Intelligent control method, system and equipment for online degassing of molten aluminum and medium

Abstract

The invention relates to an intelligent control method, system, equipment and medium for online degassing of molten aluminum, and belongs to the technical field of molten aluminum degassing, and the intelligent control method comprises the following steps: receiving a degassing starting instruction, loading a process parameter packet, controlling a rotor to descend, and starting a heater for preheating; when the rotor descends to the target preheating ending height, preheating is stopped; after the rotor contacts the surface of the molten aluminum, the rotor is driven to rotate in an accelerated manner and obtain actual torque. And after the actual torque rises to a target set torque + / -starting section torque tolerance threshold range, rotating at a constant speed, and dynamically adjusting the gas flow and the gas pressure at the same time, so that the torque is stabilized in a target set torque + / -steady state section torque tolerance threshold range. After the degassing duration reaches the target set duration, entering a termination stage: reducing the rotating speed of the rotor, and reducing the gas flow in proportion; and controlling the rotor to lift after the rotating speed is reduced to the target safety value. And reducing the power of the heater in the lifting process, and performing heat dissipation treatment after the rotor reaches the target height. The degassing device has the beneficial effect of improving the degassing effect.

Description

Technical Field

[0001] This application relates to the technical field of aluminum liquid degassing, and in particular to an intelligent control method, system, equipment and medium for online aluminum liquid degassing. Background Technology

[0002] During the production of aluminum and aluminum alloys, a certain amount of gas, mainly hydrogen, is usually dissolved in the molten aluminum. It may also contain harmful substances such as chemical inclusions or alkaline compounds. These gases and impurities can severely affect the quality and performance of aluminum alloys, leading to problems such as pinholes, porosity, or mechanical defects caused by the material itself, thus reducing the strength, toughness, and corrosion resistance of the aluminum alloy. Therefore, to obtain high-quality aluminum alloy products, it is necessary to degas the molten aluminum to improve its purity and ensure the stability of the aluminum alloy's composition and properties.

[0003] Currently, the most common method for degassing molten aluminum is rotary jet degassing technology. This technology involves inserting a rotor into the molten aluminum, where the high-speed rotation of the rotor disperses inert gases (such as argon, nitrogen, etc.) into tiny bubbles, ensuring their uniform distribution throughout the molten aluminum. As these tiny bubbles rise, they adsorb and collide with hydrogen and impurities in the molten aluminum, carrying these gases and impurities to the surface, thus achieving degassing and purification. During operation, parameters such as rotor speed, gas flow rate, and gas pressure are typically preset based on experience and then maintained constant throughout the degassing process.

[0004] However, the temperature, viscosity, and gas content of the molten aluminum will change during the degassing process, and the pre-set fixed parameters cannot adapt to these changes, resulting in unstable degassing effect. Summary of the Invention

[0005] To improve the degassing effect, this application provides an intelligent control method, system, equipment and medium for online degassing of molten aluminum.

[0006] Firstly, this application provides an intelligent control method for online degassing of molten aluminum, employing the following technical solution: A smart control method for online degassing of molten aluminum includes: The system receives a degassing start command, loads a preset process parameter package, controls the rotor to descend, and starts the heater to preheat the rotor. The process parameter package includes various target values ​​and thresholds related to degassing. When the rotor descends to the target preheating end height, preheating is stopped, and when the rotor contacts the surface of the molten aluminum, the rotor is driven to accelerate and the actual torque of the rotor is obtained. After the actual torque rises to the range of the target set torque ± the torque tolerance threshold of the starting section, the rotor is controlled to rotate at a constant speed, and the actual flow rate and actual gas pressure of the gas entering the rotor are dynamically adjusted so that the actual torque is stabilized within the range of the target set torque ± the torque tolerance threshold of the steady state section. After the degassing time reaches the target set time, the degassing termination stage begins. The rotor speed is controlled to decrease, and the gas flow rate is controlled to decrease proportionally with the decrease in speed. After the speed drops to the target safe value, the rotor is controlled to lift. During the rotor lifting process, the heater power is reduced, and the rotor is cooled after reaching the target lifting height.

[0007] By adopting the above technical solution, upon receiving the degassing start command, the rotor is first controlled to descend and the heater is activated to preheat the rotor. Preheating avoids thermal stress caused by the rotor's sudden contact with high-temperature molten aluminum, reducing the risk of rotor damage and extending its service life. After the rotor descends and contacts the molten aluminum, the actual torque is increased to within the range of the target set torque ± the torque tolerance threshold of the start-up section. During the constant-speed rotation phase, the actual gas flow rate and actual gas pressure are continuously and dynamically adjusted to stabilize the actual torque within the range of the target set torque ± the torque tolerance threshold of the steady-state section. This ensures that the gas exists in the molten aluminum in a suitable quantity and state, allowing for sufficient contact between the gas and the molten aluminum, thereby effectively removing hydrogen and impurities from the molten aluminum and improving its purity. By controlling the rotor's speed and torque, stable and effective stirring of the rotor in the molten aluminum is ensured. Appropriate stirring intensity helps the gas to disperse evenly in the molten aluminum, forming microbubbles, increasing the contact area between the gas and the molten aluminum, further improving degassing efficiency and overall degassing effect.

[0008] Optionally, the steps following controlling the rotor to rotate at a constant speed include: When the actual torque is detected to be continuously higher than the target set torque plus the steady-state torque tolerance threshold, the rotor torque change rate is calculated. Determine whether the torque change rate undergoes a negative abrupt change; If so, it is determined that the rotor is abnormal, a stop command is sent, an alarm is triggered, and all parameters are recorded.

[0009] By adopting the above technical solution, the torque change rate is calculated when the actual torque consistently exceeds the target torque plus the steady-state torque tolerance threshold. This allows for the determination of whether a negative abrupt change occurs, enabling timely detection of potential rotor anomalies. This prevents the equipment from continuing to operate under abnormal conditions, thus avoiding more severe damage and ensuring equipment safety. Upon detecting a rotor anomaly, the system not only shuts down the machine but also triggers an alarm and records all parameters. The alarm function promptly notifies operators to take appropriate measures, reducing response time for fault handling. Recording all parameters facilitates in-depth analysis of the fault's cause, providing a basis for equipment maintenance and improvement, thereby reducing losses from equipment failures.

[0010] Optionally, the step of determining whether the torque change rate undergoes a negative abrupt change further includes: If not, then increase the gas flow rate first; If the flow rate adjustment has reached its upper limit and the actual torque has not returned to the normal range, then increase the rotor speed.

[0011] By adopting the above technical solution, when the actual torque continuously exceeds the target setting range but the torque change rate does not undergo a negative abrupt change, the gas flow rate is increased first. This dynamic adjustment method can adjust the degassing parameters in a timely manner according to the actual state of the molten aluminum, allowing the gas to be better dispersed in the molten aluminum, increasing the contact area between the gas and the molten aluminum, thereby enhancing the degassing effect and ensuring the purity of the molten aluminum. If the flow rate adjustment has reached its upper limit and the actual torque has not yet returned to the normal range, the rotor speed is increased. This demonstrates the system's flexibility and adaptability, enabling it to maintain the stability of the degassing process under different operating conditions through various adjustment methods, ensuring that the degassing effect is not affected.

[0012] Optionally, the intelligent control method further includes: During the degassing process, if the gas pressure or flow rate is detected to be lower than the target minimum set value, a low gas supply warning will be triggered, and the following actions will be performed: (1) Open the auxiliary air circuit valve; (2) Control the rotor speed to drop to a safe value; (3) Control the rotor to rise by 20mm-30mm.

[0013] By adopting the above technical solution, the risk of aluminum liquid backflow and blockage due to insufficient gas can be greatly reduced.

[0014] Optionally, the step of dynamically adjusting the actual flow rate and actual pressure of the gas entering the rotor to stabilize the actual torque within the target set torque ± steady-state torque tolerance threshold range includes: Collect the physical properties of molten aluminum, retrieve historical adjustment records, and calculate torque deviation values; If the absolute value of the torque deviation is greater than the steady-state torque tolerance threshold, the aluminum liquid viscosity-temperature model is invoked to calculate the viscosity compensation coefficient, and the baseline flow rate is calculated based on the viscosity compensation coefficient. From the historical adjustment records, query historical adjustment records of similar operating conditions to generate a correction adjustment amount, and adjust the baseline flow rate according to the correction adjustment amount to obtain the correction flow rate, and obtain the correction pressure according to the correction flow rate; When the rotor operates according to the corrected flow rate and the corrected air pressure, it is determined whether the adjusted torque deviation value converges; If not, then the PID increment is added to the current gas flow rate, and the current gas pressure is adjusted according to the ratio of gas flow rate to aluminum liquid circulation volume.

[0015] By employing the above technical solution, physical properties of molten aluminum, such as temperature and viscosity, are collected, and historical adjustment records are retrieved. This allows for a comprehensive consideration of different molten aluminum states and past adjustment experience. The physical properties of molten aluminum affect the flow and dispersion of gas within it, thus influencing the rotor torque. By combining this information, the current state of the degassing process can be determined more accurately. The viscosity of molten aluminum changes with temperature, affecting the flow resistance and dispersion of gas within it, thereby impacting the rotor torque. Introducing a viscosity compensation coefficient allows for more precise adjustment of the gas flow rate to adapt to changes in molten aluminum viscosity, improving the stability and accuracy of the degassing process. Historical adjustment records contain adjustment experience under different operating conditions. By referencing these records, successful adjustment strategies can be learned from, avoiding repeated trials and errors, and finding suitable gas flow and pressure parameters for the current operating conditions more quickly, improving adjustment efficiency and effectiveness. If the adjusted torque deviation does not converge, it indicates that the current adjustment strategy may not be effective enough. By superimposing PID increments and adjusting the gas pressure, the gas flow and pressure parameters can be further optimized, ensuring that the actual torque remains stable within the target torque ± steady-state torque tolerance threshold range.

[0016] Optionally, the intelligent control method further includes: During the degassing process, the aluminum liquid temperature, rotor speed, gas flow rate, gas pressure and actual torque are collected in real time to construct a degassing effect prediction model; Based on the degassing effect prediction model, the hydrogen content of the aluminum liquid under the current process parameters is predicted in real time, and the target set torque and steady-state torque tolerance threshold are dynamically optimized according to the deviation between the predicted value and the target hydrogen content.

[0017] By adopting the above technical solution, the control parameters can be adjusted in real time according to the actual degassing effect, making the degassing process more precise and efficient, and always maintaining the best degassing effect; even under different production batches or operating conditions, the hydrogen content of the aluminum liquid can be guaranteed to stably meet the target requirements.

[0018] Optionally, the intelligent control method further includes: After the rotor reaches the target height, or during routine maintenance shutdown, initiate the rotor health diagnostic program: The torque fluctuation spectrum, vibration characteristic values, and temperature gradient curves during preheating and heat dissipation of the rotor during this and historical operation are analyzed. Combined with the rotor material fatigue model, the remaining life and potential damage of the rotor are predicted. If the predicted lifespan is below the safety threshold or high-risk damage characteristics are detected, a pre-maintenance alarm is issued, prompting inspection or replacement of the rotor; and, Calculate the unit aluminum liquid energy consumption and overall degassing efficiency for this degassing cycle, and compare it with the historical average and the best value. If the energy consumption is significantly higher and the efficiency is not optimal, an optimization report will be automatically generated.

[0019] By adopting the above technical solution, a multi-dimensional analysis method considers various characteristics of the rotor under different operating stages and conditions, thereby accurately predicting the rotor's remaining lifespan and potential damage. When the predicted lifespan falls below the safety threshold or high-risk damage characteristics are detected, the system issues a pre-maintenance alarm, prompting inspection or replacement of the rotor. This allows enterprises to take measures before serious rotor problems occur, preventing further equipment damage and ensuring production continuity and safety. Simultaneously, it avoids over-maintenance, reducing unnecessary maintenance costs and downtime. Calculating the unit aluminum liquid energy consumption and overall degassing efficiency for this degassing cycle, and comparing it with historical averages and best values, provides a clear understanding of the current production process's energy consumption and efficiency, offering crucial information for enterprises to assess the economic and environmental benefits of their production processes.

[0020] Secondly, this application provides an intelligent control system for online degassing of molten aluminum, employing the following technical solution: An intelligent control system for online degassing of molten aluminum includes: The instruction receiving module is used to receive degassing start instructions; The parameter loading module is used to load a preset process parameter package, which includes various target values ​​and thresholds related to degassing. The control module is used to control the rotor's descent, start the heater to preheat the rotor, stop preheating when the rotor descends to the target preheating end height, and drive the rotor to accelerate rotation when the rotor contacts the surface of the molten aluminum. The data acquisition module is used to acquire the actual torque of the rotor. The control module is used to control the rotor to rotate at a constant speed after the actual torque rises to the range of the target set torque ± the torque tolerance threshold of the starting section, and to dynamically adjust the actual flow rate and actual gas pressure of the gas entering the rotor so that the actual torque is stabilized within the range of the target set torque ± the torque tolerance threshold of the steady state section. The control module is also used to enter the degassing termination stage after the degassing time reaches the target set time, control the rotor speed to decrease, control the gas flow rate to decrease proportionally with the decrease in speed, and control the rotor to lift after the speed drops to the target safe value. It is also used to control the heater power to decrease during the rotor lifting process, and control the heat dissipation structure to dissipate heat from the rotor after the rotor reaches the target lifting height.

[0021] Thirdly, this application provides a computer device that adopts the following technical solution: A computer device includes a memory, a processor, and a computer program stored in the memory, wherein the processor executes the computer program to implement the intelligent control method for online degassing of molten aluminum as described in the first aspect.

[0022] Fourthly, this application provides a computer-readable storage medium, which adopts the following technical solution: A computer-readable storage medium storing a computer program capable of being loaded by a processor and executing an intelligent control method for online degassing of molten aluminum as described in the first aspect.

[0023] In summary, this application includes at least one of the following beneficial technical effects: Upon receiving the degassing start command, the rotor is first lowered and the heater is activated to preheat it. Preheating prevents thermal stress from sudden contact with molten aluminum, reducing the risk of rotor damage and extending its service life. After the rotor descends and contacts the molten aluminum, the actual torque is increased to within the range of the target set torque ± the torque tolerance threshold of the start-up phase. During the constant-speed rotation phase, the actual gas flow rate and pressure are continuously and dynamically adjusted to stabilize the actual torque within the range of the target set torque ± the torque tolerance threshold of the steady-state phase. This ensures that the gas exists in the molten aluminum in a suitable quantity and state, allowing for sufficient contact between the gas and the molten aluminum, thereby effectively removing hydrogen and impurities and improving the purity of the molten aluminum. By controlling the rotor's speed and torque, stable and effective stirring is ensured. Appropriate stirring intensity helps the gas to disperse evenly in the molten aluminum, forming microbubbles, increasing the contact area between the gas and the molten aluminum, further improving degassing efficiency and overall degassing effect. Attached Figure Description

[0024] Figure 1 This is a first flowchart of an embodiment of the method of this application; Figure 2This is a second flowchart of an embodiment of the method of this application; Figure 3 This is a third flowchart of an embodiment of the method of this application; Figure 4 This is the fourth flowchart of an embodiment of the method of this application. Detailed Implementation

[0025] To make the purpose, technical solution, and advantages of this application clearer, the following description is provided in conjunction with the appendix. Figure 1-4 The present application will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the application.

[0026] The first embodiment of this application discloses an intelligent control method for online degassing of molten aluminum. (Refer to...) Figure 1 The intelligent control method includes S110-S150: S110 receives the degassing start command, loads the preset process parameter package, controls the rotor to descend, and starts the heater to preheat the rotor. The process parameter package includes various target values ​​and thresholds related to degassing. S120 stops preheating when the rotor descends to the target preheating end height, and drives the rotor to accelerate rotation when the rotor contacts the surface of the molten aluminum, and obtains the actual torque of the rotor. S130: After the actual torque rises to the range of the target set torque ± the torque tolerance threshold of the starting section, the rotor is controlled to rotate at a constant speed, and the actual flow rate and actual gas pressure of the gas entering the rotor are dynamically adjusted so that the actual torque is stabilized within the range of the target set torque ± the torque tolerance threshold of the steady state section. S140: After the degassing time reaches the target set time, the degassing termination stage is entered. The rotor speed is controlled to decrease, and the gas flow rate is controlled to decrease proportionally with the decrease in speed. After the speed drops to the target safe value, the rotor is controlled to lift. S150 controls the heater power to decrease during rotor lifting and performs heat dissipation treatment on the rotor after it reaches the target lifting height.

[0027] Specifically, the system receives the degassing start command from the central control system or human-machine interface via the industrial bus, and then loads the preset process parameter package that matches the current aluminum liquid grade and smelting furnace type from the local database or cloud server. This data package adopts a structured storage format (such as JSON or XML) and contains key parameters such as the target hydrogen content of aluminum liquid required in the degassing process, the target set torque of the rotor, the gas source pressure threshold, the torque tolerance threshold of the start-up section and the steady-state section, the upper and lower limits of gas flow, and the target degassing duration. The parameter verification mechanism ensures the integrity and validity of the data.

[0028] The system calls upon a high-precision pressure transmitter (accuracy class 0.1%FS) installed on the main gas supply line to detect the gas supply pressure in real time. The sampling frequency is set to 10Hz. If the detected value is less than the minimum gas pressure for three consecutive sampling cycles, the PLC controller immediately triggers the delayed start logic and displays a "low gas pressure warning" flashing red on the HMI interface. At the same time, it outputs a switch signal to control the opening of the auxiliary gas circuit solenoid valve to replenish the pressure using the gas storage tank. During the pressure replenishment process, the pressure transmitter provides continuous feedback until the pressure rises above the minimum gas pressure and stabilizes for 5 seconds, at which point the delayed start state is released.

[0029] After the pressure is compensated, the rotor is lowered by a drive structure (e.g., a ball screw structure). The descent speed is controlled by a closed-loop pulse encoder. Simultaneously, the rotor's built-in heater (e.g., an electric heating rod) is activated to preheat the rotor. The heater power is set according to P. heater =P0+α·e βt Increase, P heater P0 represents the initial heating power, t represents the descent duration, and α and β are adjustment coefficients set according to actual conditions. The preheating temperature is monitored in real-time by a PT100 thermal resistor integrated inside the rotor. When the rotor descends to the target preheating end height detected by the laser displacement sensor (position accuracy ±0.5mm), the system cuts off the heating rod power to stop preheating. The rotor continues to descend, and when it contacts the surface of the molten aluminum (determined by a sudden signal from the torque sensor or displacement closed-loop feedback), the frequency converter drives the motor to accelerate the rotor. The acceleration process uses an S-curve design to avoid impact, and simultaneously, the torque sensor (dynamic response time <10ms) installed on the motor output shaft begins to collect actual torque data.

[0030] Reference Figure 2 The steps following controlling the rotor to rotate at a constant speed also include S210-S250: S210, when the actual torque is detected to be continuously higher than the target set torque + steady-state torque tolerance threshold, calculate the rotor torque change rate; S220, determine whether the torque change rate has a sudden negative change; S230, if so, it is determined that the rotor is abnormal, a stop command is sent, an alarm is triggered and all parameters are recorded; S240, if not, then prioritize increasing the gas flow rate; S250: If the flow rate regulation has reached its upper limit and the actual torque has not returned to the normal range, then increase the rotor speed.

[0031] Specifically, during the entire degassing process, the actual torque is continuously monitored by a torque sensor, and the torque change rate (ΔT / Δt, Δt = 100ms) is calculated using the first-order difference method. When the actual torque is higher than the target set torque + steady-state torque tolerance threshold for 5 consecutive seconds, the abnormal handling process is initiated.

[0032] By comparing the difference between the current rate of change of torque and the rate of change of torque at the previous moment, it is determined whether a negative abrupt change has occurred (the abrupt change threshold is set at -5 N·m / s). 2 (This can be adjusted according to the rotor model). If a negative sudden change is detected, the system immediately determines that it is an abnormality such as rotor jamming or breakage, cuts off the main motor power supply through the emergency stop relay, sends a stop command, and simultaneously triggers the audible and visual alarm (≥85dB). The system also writes all process parameters (with timestamps), such as the torque curve, speed, flow rate, and temperature at the current moment, into the fault record database for subsequent analysis.

[0033] If no negative abrupt change is detected, the gas flow rate is increased by increasing the set value of the mass flow controller, with each adjustment step being 5% of the current flow rate. After adjustment, the torque change is observed for 3 seconds. When the flow rate adjustment has reached its upper limit (set by the process parameter package) and the actual torque has not yet returned to the normal range, the system increases the rotor speed in small steps of 0.5Hz to avoid sudden speed increases that could cause aluminum molten metal to splash or rotor overload.

[0034] Reference Figure 3 The steps of dynamically adjusting the actual flow rate and actual pressure of the gas entering the rotor to stabilize the actual torque within the target set torque ± steady-state torque tolerance threshold range include S310-S350: S310: Collects physical properties of molten aluminum, retrieves historical adjustment records, and calculates torque deviation values; S320, if the absolute value of the torque deviation is greater than the steady-state torque tolerance threshold, the aluminum liquid viscosity-temperature model is called to calculate the viscosity compensation coefficient, and the baseline flow rate is calculated based on the viscosity compensation coefficient. S330: Query historical similar operating condition control records from historical control records to generate a correction control amount, and correct the baseline flow rate to obtain the correction flow rate based on the correction control amount, and obtain the correction pressure based on the correction flow rate; S340, when the rotor operates according to the corrected flow rate and corrected air pressure, determine whether the adjusted torque deviation value has converged; S350, if not, then add the PID increment to the current gas flow rate and adjust the current gas pressure according to the ratio of gas flow rate to aluminum liquid circulation volume.

[0035] Specifically, the system performs a moving average filter (window size 100ms) on the collected actual torque. When the filtered value falls within the range of the target set torque ± the starting torque tolerance threshold and remains stable for n seconds (e.g., 3 seconds), the controller switches to constant speed control mode, maintaining rotor speed stability through the speed closed-loop regulation of the frequency converter. After entering the stable operation phase, multi-parameter acquisition and calculation are initiated: the aluminum liquid temperature is acquired through an immersion thermocouple, and the physical properties of the aluminum liquid are obtained through a laser particle size analyzer or viscosity sensor (selected according to process requirements); simultaneously, adjustment records of the same aluminum liquid grade, similar initial temperature, and liquid level within the past 3 months are retrieved from the historical database; based on the difference between the current actual torque and the target set torque, the real-time torque deviation value is calculated (deviation value = actual torque - target set torque). If the absolute value of the deviation is greater than the steady-state torque tolerance threshold, the system calls the pre-trained aluminum liquid viscosity-temperature model (built based on neural networks or empirical formulas, with aluminum liquid temperature and alloy composition as inputs and viscosity coefficient as output), calculates the viscosity compensation coefficient under the current operating conditions, and generates the baseline flow rate by combining it with the basic gas flow rate formula. The basic gas flow rate formula is: Baseline flow rate = Target set torque × Viscosity compensation coefficient × Aluminum liquid density correction factor.

[0036] To improve adjustment accuracy, a working condition matching algorithm is used to query similar working conditions from historical adjustment records (similarity criteria include initial aluminum liquid temperature ±5℃, initial torque deviation ±10%, and consistent rotor model). The correlation between flow rate adjustment, air pressure adjustment, and torque change is extracted. A weighted average method (with higher weighting coefficients for recent data) is used to generate a correction adjustment amount, which is then used to correct the baseline flow rate to obtain the correction flow rate. Based on the characteristic curves of gas flow rate and air pressure (stored in the PLC's internal lookup table through previous no-load test calibration), the correction flow rate is converted into the corresponding correction air pressure value.

[0037] The rotor operates according to the corrected flow rate and corrected gas pressure. The gas flow rate is controlled in a closed loop by a mass flow controller (accuracy ±1%FS), and the gas pressure is regulated by a proportional valve. The system continuously monitors the torque deviation value and uses the moving standard deviation of the absolute value of the deviation (window 5 seconds) to determine whether it has converged. When the standard deviation is less than the convergence value (e.g. 0.5N·m) for 3 consecutive windows, it is determined to have converged.

[0038] If convergence is not achieved, a composite adjustment strategy is initiated: PID increments are superimposed on the current gas flow rate (PID parameters are initialized through a self-tuning algorithm and adaptively adjusted during operation based on deviation trends). Simultaneously, the current gas pressure is adjusted based on the empirical ratio of gas flow rate to aluminum liquid circulation volume (determined through previous process experiments and stored in a dynamic parameter table). For example, when the flow rate increases by 10%, the gas pressure is increased by 5% to maintain stable bubble morphology. Through the coordinated adjustment of flow rate and gas pressure, the actual torque is quickly stabilized within the target range.

[0039] When the accumulated degassing time of the PLC's internal timer reaches the target set time, the system enters the degassing termination stage, and the rotor speed follows the formula S = S0·e -t / τ The speed decreases smoothly. S represents the actual rotor speed, S0 represents the rotor speed at the start of the termination program, t represents the time elapsed since the start of the termination program, and τ represents the mechanical time constant, reflecting the system's inertia's response speed to changes in rotational speed. The larger τ is, the smoother the speed decrease. The gas flow rate decreases proportionally with decreasing rotational speed (e.g., Q). gas =Q0·(S / S0), where Q0 is the initial gas flow rate when the program is started (to avoid excessively large bubbles causing aluminum liquid to tumble and secondary gas intake after the speed decreases).

[0040] Once the rotational speed drops to the target safe value (e.g., 50 rpm), the rotor is controlled to rise smoothly at a low speed until it is completely detached from the molten aluminum and returns to the initial standby position. During the rotor lifting process, the heater power is controlled according to P. heater =P0-k·t (P0 is the power of the heater when the rotor is lifted, t is the duration of the rotor being lifted to the target lifting height, and k is the lifting coefficient, which is set according to the actual adjustment situation) decreases to prevent the rotor from generating thermal stress due to sudden cooling. When the rotor reaches the target lifting height, the power is maintained at a low level (such as 30%P0), and the air cooling system is started to force heat dissipation of the rotor. At the same time, the air source valve is closed to complete this degassing cycle.

[0041] In addition, in response to abnormal gas supply during the degassing process, when the gas pressure or flow rate is detected to be less than the target minimum set value (by dual determination of pressure transmitter and mass flow controller), the system immediately triggers a low gas supply warning and simultaneously executes three actions: opening the auxiliary gas circuit valve to replenish gas; reducing the rotor speed to a safe value (such as 30% of the operating speed) through the frequency converter; and controlling the servo system to slightly raise the rotor height by 20mm-30mm (precisely controlled by displacement sensor) to reduce the resistance of the aluminum liquid to the rotor. After the gas supply returns to normal, the original operating parameters are gradually restored in reverse order.

[0042] Furthermore, intelligent control methods also include: During the degassing process, the aluminum liquid temperature, rotor speed, gas flow rate, gas pressure and actual torque are collected in real time to construct a degassing effect prediction model; The hydrogen content of molten aluminum under the current process parameters is predicted in real time based on the degassing effect prediction model. The target torque and steady-state torque tolerance threshold are dynamically optimized based on the deviation between the predicted value and the target hydrogen content.

[0043] Specifically, during the degassing process, key parameters such as aluminum melt temperature, rotor speed, gas flow rate, gas pressure, and actual torque are collected in real time by relevant sensors. The sampling frequency is set according to the parameter characteristics (e.g., 1Hz for temperature, 1kHz for torque), and the data is preprocessed (denoising and normalization) before being input into the degassing effect prediction model. This model can use an LSTM neural network architecture, using historical process parameters and corresponding aluminum melt hydrogen content detection values ​​(obtained through offline detection or online hydrogen sensors) as training samples, and outputs the predicted value of aluminum melt hydrogen content under the current process parameters in real time. The predicted hydrogen content is compared with the target hydrogen content. If the deviation exceeds the allowable range (e.g., ±0.1ml / 100gAl), the target torque setting (adjustment range ±5%) and the steady-state torque tolerance threshold (adjustment range ±10%) are dynamically optimized. In addition, the optimization algorithm can also comprehensively consider degassing efficiency and energy consumption costs, and update process parameters through a rolling optimization strategy.

[0044] Reference Figure 4 The intelligent control methods also include S410-S440: S410: After the rotor reaches the target height, or during routine maintenance shutdown, initiate the rotor health diagnostic program. S420 analyzes the torque fluctuation spectrum, vibration characteristic value, and temperature gradient curve during preheating and heat dissipation of the rotor during the current and historical operation, and predicts the remaining life and potential damage of the rotor by combining the rotor material fatigue model. S430, if the predicted lifespan is below the safety threshold or high-risk damage characteristics are detected, issues a pre-maintenance alarm, prompting inspection or replacement of the rotor; and, S440 calculates the unit aluminum liquid energy consumption and overall degassing efficiency for this degassing cycle, and compares it with the historical average and the best value. If the energy consumption is significantly higher and the efficiency is not optimal, an optimization report will be automatically generated.

[0045] Specifically, when the rotor reaches the target height or during routine maintenance shutdown, the system automatically initiates the rotor health diagnosis program. Fourier transform is used to perform spectral analysis on the torque fluctuation signals from the current and the last 10 runs, extracting characteristic frequency components. Vibration characteristic values ​​are collected by an accelerometer (range ±50g) mounted on the rotor bearing housing, calculating the root mean square (RMS) value and kurtosis index. Combined with the temperature gradient curves during preheating and heat dissipation (plotted using PT100 RTD data), the rotor thermal fatigue trend is analyzed. These characteristic parameters are input into a rotor material fatigue model based on Support Vector Machine (SVM) to predict the remaining life (in hours) and identify potential damage modes (such as cracks and wear). If the predicted life is lower than the safety threshold (set according to the production plan, e.g., remaining life < 200 hours) or high-risk damage characteristics are detected (e.g., vibration RMS value exceeds the baseline by 20%), the system issues a pre-maintenance alarm, displays maintenance recommendations on the HMI interface, and notifies the equipment management department via email / SMS. Simultaneously, the unit aluminum liquid energy consumption (total power consumption / aluminum liquid volume processed) and comprehensive degassing efficiency (degassing volume / theoretical maximum degassing volume) of this degassing cycle are calculated and compared with the historical average (e.g., the past 30 times) and the historical best value. If the energy consumption is significantly higher (e.g., exceeding the average by 15%) and the efficiency is not optimal (e.g., lower than the optimal value by 10%), an optimization report is automatically generated, including parameter deviation analysis and suggested adjustment directions (e.g., optimizing preheating temperature, adjusting speed curve, etc.), and stored in the knowledge base for staff reference.

[0046] Based on the above method embodiments, the second embodiment of this application discloses an intelligent control system for online degassing of molten aluminum. The intelligent control system for online degassing of molten aluminum of this application embodiment can implement any of the above-described intelligent control methods for online degassing of molten aluminum, and the specific working process of each module in the intelligent control system for online degassing of molten aluminum can be referred to the corresponding process in the above method embodiments.

[0047] For ease of understanding, an example is provided below: An intelligent control system for online degassing of molten aluminum includes: The instruction receiving module is used to receive degassing start instructions; The parameter loading module is used to load a preset process parameter package, which includes various target values ​​and thresholds related to degassing. The control module is used to control the rotor's descent, start the heater to preheat the rotor, stop preheating when the rotor descends to the target preheating end height, and drive the rotor to accelerate rotation when the rotor contacts the surface of the molten aluminum. The data acquisition module is used to acquire the actual torque of the rotor. The control module is used to control the rotor to rotate at a constant speed after the actual torque rises to the range of the target set torque ± the torque tolerance threshold of the starting section, and to dynamically adjust the actual flow rate and actual gas pressure of the gas entering the rotor so that the actual torque is stabilized within the range of the target set torque ± the torque tolerance threshold of the steady state section. The control module is also used to control the rotor speed to decrease and control the gas flow rate to decrease proportionally with the decrease in speed after the degassing time reaches the target set time. After the speed drops to the target safe value, the control module controls the rotor to lift. During the rotor lifting process, the control module controls the heater power to decrease and controls the heat dissipation structure to dissipate heat from the rotor after the rotor reaches the target lifting height.

[0048] The third embodiment of this application provides a computer device, which may include a memory, a processor, and a computer program stored in the memory. The processor executes the computer program to realize an intelligent control method for online degassing of molten aluminum.

[0049] The memory can communicate with the processor via a communication bus, which can be an address bus, a data bus, a control bus, etc.

[0050] Additionally, the memory may include random access memory (RAM) or non-volatile memory (NVM), such as at least one disk storage device.

[0051] Furthermore, the processor can be a general-purpose processor, including a central processing unit (CPU), a network processor (NP), etc.; it can also be a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc.

[0052] The fourth embodiment of this application provides a computer-readable storage medium storing a computer program that can be loaded by a processor and executed as an intelligent control method for online degassing of molten aluminum.

[0053] The computer-readable storage medium can be any tangible medium that contains or stores a program that can be used by or in connection with an instruction execution system, apparatus, or device; the program code contained on the computer-readable medium can be transmitted using any suitable medium, including but not limited to wireless, wire, optical fiber, RF, etc., or any suitable combination thereof.

[0054] It should be noted that the computer device and storage medium in the embodiments of this application are respectively electronic devices and storage media that apply the above-described intelligent control method for online degassing of molten aluminum. Therefore, all embodiments of the above-described intelligent control method for online degassing of molten aluminum are applicable to the computer device and storage medium, and can achieve the same or similar beneficial effects. For the computer device / storage medium embodiments, since they are basically similar to the method embodiments, the description is relatively simple; relevant details can be found in the descriptions of the method embodiments.

[0055] Although this application has been described herein in conjunction with various embodiments, those skilled in the art, by reviewing the accompanying drawings, disclosure, and appended claims, will understand and implement other variations of the disclosed embodiments in carrying out the claimed application. In the claims, the word "comprising" does not exclude other components or steps, and "a" or "an" does not exclude a plurality. A single processor or other unit can implement several functions listed in the claims. While different dependent claims may recite certain measures, this does not mean that these measures cannot be combined to produce a good effect.

[0056] The above are all preferred embodiments of this application and are not intended to limit the scope of protection of this application. Any feature disclosed in this specification (including the abstract and drawings) may be replaced by other equivalent or similar features unless specifically stated otherwise. That is, unless specifically stated otherwise, each feature is only one example of a series of equivalent or similar features.

Claims

1. An intelligent control method for online degassing of molten aluminum, characterized in that, include: The system receives a degassing start command, loads a preset process parameter package, controls the rotor to descend, and starts the heater to preheat the rotor. The process parameter package includes various target values ​​and thresholds related to degassing. When the rotor descends to the target preheating end height, preheating is stopped, and when the rotor contacts the surface of the molten aluminum, the rotor is driven to accelerate and the actual torque of the rotor is obtained. After the actual torque rises to the range of the target set torque ± the torque tolerance threshold of the starting section, the rotor is controlled to rotate at a constant speed, and the actual flow rate and actual gas pressure of the gas entering the rotor are dynamically adjusted so that the actual torque is stabilized within the range of the target set torque ± the torque tolerance threshold of the steady state section. After the degassing time reaches the target set time, the degassing termination stage begins. The rotor speed is controlled to decrease, and the gas flow rate is controlled to decrease proportionally with the decrease in speed. After the speed drops to the target safe value, the rotor is controlled to lift. During the rotor lifting process, the heater power is reduced, and the rotor is cooled after reaching the target lifting height.

2. The intelligent control method for online degassing of molten aluminum according to claim 1, characterized in that, The steps following controlling the rotor to rotate at a constant speed include: When the actual torque is detected to be continuously higher than the target set torque plus the steady-state torque tolerance threshold, the rotor torque change rate is calculated. Determine whether the torque change rate undergoes a negative abrupt change; If so, it is determined that the rotor is abnormal, a stop command is sent, an alarm is triggered, and all parameters are recorded.

3. The intelligent control method for online degassing of molten aluminum according to claim 2, characterized in that, The step of determining whether the torque change rate has undergone a negative abrupt change further includes: If not, then increase the gas flow rate first; If the flow rate adjustment has reached its upper limit and the actual torque has not returned to the normal range, then increase the rotor speed.

4. The intelligent control method for online degassing of molten aluminum according to claim 3, characterized in that, The intelligent control method further includes: During the degassing process, if the gas pressure or flow rate is detected to be lower than the target minimum set value, a low gas supply warning will be triggered, and the following actions will be performed: (1) Open the auxiliary air circuit valve; (2) Control the rotor speed to drop to a safe value; (3) Control the rotor to rise by 20mm-30mm.

5. The intelligent control method for online degassing of molten aluminum according to claim 1, characterized in that, The step of dynamically adjusting the actual flow rate and actual gas pressure of the gas entering the rotor to stabilize the actual torque within the target set torque ± steady-state torque tolerance threshold range includes: Collect the physical properties of molten aluminum, retrieve historical adjustment records, and calculate torque deviation values; If the absolute value of the torque deviation is greater than the steady-state torque tolerance threshold, the aluminum liquid viscosity-temperature model is invoked to calculate the viscosity compensation coefficient, and the baseline flow rate is calculated based on the viscosity compensation coefficient. From the historical adjustment records, query historical adjustment records of similar operating conditions to generate a correction adjustment amount, and adjust the baseline flow rate according to the correction adjustment amount to obtain the correction flow rate, and obtain the correction pressure according to the correction flow rate; When the rotor operates according to the corrected flow rate and the corrected air pressure, it is determined whether the adjusted torque deviation value converges; If not, then the PID increment is added to the current gas flow rate, and the current gas pressure is adjusted according to the ratio of gas flow rate to aluminum liquid circulation volume.

6. The intelligent control method for online degassing of molten aluminum according to claim 1, characterized in that, The intelligent control method further includes: During the degassing process, the aluminum liquid temperature, rotor speed, gas flow rate, gas pressure and actual torque are collected in real time to construct a degassing effect prediction model; Based on the degassing effect prediction model, the hydrogen content of the aluminum liquid under the current process parameters is predicted in real time, and the target set torque and steady-state torque tolerance threshold are dynamically optimized according to the deviation between the predicted value and the target hydrogen content.

7. The intelligent control method for online degassing of molten aluminum according to claim 1, characterized in that, The intelligent control method further includes: After the rotor reaches the target height, or during routine maintenance shutdown, initiate the rotor health diagnostic program: The torque fluctuation spectrum, vibration characteristic values, and temperature gradient curves during preheating and heat dissipation of the rotor during this and historical operation are analyzed. Combined with the rotor material fatigue model, the remaining life and potential damage of the rotor are predicted. If the predicted lifespan is below the safety threshold or high-risk damage characteristics are detected, a pre-maintenance alarm is issued, prompting inspection or replacement of the rotor; and, Calculate the unit aluminum liquid energy consumption and overall degassing efficiency for this degassing cycle, and compare it with the historical average and the best value. If the energy consumption is significantly higher and the efficiency is not optimal, an optimization report will be automatically generated.

8. An intelligent control system for online degassing of molten aluminum, characterized in that, The intelligent control method for online degassing of molten aluminum as described in any one of claims 1 to 7 includes: The instruction receiving module is used to receive degassing start instructions; The parameter loading module is used to load a preset process parameter package, which includes various target values ​​and thresholds related to degassing. The control module is used to control the rotor's descent, start the heater to preheat the rotor, stop preheating when the rotor descends to the target preheating end height, and drive the rotor to accelerate rotation when the rotor contacts the surface of the molten aluminum. The data acquisition module is used to acquire the actual torque of the rotor. The control module is used to control the rotor to rotate at a constant speed after the actual torque rises to the range of the target set torque ± the torque tolerance threshold of the starting section, and to dynamically adjust the actual flow rate and actual gas pressure of the gas entering the rotor so that the actual torque is stabilized within the range of the target set torque ± the torque tolerance threshold of the steady state section. The control module is also used to enter the degassing termination stage after the degassing time reaches the target set time, control the rotor speed to decrease, control the gas flow rate to decrease proportionally with the decrease in speed, and control the rotor to lift after the speed drops to the target safe value. It is also used to control the heater power to decrease during the rotor lifting process, and control the heat dissipation structure to dissipate heat from the rotor after the rotor reaches the target lifting height.

9. A computer device, characterized in that, The method includes a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor, when executing the program, implements the intelligent control method for online degassing of molten aluminum as described in any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, The computer program stores a method for intelligent control of online degassing of molten aluminum as described in any one of claims 1 to 7, which can be loaded by a processor and executed.

Images