An eb furnace smelting interruption ingot transfer method and system

Abstract

This invention relates to the field of metal smelting technology and discloses a method and system for ingot receiving during interrupted EB furnace smelting. The method includes: monitoring the EB furnace smelting process to determine if smelting has been interrupted; increasing the current of the remaining second-part electron guns in response to an interruption in the crystallization zone of the EB furnace; increasing the current of the first-part electron guns based on images captured by a camera in response to troubleshooting the first-part electron guns; monitoring the ingot receiving status in real time; and adjusting the current of the second-part electron guns to the smelting state in response to ingot receiving completion. The solution of this invention monitors the EB furnace smelting process and, when the first-part electron gun is interrupted, increases the current of the second-part electron guns to maintain the ingot temperature and the vacuum level of the EB furnace. After troubleshooting, the current of each electron gun is adjusted to resume the EB furnace smelting process, thereby improving the ingot receiving success rate while ensuring product quality and reducing material waste.

Description

Technical Field

[0001] This invention relates to the field of metal smelting technology, specifically to a method and system for interrupting ingot feeding during EB furnace smelting. Background Technology

[0002] Electron beam cold hearth furnace melting technology is widely used in high-end fields such as aerospace, medical devices, and nuclear industry because it can effectively remove gases and non-metallic inclusions from metals to obtain high-purity metal materials. During EB (electron beam) furnace melting, equipment failure, raw material quality issues, or improper operation may cause the melting process to be interrupted, requiring ingot receiving operations to continue production.

[0003] In related technologies, the following drawbacks exist in the process of joining ingots: low success rate, easy to produce defects such as shrinkage cavities; serious material waste during the joining process; and unstable product quality after joining, affecting subsequent processing and use of the product.

[0004] Therefore, how to ensure the success rate of ingot receiving while taking into account product quality and reducing material waste has become an urgent problem to be solved. Summary of the Invention

[0005] In view of this, the present invention provides a method and system for interrupting ingot receiving in an EB furnace to solve the technical problem of how to ensure the success rate of ingot receiving while taking into account product quality and reducing material waste.

[0006] In a first aspect, the present invention provides a method for interrupting ingot receiving during EB furnace melting, the method comprising: monitoring the EB furnace melting process and determining whether melting has been interrupted; in response to an interruption in a first portion of the electron guns in the crystallization zone of the EB furnace, increasing the current of the remaining second portion of the electron guns; in response to troubleshooting the first portion of the electron guns, increasing the current of the first portion of the electron guns based on images captured by a camera; monitoring the ingot receiving status in real time; and in response to the completion of ingot receiving, adjusting the current of the second portion of the electron guns to the melting state.

[0007] In conjunction with the first aspect, in one possible implementation of the first aspect, monitoring the EB furnace melting process and determining whether the melting has been interrupted includes: real-time monitoring of key parameters of the furnace melting; and determining whether an interruption has occurred and the corresponding interruption type based on the key parameters; wherein the key parameters include: electron gun emission current, electron gun high voltage stability, melting vacuum degree, and gaps caused by ingot shrinkage in the crystallizer.

[0008] In conjunction with the first aspect, in one possible implementation of the first aspect, increasing the current of the remaining second part of the electron gun includes: increasing the current of the electron gun in the primary cold hearth melting zone and the electron gun in the refining cold hearth melting zone respectively; and adjusting the current of the electron gun in the primary cold hearth melting zone and the electron gun in the refining cold hearth melting zone again based on the vacuum degree of the EB furnace, so as to maintain the vacuum degree in the EB furnace within a preset range.

[0009] In conjunction with the first aspect, in one possible implementation of the first aspect, the step of increasing the current of the first part of the electron gun based on the image captured by the camera includes: determining the gap of ingot shrinkage based on a first image of the refining cold hearth melting zone captured by the camera and a second image of the crystallization zone captured by the camera; based on the correspondence between the gap and the initial current and the target current, preheating the first part of the electron gun with the initial current, and gradually increasing the current of the first part of the electron gun to the target current.

[0010] In conjunction with the first aspect, in one possible implementation of the first aspect, adjusting the current of the second part of the electron gun to a melting state includes: linearly reducing the current of the second part of the electron gun to a melting state within a preset time.

[0011] In conjunction with the first aspect, in one possible implementation of the first aspect, adjusting the current of the second electron gun to a melting state includes: linearly reducing the current of the second electron gun to a melting state within a preset time period. Secondly, the present invention provides an EB furnace melting interruption ingot receiving system, the system comprising: a judgment module for monitoring the EB furnace melting process and judging whether melting has been interrupted; a first adjustment module for increasing the current of the remaining second part of the electron guns in response to an interruption in the first part of the electron guns in the crystallization zone of the EB furnace; a second adjustment module for increasing the current of the first part of the electron guns based on images captured by a camera in response to troubleshooting the first part of the electron guns; and a monitoring module for monitoring the ingot receiving status in real time. The third adjustment module is used to adjust the current of the second part of the electron gun to the melting state in response to the completion of ingot casting and receiving.

[0012] In conjunction with the second aspect, in one possible implementation of the second aspect, the judgment module includes: a parameter submodule for real-time monitoring of key parameters of furnace smelting; and a judgment submodule for determining, based on the key parameters, whether an interruption has occurred and the corresponding interruption type; wherein the key parameters include: electron gun emission current, electron gun high voltage stability, smelting vacuum degree, and gaps in the ingot shrinkage within the crystallizer.

[0013] In conjunction with the second aspect, in one possible implementation of the second aspect, the first adjustment module includes: a current increasing submodule, used to increase the current of the electron gun in the primary refining cold hearth melting zone and the electron gun in the refining cold hearth melting zone respectively; and a current adjusting submodule, used to adjust the current of the electron gun in the primary refining cold hearth melting zone and the electron gun in the refining cold hearth melting zone again based on the vacuum degree of the EB furnace.

[0014] In conjunction with the second aspect, in one possible implementation of the second aspect, the second adjustment module includes: a gap determination submodule, used to determine the gap of ingot shrinkage based on a first image of the refining cold hearth melting zone captured by a camera and a second image of the crystallization zone captured by a camera; and a current determination submodule, used to preheat the first part of the electron gun with the initial current based on the correspondence between the gap and the initial current and the target current, and gradually increase the current of the first part of the electron gun to the target current.

[0015] In conjunction with the second aspect, in one possible implementation of the second aspect, the third adjustment module includes: a linear adjustment submodule, used to linearly reduce the current of the second part of the electron gun to a melting state within a preset time.

[0016] The technical solution of this invention has the following advantages: This invention provides a method and system for ingot receiving during EB furnace melting interruptions. The method includes: monitoring the EB furnace melting process to determine if melting has been interrupted; increasing the current of the remaining second electron guns in response to an interruption in the first part of the EB furnace's crystallization zone; increasing the current of the first part of the electron guns based on images captured by a camera in response to troubleshooting the first part of the electron guns; monitoring the ingot receiving status in real time; and adjusting the current of the second part of the electron guns to the melting state in response to ingot receiving completion. In this process, by monitoring the EB furnace melting process, increasing the current of the second part of the electron guns when the first part of the electron guns is interrupted ensures the ingot temperature and the vacuum level of the EB furnace. After troubleshooting, the currents of the first and second part of the electron guns are adjusted respectively to restore the EB furnace melting process, thereby improving the ingot receiving success rate while ensuring product quality and reducing material waste. Attached Figure Description

[0017] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0018] Figure 1This is a schematic diagram of an EB furnace melting structure provided according to an embodiment of the present invention; Figure 2 This is a schematic flowchart of an EB furnace melting interruption ingot receiving method provided by an embodiment of the present invention. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] According to an embodiment of the present invention, an embodiment of an interrupted ingot receiving method for EB furnace melting is provided. It should be noted that the steps shown in the flowchart in the accompanying drawings can be executed in a computer system such as a set of computer-executable instructions. Furthermore, although a logical order is shown in the flowchart, in some cases, the steps shown or described may be executed in a different order than that shown here.

[0021] This embodiment provides a schematic diagram of an EB furnace, as shown below. Figure 1 As shown, the EB furnace includes a primary cold hearth melting zone, a refining cold hearth melting zone, and a crystallization zone. The refining cold hearth melting zone is connected to both the primary cold hearth melting zone and the crystallization zone. The primary cold hearth melting zone melts granular metal, the refining cold hearth melting zone removes impurities, and the crystallization zone produces ingots. In the illustration, one electron gun is located in the primary cold hearth melting zone, two electron guns are located in the refining cold hearth melting zone, and one electron gun is located in the crystallization zone. The electron gun located in the crystallization zone is the one at the overflow port in the illustration, corresponding to the first part of the electron guns in the subsequent steps. The remaining electron guns correspond to the second part of the electron guns in the subsequent steps. Multiple cameras are deployed in the primary smelting zone, the refining smelting zone, and the crystallization zone. By illuminating the refining smelting zone, the crystallization zone, and the crystallization zone, it is possible to detect whether there are gaps between the remaining melt in the EB furnace and the inner wall of the crystallizer after cooling and contraction. It should be understood that during normal casting, the metal is in a liquid state under the heating of the first electron gun. However, if the first electron gun malfunctions, the metal temperature will drop, forming a solid state, thus reducing its volume and creating gaps between it and the inner wall of the crystallizer. The ingot can be, for example, a titanium ingot or other metal ingot.

[0022] This embodiment provides a method for interrupting ingot feeding during EB furnace melting, such as... Figure 2 As shown, the method includes the following steps: S101. Monitor the smelting process in the EB furnace and determine whether the smelting process has been interrupted.

[0023] S102. In response to the interruption of the first part of the electron gun in the crystallization zone of the EB furnace, the current of the remaining second part of the electron gun is increased.

[0024] S103. In response to the first part of the electron gun malfunction being resolved, the current of the first part of the electron gun is increased based on the image captured by the camera.

[0025] S104. Real-time monitoring of ingot receiving status.

[0026] Specifically, real-time monitoring of ingot receiving refers to monitoring the ingot receiving process in real time to detect whether a melting interruption occurs, and repeating steps S101 to S103 if an interruption occurs. Real-time monitoring of the ingot receiving process can be achieved through image observation using a camera with strobe function, or through ultrasonic testing to confirm the presence of defects such as shrinkage cavities.

[0027] S105. In response to the completion of ingot casting and receiving, adjust the current of the second part of the electron gun to the melting state.

[0028] This invention provides a method and system for ingot receiving during EB furnace melting interruptions. The method includes: monitoring the EB furnace melting process to determine if melting has been interrupted; increasing the current of the remaining second electron guns in response to an interruption in the first part of the EB furnace's crystallization zone; increasing the current of the first part of the electron guns based on images captured by a camera in response to troubleshooting the first part of the electron guns; monitoring the ingot receiving status in real time; and adjusting the current of the second part of the electron guns to the melting state in response to ingot receiving completion. In this process, by monitoring the EB furnace melting process, increasing the current of the second part of the electron guns when the first part of the electron guns is interrupted ensures the ingot temperature and the vacuum level of the EB furnace. After troubleshooting, the currents of the first and second part of the electron guns are adjusted respectively to restore the EB furnace melting process, thereby improving the ingot receiving success rate while ensuring product quality and reducing material waste.

[0029] In one optional implementation, monitoring the EB furnace melting process and determining whether the melting process has been interrupted includes: Real-time monitoring of key parameters in the furnace smelting process; based on these key parameters, determination of whether an interruption has occurred and the corresponding interruption type; wherein, the key parameters include: electron gun emission current, electron gun high voltage stability, smelting vacuum degree, and gaps caused by ingot shrinkage in the crystallizer.

[0030] Specifically, determining whether an interruption has occurred based on key parameters means judging whether the corresponding key parameters are within the preset range based on the preset range of each key parameter. For example, judging whether the electron gun is in normal working condition based on the electron gun emission current and the high voltage stability of the electron gun, or whether the vacuum degree in the EB furnace during the melting process meets the preset range, such as less than 0.4 Pa.

[0031] In one alternative implementation, increasing the current of the remaining second portion of the electron gun includes: The current of the electron gun in the primary cold hearth melting zone and the electron gun in the refining cold hearth melting zone are increased respectively. Based on the vacuum level of the EB furnace, the current of the electron gun in the primary cold hearth melting zone and the electron gun in the refining cold hearth melting zone are adjusted again to maintain the vacuum level in the EB furnace within a preset range.

[0032] Specifically, increasing the current of the electron guns in the primary and refining cold hearth melting zones is to maintain the temperature of the remaining melt in the EB furnace, preventing it from solidifying due to temperature drop and causing contraction, thus creating a heat preservation process. Typically, the current of the electron guns in the primary and refining cold hearth melting zones is increased for 20-30 minutes, which can be set according to actual operating conditions; this embodiment does not impose a specific limitation on this.

[0033] Specifically, adjusting the current of the electron guns in the primary smelting zone and the refining smelting zone based on the vacuum level of the EB furnace means that during the heat preservation process, it is necessary to ensure that the vacuum level inside the EB furnace is below a preset threshold. Typically, the preset threshold for vacuum is 0.4 Pa, but this can be set according to actual operating conditions; this embodiment does not impose a specific limitation on it. Therefore, it is necessary to increase the current of the electron guns in the primary smelting zone and the refining smelting zone respectively to maintain the vacuum level inside the furnace within the preset range.

[0034] In one alternative implementation, increasing the current of the first portion of the electron gun based on the image captured by the camera includes: Based on the first image of the refining cold hearth melting zone captured by the camera and the second image of the crystallization zone captured by the camera, the gap of ingot shrinkage is determined; based on the correspondence between the gap and the initial current and the target current, the first part of the electron gun is preheated with the initial current, and the current of the first part of the electron gun is gradually increased to the target current.

[0035] Specifically, determining the gap in the ingot shrinkage based on the first image of the refining cold hearth melting zone and the second image of the crystallization zone captured by the camera means that by deploying cameras that illuminate the refining cold hearth melting zone and the crystallization zone, as well as the crystallization zone, and comparing the first and second images, it can be known whether there is a gap between the remaining melt in the EB furnace and the inner wall of the crystallizer after shrinkage.

[0036] Specifically, the relationship between the gap and the initial current and the target current means that the larger the gap, the higher the initial current. The target current refers to the working current in the melting state. The process from the initial current to the target current is a slow rise, thereby achieving the preheating of the first part of the electron gun. This also avoids situations where the melt in the EB furnace melts from the solid to the liquid state due to excessively rapid heating, and then flows back from places such as the overflow port at the workstation.

[0037] In one alternative implementation, adjusting the current of the second electron gun to a melting state includes: linearly reducing the current of the second electron gun to a melting state within a preset time period.

[0038] Specifically, the preset time is usually 10-20 minutes, which allows the current in the second electron gun to gradually decrease, preventing damage to the second electron gun, etc. This embodiment provides an interrupted ingot receiving system for EB furnace smelting, the system including the following modules: The judgment module is used to monitor the EB furnace melting process and determine whether the melting has been interrupted. For details, please refer to the description of step S101 in the above embodiments, which will not be repeated here.

[0039] The first adjustment module is used to increase the current of the remaining second electron guns in response to an interruption in the first part of the crystallization zone of the EB furnace. For details, please refer to the description of step S102 in the above embodiments, which will not be repeated here.

[0040] The second adjustment module is used to increase the current of the first electron gun based on the image captured by the camera in response to the first electron gun malfunction being resolved. For details, please refer to the description of step S103 in the above embodiments, which will not be repeated here.

[0041] The monitoring module is used to monitor the ingot receiving process in real time. For details, please refer to the description of step S104 in the above embodiments, which will not be repeated here.

[0042] The third adjustment module is used to adjust the current of the second part of the electron gun to the melting state in response to the completion of ingot casting and receiving. For details, please refer to the relevant description of step S105 in the above embodiments, which will not be repeated here.

[0043] In one optional implementation, the determination module includes: The parameter submodule is used to monitor key parameters of the furnace smelting process in real time; the judgment submodule is used to determine whether an interruption has occurred and the corresponding interruption type based on the key parameters; wherein, the key parameters include: electron gun emission current, electron gun high voltage stability, smelting vacuum degree, and the gap of ingot shrinkage in the crystallizer. For specific details, please refer to the relevant descriptions in the above embodiments, which will not be repeated here.

[0044] In one optional implementation, the first adjustment module includes: The current enhancement submodule is used to increase the current of the electron gun in the primary refining cold hearth melting zone and the electron gun in the refining cold hearth melting zone, respectively. The current adjustment submodule is used to adjust the current of the electron gun in the primary refining cold hearth melting zone and the electron gun in the refining cold hearth melting zone based on the vacuum level of the EB furnace. For details, please refer to the relevant descriptions in the above embodiments, which will not be repeated here.

[0045] In one optional implementation, the second adjustment module includes: The gap determination submodule is used to determine the gap of ingot shrinkage based on a first image of the refining cold hearth melting zone captured by a camera and a second image of the crystallization zone captured by a camera. The current determination submodule is used to preheat the first part of the electron gun with the initial current based on the correspondence between the gap and the initial current and the target current, and gradually increase the current of the first part of the electron gun to the target current. For details, please refer to the relevant description in the above embodiments, which will not be repeated here.

[0046] In one optional implementation, the third adjustment module includes a linear adjustment submodule, used to linearly reduce the current of the second electron gun to a melting state within a preset time. For details, please refer to the relevant descriptions in the above embodiments, which will not be repeated here.

[0047] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A method for interrupting ingot feeding during EB furnace melting, characterized in that, The method includes: Monitor the EB furnace melting process to determine if the melting of multiple electron guns has been interrupted; In response to an interruption of a first portion of the electron guns in the crystallization zone of the EB furnace, the current of the remaining second portion of the electron guns is increased, wherein the number of the first portion of the electron guns is greater than or equal to 1 and less than the total number of electron guns. In response to the first part of the electron gun malfunctioning, the current of the first part of the electron gun is increased based on the image captured by the camera; Real-time monitoring of ingot receiving status; In response to the completion of ingot casting and receiving, the current of the second part of the electron gun is adjusted to the melting state.

2. The method according to claim 1, characterized in that, The monitoring of the EB furnace smelting process to determine whether smelting has been interrupted includes: Real-time monitoring of key parameters in the furnace smelting process; Based on the aforementioned key parameters, determine whether an interrupt has occurred and the corresponding interrupt type; The key parameters include: electron gun emission current, electron gun high voltage stability, melting vacuum degree, and the gap of ingot shrinkage in the crystallizer.

3. The method according to claim 1, characterized in that, The method of increasing the current of the remaining second part of the electron gun includes: Increase the current of the electron gun in the primary refining cold bed smelting zone and the electron gun in the refining cold bed smelting zone, respectively; Based on the vacuum level of the EB furnace, the current of the electron gun in the primary smelting cold bed melting zone and the electron gun in the refining cold bed melting zone is adjusted again to maintain the vacuum level in the EB furnace within the preset range.

4. The method according to claim 1, characterized in that, The method of increasing the current of the first part of the electron gun based on the image captured by the camera includes: Based on the first image of the refining cold bed smelting zone captured by the camera and the second image of the crystallization zone captured by the camera, the gap of ingot cold shrinkage is determined. Based on the correspondence between the gap and the initial current and the target current, the first part of the electron gun is preheated with the initial current, and the current of the first part of the electron gun is gradually increased to the target current.

5. The method according to claim 1, characterized in that, Adjusting the current of the second electron gun to a melting state includes: linearly reducing the current of the second electron gun to a melting state within a preset time.

6. An interrupted ingot receiving system for EB furnace smelting, characterized in that, The system includes: The judgment module is used to monitor the EB furnace melting process and determine whether the melting has been interrupted. The first adjustment module is used to increase the current of the remaining second electron guns in response to an interruption of the first part of the electron guns in the crystallization zone of the EB furnace. The second adjustment module is used to increase the current of the first part of the electron gun based on the image captured by the camera in response to the first part of the electron gun being troubleshooted. The monitoring module is used to monitor the ingot receiving process in real time. The third adjustment module is used to adjust the current of the second part of the electron gun to the melting state in response to the completion of ingot casting and receiving.

7. The system according to claim 6, characterized in that, The judgment module includes: The parameter submodule is used for real-time monitoring of key parameters in the furnace smelting process; The judgment submodule is used to determine whether an interrupt has occurred and the corresponding interrupt type based on the key parameters. The key parameters include: electron gun emission current, electron gun high voltage stability, melting vacuum degree, and the gap of ingot shrinkage in the crystallizer.

8. The system according to claim 6, characterized in that, The first adjustment module includes: The current enhancement submodule is used to increase the current of the electron gun in the primary refining cold hearth smelting zone and the electron gun in the refining cold hearth smelting zone, respectively. The current adjustment submodule is used to readjust the current of the electron gun in the primary refining cold hearth melting zone and the electron gun in the refining cold hearth melting zone based on the vacuum level of the EB furnace.

9. The system according to claim 6, characterized in that, The second adjustment module includes: The gap determination submodule is used to determine the gap of ingot shrinkage based on the first image of the refining cold bed smelting zone captured by the camera and the second image of the crystallization zone captured by the camera. The current determination submodule is used to preheat the first part of the electron gun with the initial current based on the correspondence between the gap and the initial current and the target current, and to gradually increase the current of the first part of the electron gun to the target current.

10. The system according to claim 6, characterized in that, The third adjustment module includes a linear adjustment submodule, used to linearly reduce the current of the second part of the electron gun to a melting state within a preset time.

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