Automatic control method and device for furnace plug of aluminum ingot casting holding furnace

Abstract

The invention discloses an automatic control method and device for a furnace plug of an aluminum ingot casting holding furnace, the device comprises a holding furnace (11), the holding furnace (11) is connected with an annular distributor through a chute (16), and the annular distributor is connected with a casting mould (15), and the automatic control method is characterized in that after production is started, a furnace mouth of the holding furnace (11) is closed firstly, and after the temperature and the liquid level of molten aluminum in the holding furnace (11) reach the standard, the furnace mouth of the holding furnace (11) is opened; molten aluminum flows into a chute (16), passes through an annular distributor and then enters a casting mold (15); when molten aluminum flows into the annular distributor, the conveying speed of the casting mould (15) is controlled by detecting the liquid level of the molten aluminum, and accurate casting of aluminum ingots is achieved. The opening degree of the furnace plug and the conveying speed of the aluminum ingot casting mold can be adjusted, so that the flow of molten aluminum is stable, and the quality of cast aluminum ingots reaches the standard; in addition, the casting mold conveying speed can be adjusted in time according to liquid level fluctuation, and the situation that molten aluminum overflows or is cut off is avoided.

Description

Technical Field

[0001] This invention relates to an automatic control method and device for the furnace plug of a mixing furnace for aluminum ingot casting, belonging to the field of aluminum ingot casting technology. Background Technology

[0002] Aluminum, as a widely used metallic material, continues to see increasing demand. Technical control during aluminum ingot production is crucial for product quality and production efficiency. Rational production organization, strict quality control, and effective production control measures are key to ensuring stable aluminum ingot quality and meeting market demands.

[0003] In the aluminum ingot casting process, controlling the casting speed, cooling rate, and crystallizer parameters is crucial to the quality of the aluminum ingots. Too high a casting speed can lead to defects such as cracks and segregation on the aluminum ingot surface; too low a casting speed will affect production efficiency. After the molten aluminum has settled and slag has been removed, it enters the casting stage. At this point, the furnace is opened and aluminum is discharged. Workers at the aluminum outlet observe the molten aluminum level in the steel mold and manually adjust the speed of the steel mold conveyor belt (synchronized with the casting machine speed) and the position of the flow control pins at the furnace outlet and the end of the aluminum molten flow channel to control the aluminum discharge speed and ensure it matches the ingot casting speed. This process is currently entirely manual, resulting in low control precision, poor stability, and unreliable product quality. The working environment is hot and dusty, and there is a risk of burns from splashing molten aluminum.

[0004] In the prior art, CN108723321A discloses a method for controlling the aluminum level in an aluminum wire rod mill, which is based on a variable parameter incremental PI control algorithm. This method continuously collects multiple level data points using a laser level gauge and transmits the data to a PLC controller. The PLC controller first applies median filtering to the multiple level data points collected by the laser level gauge, and then performs smoothing filtering to obtain the current level value. The PLC controller analyzes this current level value to determine which level limit it belongs to. A deviation value e(k) = gk + yk is formed by comparing the current level value yk with the set height value gk of the aluminum level. This deviation value is then used to control the stepper motor to rotate forward or backward using an incremental PI control algorithm. However, this technology is difficult to control and has high implementation costs, hindering its widespread adoption. Summary of the Invention

[0005] The purpose of this invention is to address the problems in aluminum ingot casting processes, such as unstable initial flow of molten aluminum due to manual adjustment of the furnace plug opening and conveyor belt speed, resulting in substandard casting; delayed response when the liquid level fluctuates greatly, easily causing molten aluminum to overflow or stop flowing; and low control precision affecting the quality of aluminum ingot forming. This invention provides an automatic control method and device for the furnace plug of an aluminum ingot casting mixing furnace, overcoming the many defects of manual control, improving ingot production efficiency and quality, and reducing operational risks.

[0006] The present invention discloses an automatic control method for the furnace plug of an aluminum ingot casting mixing furnace, comprising a mixing furnace, the mixing furnace being connected to an annular distributor via a chute, and the annular distributor being connected to a casting mold. After production starts, the furnace nozzle of the mixing furnace is first closed. When the temperature and level of the molten aluminum in the mixing furnace reach the standard, the furnace nozzle of the mixing furnace is opened, allowing the molten aluminum to flow into the chute, pass through the annular distributor, and enter the casting mold. When the molten aluminum flows into the annular distributor, the conveying speed of the casting mold is controlled by detecting the molten aluminum level, thereby achieving precise casting of aluminum ingots.

[0007] The method of controlling the mold conveying speed by detecting the aluminum liquid level involves collecting liquid level information in the chute using a liquid level sensor, comparing it with the previous liquid level information to calculate the liquid level difference and liquid level fluctuation rate, using the liquid level difference as the error e of the fuzzy inference engine, and the liquid level fluctuation rate as the error rate ec, and controlling the mold conveying speed by the changes in the liquid level difference and liquid level fluctuation rate.

[0008] The conveying speed of the mold is 1.38-2.7 r / min, the liquid level difference in the chute is 2-4 mm, and the liquid level fluctuation rate is [-1, 1]. The greater the liquid level difference in the chute, the faster the conveying speed of the mold.

[0009] An automatic control device for the furnace plug of an aluminum ingot casting mixing furnace includes a mixing furnace, a thermocouple connected inside the mixing furnace, a chute connected to the mixing furnace, a mold connected to the chute via an annular distributor, a plug rod connected to the furnace nozzle of the mixing furnace, an actuator connected to the plug rod, a first laser level sensor is provided on the chute at the outlet of the furnace nozzle, and a second laser level sensor is provided on the rear section of the chute.

[0010] The chute is equipped with a heat preservation mechanism.

[0011] The second laser level sensor is located at the outlet of the insulation mechanism.

[0012] It also includes a production control system, which has a control center. The control center is connected to a mixing furnace aluminum liquid level measurement module, a distributor drive mechanism, a furnace plug rod drive module, a chute aluminum liquid level measurement module, a furnace temperature detection module, and a variable frequency speed control system. The furnace temperature detection module is connected to a thermocouple, the mixing furnace aluminum liquid level measurement module is connected to a first laser level sensor, the distributor drive mechanism is connected to a stepper motor of the casting mold conveyor line, the furnace plug rod drive module is connected to an actuator, the chute aluminum liquid level measurement module is connected to a second laser level sensor, and the variable frequency speed control system is connected to the motor of the casting mold conveyor line.

[0013] Beneficial effects: This invention can adjust the opening and closing degree of the furnace plug and the conveying speed of the aluminum ingot casting mold, thus stabilizing the aluminum liquid flow and ensuring the quality of the cast aluminum ingots meets standards. Furthermore, it can adjust the mold conveying speed in a timely manner according to liquid level fluctuations, preventing aluminum liquid overflow or flow interruption. Compared with existing technologies, it has the advantages of simple control methods, high casting control precision, and good aluminum ingot forming quality. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of the present invention;

[0015] Figure 2 This is a schematic diagram of the control center module of the present invention.

[0016] Figure reference numerals: 1. Control center; 2. Mixing furnace liquid level measurement module; 3. Distributor drive mechanism; 4. Furnace plug rod drive module; 5. Sluice aluminum liquid laser ranging module; 6. Furnace temperature detection module; 7. Variable frequency speed control system; 8. Production control system; 9. First laser liquid level sensor; 10. Actuation structure; 11. Mixing furnace; 12. Insulation mechanism; 13. Second laser liquid level sensor; 14. Plug rod; 15. Casting mold; 16. Sluice; 17. Thermocouple. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0018] Embodiment 1 of the present invention:

[0019] like Figure 1 and 2 As shown, an automatic control device for the furnace plug of an aluminum ingot casting mixing furnace includes a mixing furnace 11, a thermocouple 17 connected inside the mixing furnace 11, a chute 16 connected to the mixing furnace 11, a casting mold 15 connected to the chute 16 via an annular distributor, a stopper rod 14 connected to the furnace nozzle of the mixing furnace 11, and an actuator 10 connected to the stopper rod 14. A first laser liquid level sensor 9 is provided on the chute 16 at the outlet of the furnace nozzle of the mixing furnace 11, and a second laser liquid level sensor 13 is provided on the rear section of the chute 16.

[0020] The chute 16 is equipped with a heat preservation mechanism 12.

[0021] The second laser level sensor 13 is located at the outlet of the heat preservation mechanism 12.

[0022] It also includes a production control system 8, which has a control center 1. The control center 1 is connected to a mixing furnace aluminum liquid level measurement module 2, a distributor drive mechanism 3, a furnace plug rod drive module 4, a chute aluminum liquid level measurement module 5, a furnace temperature detection module 6, and a variable frequency speed control system 7. The furnace temperature detection module 6 is connected to a thermocouple 17, the mixing furnace aluminum liquid level measurement module 2 is connected to a first laser level sensor 9, the distributor drive mechanism 3 is connected to a stepper motor of the casting mold 15 conveyor line, the furnace plug rod drive module 4 is connected to an actuator 10, the chute aluminum liquid level measurement module 5 is connected to a second laser level sensor 13, and the variable frequency speed control system 7 is connected to a motor of the casting mold 15 conveyor line.

[0023] The specific control process is as follows: Upon receiving the production task, the foundry workshop begins producing aluminum ingots, and the production control system 8 is activated. According to the production process requirements, the aluminum molten metal casting temperature in the mixing furnace 11 must be maintained between 690℃ and 710℃. Therefore, continuous monitoring of the aluminum molten metal casting temperature is necessary during production. The aluminum molten metal casting temperature detection device uses a contact thermocouple 17 to acquire the furnace temperature and transmits the collected temperature data to the furnace temperature detection module 6. The data transmission link of the furnace temperature detection module is configured using RS-485 transmission, responsible for uploading the detected temperature data to the control center 1 of the production control system 8 for analysis and processing. This also involves adjusting the opening and closing of the aluminum burners in the mixing furnace 11 to precisely maintain the casting temperature within the specified range. The mixing furnace level measurement module inside the mixing furnace 11 collects the aluminum liquid level height and transmits it to the microcontroller in the control center module 1. After receiving the aluminum liquid level information, the microcontroller transmits the liquid level information to the embedded industrial computer in real time. The industrial computer then sends commands to the microcontroller according to the control strategy, driving the stepper motor 3 to drive the furnace plug rod execution module 4, and the execution structure 10 to start acting, linking the opening and closing degree of the plug rod 14 to prepare for opening the plug and releasing aluminum. The aluminum liquid enters the chute 16, flows through the aluminum liquid chute into the annular distributor, and then into the casting mold 15. When the system is first started, due to the small aluminum liquid flow rate in the previous period, the aluminum liquid level in the chute is insufficient, which will lead to substandard casting quality. In order to obtain the real-time liquid level in the chute, a first laser liquid level sensor 9 and a second laser liquid level sensor 13 are set at the aluminum outlet of the mixing furnace and the outlet of the holding furnace 12, and the liquid level information is transmitted to the aluminum liquid laser ranging module 5 in the chute.

[0024] When molten aluminum flows into the annular distributor, the conveying speed of the mold 15 is controlled by detecting the molten aluminum level, thereby achieving precise casting of aluminum ingots.

[0025] Furthermore, the method of controlling the conveying speed of the mold 15 by detecting the aluminum liquid level involves collecting liquid level information within the chute 16 using a liquid level sensor, comparing it with the previous liquid level information to calculate the liquid level difference and liquid level fluctuation rate. The liquid level difference is used as the error e of the fuzzy inference engine, and the liquid level fluctuation rate is used as the error rate ec. The conveying speed of the mold 15 is controlled by the changes in the liquid level difference and liquid level fluctuation rate. The real-time liquid level in the chute can be calculated based on the data collected by the second laser liquid level sensor 13, or it can be calculated by averaging the data from the first laser liquid level sensor 9 and the second laser liquid level sensor 13. The liquid level fluctuation rate is calculated from the liquid level difference per unit time.

[0026] Furthermore, the conveying speed of the mold 15 is 1.38-2.7 r / min, the liquid level difference in the chute 16 is 2-4 mm, and the liquid level fluctuation rate is [-1, 1]. The greater the liquid level difference in the chute 16, the faster the conveying speed of the mold 15.

[0027] Because the control method of the fuzzy inference engine is simple and does not require too much complexity, as long as the conveying speed, liquid level difference and liquid level fluctuation rate are set to an appropriate range, the speed control of the mold 15 can be met, and the precise casting of aluminum ingots can be achieved.

[0028] In addition to the preferred embodiments described above, the present invention has other embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection claimed by the present invention.

Claims

1. An automatic control method for the furnace plug of a mixing furnace for aluminum ingot casting, comprising a mixing furnace (11), wherein the mixing furnace (11) is connected to an annular distributor via a chute (16), and the annular distributor is connected to a casting mold (15), characterized in that: After production starts, the nozzle of the mixing furnace (11) is closed first. When the temperature and level of the aluminum liquid in the mixing furnace (11) reach the standard, the nozzle of the mixing furnace (11) is opened so that the aluminum liquid flows into the chute (16) and enters the mold (15) after passing through the ring distributor. When the aluminum liquid flows into the ring distributor, the conveying speed of the mold (15) is controlled by detecting the aluminum liquid level to achieve precise casting of aluminum ingots.

2. The automatic control method for the furnace plug of an aluminum ingot casting mixing furnace according to claim 1, characterized in that: The method of controlling the conveying speed of the mold (15) by detecting the liquid level of aluminum liquid is to collect the liquid level information in the chute (16) by liquid level sensor, and compare it with the previous liquid level information to calculate the liquid level difference and liquid level fluctuation rate. The liquid level difference is used as the error e of the fuzzy inference engine, and the liquid level fluctuation rate is used as the error rate ec. The conveying speed of the mold (15) is controlled by the changes in liquid level difference and liquid level fluctuation rate.

3. The automatic control method for the furnace plug of an aluminum ingot casting mixing furnace according to claim 2, characterized in that: The conveying speed of the mold (15) is 1.38-2.7 r / min, the liquid level difference in the chute (16) is 2-4 mm, and the liquid level fluctuation rate is [-1, 1]. The greater the liquid level difference in the chute (16), the faster the conveying speed of the mold (15).

4. An automatic control device for the furnace plug of an aluminum ingot casting mixing furnace, comprising a mixing furnace (11), wherein a thermocouple (17) is connected inside the mixing furnace (11), characterized in that: The mixing furnace (11) is connected to the chute (16), the chute (16) is connected to the mold (15) through the annular distributor, the nozzle of the mixing furnace (11) is connected to the stopper rod (14), the stopper rod (14) is connected to the actuator (10), a first laser liquid level sensor (9) is provided on the chute (16) at the outlet of the nozzle of the mixing furnace (11), and a second laser liquid level sensor (13) is provided on the rear section of the chute (16).

5. The automatic control device for the furnace plug of an aluminum ingot casting mixing furnace according to claim 4, characterized in that: The chute (16) is equipped with a heat preservation mechanism (12).

6. The automatic control device for the furnace plug of an aluminum ingot casting mixing furnace according to claim 4, characterized in that: The second laser level sensor (13) is located at the outlet of the heat preservation mechanism (12).

7. The automatic control device for the furnace plug of an aluminum ingot casting mixing furnace according to claim 4, characterized in that: It also includes a production control system (8), which is equipped with a control center (1). The control center (1) is connected to the mixing furnace aluminum liquid level measurement module (2), the distributor drive mechanism (3), the furnace plug rod drive module (4), the chute aluminum liquid level measurement module (5), the furnace temperature detection module (6), and the frequency conversion speed regulation system (7). The furnace temperature detection module (6) is connected to the thermocouple (17), the mixing furnace aluminum liquid level measurement module (2) is connected to the first laser level sensor (9), the distributor drive mechanism (3) is connected to the stepper motor of the mold (15) conveyor line, the furnace plug rod drive module (4) is connected to the actuator (10), the chute aluminum liquid level measurement module (5) is connected to the second laser level sensor (13), and the frequency conversion speed regulation system (7) is connected to the motor of the mold (15) conveyor line.

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