskets, etc., to reduce wear and maintain sealing.

[0051] The end of the moving rod 8 away from the fixed sleeve 7 is fixedly connected to a bent sleeve 3. Two bent rods 4 are arranged between the two bent sleeves 3, and the ends of the bent rods 4 are slidably arranged in the corresponding bent sleeves 3. The two bent sleeves 3 and the two bent rods 4 form a ring structure, and the diameter of the ring can be varied.

[0052] Both ends of the bend sleeve 3 are provided with bends 5, and a round block 6 is slidably arranged inside the bend 5. The round block 6 is fixedly connected to the corresponding bend rod 4. The bends 5 and the round block 6 are provided to ensure the stability of the sliding of the bend rod 4.

[0053] Reference Figure 9 As shown, when the two moving rods 8 move in opposite directions, the two bends 3 move in opposite directions synchronously. At this time, the two bends 4 also move in opposite directions and slide adaptively inside the bends 3, while the circular block 6 slides inside the bend 5 to ensure the stability of the sliding.

[0054] To enable the movement of the sleeve 3, a sliding ring 14 is slidably mounted on the vertical rod 2. Upper ear seats 15 are fixedly connected to both sides of the sliding ring 14, and ball bearings or similar components can be mounted on the inner wall of the sliding ring 14 to improve the smoothness of the sliding. A connecting plate 16 is rotatably mounted on the upper ear seat 15, and a lower ear seat 13 is rotatably mounted at the end of the connecting plate 16 away from the upper ear seat 15. The lower ear seat 13 is fixedly connected to the corresponding sleeve 3.

[0055] A first electric push rod 17 is fixedly connected to the outer wall of the vertical rod 2, and a slip ring 14 is fixedly connected to the telescopic end of the first electric push rod 17. Specifically, when the telescopic end of the first electric push rod 17 is extended, the slip ring 14 slides downward on the outer wall of the vertical rod 2, the bottom end of the connecting plate 16 opens outward, causing the two moving rods 8 to move in opposite directions, and the two bent sleeves 3 to move in opposite directions synchronously, increasing the diameter of the ring; conversely, when the telescopic end of the first electric push rod 17 is retracted, the slip ring 14 slides upward on the outer wall of the vertical rod 2, the bottom end of the connecting plate 16 moves inward, causing the two moving rods 8 to move towards each other, and the two bent sleeves 3 to move towards each other synchronously, decreasing the diameter of the ring.

[0056] Sensor 10 is installed at the bottom of the sleeve 3. Multiple sensors 10 can be set, including infrared dual-mode sensors, temperature sensors, dust sensors, etc., to detect melt level, temperature, dust, etc. in real time. LiDAR and other sensors can also be set, and adjustments can be made according to specific usage conditions.

[0057] During testing, the height of the sensor 10 can be adjusted by moving the top plate 25 and the vertical rod 2 up and down. If the liquid level is low, the vertical rod 2 moves downward so that the bend sleeve 3, sensor 10, etc. extend into the top opening of the furnace body 1. If the liquid level is high, it can be positioned 30-50cm above the furnace body 1, depending on the specific usage.

[0058] After the test, the bending sleeve 3, sensor 10, etc. are moved upward and retracted, and the top of the furnace body 1 is covered to avoid being affected by the high temperature inside the furnace body 1.

[0059] At the same time, the motor 26 drives the first gear 27 to rotate. Since the first gear 27 is meshed with the second gear 28, the second gear 28 drives the vertical rod 2 to rotate, so that the sensor 10 can rotate around the axis of the furnace body 1. The diameter of the ring can be changed, so that the position of the sensor 10 in the furnace body 1 can be adjusted, expanding the coverage area, realizing multiple detections, and ensuring the accuracy of detection.

[0060] By setting up structures such as vertical rod 2, bent sleeve 3, and top plate 25, the position of sensor 10 can be flexibly adjusted in the axial and radial directions of furnace body 1 to ensure detection accuracy.

[0061] Considering that dust may easily remain on the outside of the sensor 10, an air outlet 9 is provided on the moving rod 8 to clean the dust. The fixed sleeve 7 is connected to the bent sleeve 3 through the air outlet 9. The bottom of the bent sleeve 3 is provided with an air hole 11 close to the sensor 10. Multiple air holes 11 are provided and distributed around the sensor 10. A first one-way valve 12 is installed in the air outlet 9 so that the gas in the air outlet 9 can enter the interior of the bent sleeve 3 without flowing in the opposite direction.

[0062] Meanwhile, partitions are installed at both ends of the connection between the sleeve 3 and the moving rod 8 to isolate the gas (not shown in the figure). This ensures that when the gas in the outlet 9 enters the interior of the sleeve 3, it is between the two partitions and can only be ejected through the air hole 11, instead of being discharged from the bend 5, the end of the outlet 9, or other locations.

[0063] An air inlet 18 is provided on the vertical rod 2. The bottom end of the air inlet 18 is connected to the fixed sleeve 7, and the top end of the air inlet 18 penetrates the top outer wall of the vertical rod 2. A dustproof net or similar device can be installed at the top end of the air inlet 18 to prevent dust from entering the interior of the air inlet 18. A second one-way valve 19 is installed inside the air inlet 18. The second one-way valve 19 allows external gas to enter the interior of the air inlet 18 without reverse flow.

[0064] In actual use, when the extension end of the first electric push rod 17 is extended, the two moving rods 8 move in opposite directions inside the fixed sleeve 7, the gas storage space inside the fixed sleeve 7 gradually increases, and external gas enters the interior of the fixed sleeve 7 through the air inlet 18.

[0065] Since the top of the air intake duct 18 is located on the outer wall of the top of the vertical rod 2, there is less dust here, and with the help of the dustproof net, the gas entering the fixed sleeve 7 is dust-free.

[0066] Next, the telescopic end of the first electric push rod 17 is retracted, and the two moving rods 8 move towards each other inside the fixed sleeve 7, forcing the gas inside the fixed sleeve 7 into the curved sleeve 3 through the air outlet 9, and spraying it towards the sensor 10 through the air hole 11, blowing away the dust remaining on the outside of the sensor 10. The above steps are repeated multiple times to achieve the effect of automatic cleaning.

[0067] By setting up structures such as the air outlet 9 and the air inlet 18, and utilizing the movement of the moving rod 8, the residual dust on the outside of the sensor 10 is automatically cleaned, improving the efficiency of use.

[0068] In actual production, the automatic control method for the level of recycled copper melt also includes the following embodiments:

[0069] Example 1

[0070] The target liquid level is set at 400mm, and the detection frequency is 5Hz. LiDAR (dust ≤ 50mg / m³) 3 The system detects the liquid level using a sliding average window of 5, with a data accuracy of ±2mm after wavelet denoising. When the actual liquid level is 412mm (ΔH=12mm) and the rate of change dH / dt=3mm / s, the adaptive PID controller is activated: Kp=5, Ki=0.1, Kd=0.05. The execution module adjusts the feed valve to close slightly, reducing the flow rate from 30L / min to 25L / min. After 1.5s, the liquid level stabilizes at 403mm (ΔH=3mm). The system operates under nitrogen-protected smelting conditions, with the water-cooled cover filled with 30℃ water, providing good dust protection and triggering no alarms.

[0071] Example 2

[0072] Target liquid level 500mm, detection frequency 6Hz. High dust conditions (60mg / m³). 3 The system automatically switches to an infrared sensor with a detection accuracy of ±3mm. With a filter window of 6, when the liquid level is 515mm (ΔH=15mm) and dH / dt=4mm / s, Kp=8, Ki=0.3, and Kd=0.1. Adjusting the discharge valve opening from 20% to 25% increases the flow rate from 15L / min to 18L / min; the liquid level stabilizes at 504mm after 1.8 seconds. The temperature sensor displays a furnace temperature of 1100℃; the system exhibits no drift and operates stably.

[0073] Example 3

[0074] Target liquid level: 600mm; detection frequency: 7Hz. Normal dust concentration: 40mg / m³. 3 Laser detection was used, with a filter window of 7. The liquid level was 585 mm (ΔH = -15 mm), dH / dt = -2 mm / s, Kp = 10, Ki = 0.5, and Kd = 0.2. The feed pump frequency was adjusted from 40 Hz to 45 Hz, and the flow rate increased from 20 L / min to 25 L / min. After 2 seconds, the liquid level reached 598 mm. The control module displayed parameters in real time, and the human-machine interface operated smoothly.

[0075] Example 4

[0076] Target liquid level 700mm, detection frequency 8Hz. Dust suddenly increases to 70mg / m³. 3The sensor automatically switched to infrared. Liquid level was 718 mm (ΔH = 18 mm), dH / dt = 6 mm / s, Kp = 12, Ki = 0.7, Kd = 0.3. The feed valve was closed to 30%, reducing the flow rate from 40 L / min to 32 L / min. After 1.6 seconds, the liquid level was 705 mm. The alarm module did not trigger; adaptive adjustment effectively suppressed fluctuations.

[0077] Example 5

[0078] Target liquid level 800mm, detection frequency 10Hz. Laser detection (dust 30mg / m³). 3 The filter window is 10. The liquid level is 780 mm (ΔH = -20 mm), dH / dt = -4 mm / s, Kp = 15, Ki = 0.9, Kd = 0.4. The feed flow rate increases from 25 L / min to 35 L / min, and the liquid level reaches 797 mm after 1.9 seconds. The execution module responds quickly with no overshoot.

[0079] Example 6

[0080] Target liquid level: 450mm; detection frequency: 5Hz; infrared sensor (dust concentration: 55mg / m³). 3 The filter window is 5. The liquid level is 462 mm (ΔH = 12 mm), dH / dt = 3 mm / s, Kp = 6, Ki = 0.2, Kd = 0.08. The discharge flow rate increases from 10 L / min to 12 L / min, and the liquid level is 453 mm after 1.7 s. The system self-diagnosis shows that the sensor status is normal and there is no communication delay.

[0081] Example 7

[0082] Target liquid level 550mm, detection frequency 6Hz. Laser detection (dust 45mg / m³). 3 The filter window is 6. The liquid level is 530 mm (ΔH = -20 mm), dH / dt = -3 mm / s, Kp = 9, Ki = 0.4, Kd = 0.15. The feed flow rate increases from 18 L / min to 28 L / min, and the liquid level is 548 mm after 2 seconds. The real-time curve display on the human-machine interface shows that the adjustment process is smooth and without oscillation.

[0083] Example 8

[0084] Target liquid level: 650mm; detection frequency: 7Hz. High dust concentration (75mg / m³). 3 Infrared detection, filter window 7. Liquid level 668mm (ΔH=18mm), dH / dt=5mm / s, Kp=11, Ki=0.6, Kd=0.25. The feed valve opening decreased from 50% to 40%, the flow rate decreased from 30L / min to 24L / min, and the liquid level reached 655mm after 1.7s. The alarm module threshold was not triggered, and the operation was safe.

[0085] Example 9

[0086] Target liquid level 750mm, detection frequency 8Hz. Laser detection (dust 35mg / m³). 3 The filter window is 8. The liquid level is 732 mm (ΔH = -18 mm), dH / dt = -3 mm / s, Kp = 13, Ki = 0.8, Kd = 0.35. The feed pump is adjusted to 50 Hz, and the flow rate is increased from 22 L / min to 30 L / min. After 1.9 seconds, the liquid level is 747 mm. Communication between the system and the host computer is normal, and data is uploaded promptly.

[0087] Example 10

[0088] Target liquid level 400mm, detection frequency 9Hz. Infrared sensor (dust 65mg / m³). 3 The filter window is 9. The liquid level is 418 mm (ΔH = 18 mm), dH / dt = 5 mm / s, Kp = 7, Ki = 0.25, Kd = 0.12. The discharge flow rate increases from 12 L / min to 15 L / min, and the liquid level reaches 405 mm after 1.6 s. The water temperature at the water-cooled cover outlet is 45℃, and the sensor shows no overheating.

[0089] Example 11

[0090] Target liquid level 500mm, detection frequency 10Hz. Laser detection (dust 25mg / m³). 3 The filter window is 10. The liquid level is 482 mm (ΔH = -18 mm), dH / dt = -4 mm / s, Kp = 14, Ki = 0.75, Kd = 0.3. The feed flow rate increases from 20 L / min to 30 L / min, and the liquid level reaches 497 mm after 1.8 seconds. The PID parameters are dynamically adjusted to adapt to the operating conditions, ensuring precise control.

[0091] Example 12

[0092] Target liquid level 600mm, detection frequency 5Hz. High dust (80mg / m³) 3 Infrared detection, filter window 5. Liquid level 620mm (ΔH=20mm), dH / dt=7mm / s, alarm triggered, Kp=16, Ki=0.85, Kd=0.45. Feed valve is abruptly closed to 20%, flow rate drops from 35L / min to 15L / min, liquid level reaches 608mm after 1.5s, alarm cleared.

[0093] Example 13

[0094] Target liquid level 700mm, detection frequency 6Hz. Laser detection (dust 45mg / m³). 3The filter window is 6. The liquid level is 680mm (ΔH=-20mm), dH / dt=-5mm / s, Kp=12, Ki=0.6, Kd=0.2. The feed pump frequency is increased to 50Hz, the flow rate is increased from 25L / min to 35L / min, and the liquid level is 698mm after 2s. The actuator is smooth and there is no jamming.

[0095] Example 14

[0096] Target liquid level 800mm, detection frequency 7Hz. Infrared sensor (dust 50mg / m³). 3 The filter window is 7. The liquid level is 815 mm (ΔH = 15 mm), dH / dt = 3 mm / s, Kp = 9, Ki = 0.4, Kd = 0.18. The discharge flow rate increases from 18 L / min to 22 L / min, and the liquid level reaches 803 mm after 1.9 s. The system self-diagnosis records show no abnormalities, and historical data is available.

[0097] Example 15

[0098] Target liquid level: 550mm; detection frequency: 8Hz; dust fluctuation: 30-60mg / m³. 3 The sensor automatically switches. Liquid level is 565mm (ΔH=15mm), dH / dt=4mm / s, Kp=11, Ki=0.5, Kd=0.22. Bidirectional adjustment: feed rate decreases by 5L / min, discharge rate increases by 3L / min, liquid level reaches 552mm after 1.7s. Good adaptability to all operating conditions, and control accuracy meets standards.

Claims

1. A method for automatic control of the liquid level of recycled copper molten metal, characterized in that: The following steps are included: S1. Initialize and set the target liquid level H0, with a range of 400-800 mm, and set the allowable deviation threshold ΔHmax = ±10 mm; S2. The melt level is detected in real time using a dual-mode sensor of lidar and infrared, with a detection frequency of 5-10Hz. S3. Filter the detection data by using a moving average filter combined with a wavelet denoising algorithm to remove outliers. S4. Calculate the deviation ΔH between the actual liquid level H and the target liquid level H0, and make adjustments when |ΔH| > ΔHmax. S5. The control module uses an adaptive PID algorithm to output an adjustment signal based on ΔH and the liquid level change rate dH / dt. The PID parameters are dynamically adjusted according to the working conditions. S6. Adjust the feed flow rate or discharge flow rate according to the adjustment signal. The feed adjustment range is 0-50L / min, and the discharge adjustment range is 0-30L / min. The response time is ≤2s until |ΔH|≤ΔHmax.

2. An automatic control system for the liquid level of recycled copper melt, characterized in that: The method for automatic control of the liquid level of recycled copper melt as described in claim 1 further includes a furnace body (1), a vertical rod (2) is provided at the top of the furnace body (1), a fixed sleeve (7) is fixedly connected to the bottom end of the vertical rod (2), a movable rod (8) is slidably provided at both ends of the fixed sleeve (7), a bent sleeve (3) is fixedly connected to the end of the movable rod (8) away from the fixed sleeve (7), a sensor (10) is installed at the bottom end of the bent sleeve (3), and an air outlet is provided on the movable rod (8). The fixed sleeve (7) is connected to the bent sleeve (3) through the air outlet (9). The bottom of the bent sleeve (3) is provided with an air hole (11) close to the sensor (10). The vertical rod (2) is provided with an air inlet (18). The bottom end of the air inlet (18) is connected to the fixed sleeve (7). The top end of the air inlet (18) penetrates the top outer wall of the vertical rod (2). A first one-way valve (12) is installed in the air outlet (9), and a second one-way valve (19) is installed in the air inlet (18).

3. The automatic control system for the level of recycled copper melt according to claim 2, characterized in that: Two bent rods (4) are provided between the two bent sleeves (3), and the ends of the bent rods (4) are slidably disposed in the corresponding bent sleeves (3).

4. The automatic control system for the level of recycled copper melt according to claim 3, characterized in that: Both ends of the bend sleeve (3) are provided with bends (5), and a round block (6) is slidably arranged inside the bend (5), and the round block (6) is fixedly connected to the corresponding bend rod (4).

5. The automatic control system for the level of recycled copper melt according to claim 2, characterized in that: A sliding ring (14) is slidably provided on the vertical rod (2). Upper ear seats (15) are fixedly connected to both sides of the sliding ring (14). A connecting plate (16) is rotatably provided on the upper ear seat (15). A lower ear seat (13) is rotatably provided at the end of the connecting plate (16) away from the upper ear seat (15). The lower ear seat (13) is fixedly connected to the corresponding bent sleeve (3).

6. The automatic control system for the level of recycled copper melt according to claim 5, characterized in that: A first electric push rod (17) is fixedly connected to the outer wall of the vertical rod (2), and the slip ring (14) is fixedly connected to the telescopic end of the first electric push rod (17).

7. The automatic control system for the level of recycled copper melt according to claim 2, characterized in that: An outer ring (20) is fixedly connected to the outer wall of the furnace body (1). A support plate (21) is fixedly connected to the outer ring (20). A vertical box (22) is fixedly connected to the top of the support plate (21). A vertical plate (23) is slidably arranged inside the vertical box (22), and the vertical plate (23) passes through the top of the vertical box (22). A top plate (25) is fixedly connected to the top of the vertical plate (23). The vertical rod (2) is rotatably arranged on the vertical plate (23).

8. The automatic control system for the level of recycled copper melt according to claim 7, characterized in that: A motor (26) is fixedly connected to the top plate (25), a first gear (27) is fixedly connected to the drive shaft of the motor (26), and a second gear (28) is fixedly connected to the vertical rod (2). The first gear (27) and the second gear (28) are meshed together.

9. The automatic control system for the level of recycled copper melt according to claim 8, characterized in that: A second electric push rod (24) is fixedly connected to the support plate (21), and the top plate (25) is fixedly connected to the telescopic end of the second electric push rod (24).

10. The automatic control system for the level of recycled copper melt according to claim 2, characterized in that: Multiple sensors (10) are provided.

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