Gas-liquid ratio real-time feedback and control system for gas atomization device

Abstract

The utility model relates to a gas-liquid ratio real-time feedback and control system for a gas atomization device, which is used in a tilting pouring type gas atomization device and comprises a controller, and a melt monitoring module, a gas monitoring module, a gas adjusting module and / or a smelting crucible tilting adjusting module which are connected with the controller, the melt monitoring module comprises an angle displacement sensor and a distance sensor; the gas monitoring module comprises a gas flow sensor connected to an atomized gas pipeline; the gas adjusting module is used for adjusting the pressure and flow of atomized gas, and the smelting crucible tilting adjusting module is used for controlling the tilting angle speed of the pouring driving system. According to the utility model, the states of the pouring melt and the atomized gas are monitored in real time, and equipment abnormity can be automatically found and prompted or automatic feedback adjustment can be carried out, so that the gas-liquid ratio is monitored and adjusted in real time, the quality and the efficiency of gas atomization powder preparation are improved, and meanwhile, the process stability is effectively ensured.

Description

Technical Field

[0001] The utility model relates to the technical field of gas atomization powder making, in particular to a real-time feedback and control system for gas-liquid ratio of a gas atomization device. Background Technique

[0002] The gas-liquid ratio is an important parameter in the gas atomization powder making process, which refers to the volume or mass ratio of gas to liquid during the powder making process. This ratio is usually expressed as V g / V l or m g / m l where V g is the volume of gas, V l is the volume of liquid, m g is the mass of gas, and m l is the mass of liquid. In the electrode induction gas atomization powder making process, the selection of the gas-liquid ratio directly affects the quality of the powder and the efficiency of the process.

[0003] In gas atomization powder making, gas is usually used to atomize liquid raw materials into tiny particles to form powder. The selection of the gas-liquid ratio directly affects the atomization effect, and thus affects the particle size distribution, morphology and uniformity of the powder. An appropriate gas-liquid ratio can ensure that the alloy melt is fully atomized, so as to obtain powder with uniform particle size and good morphology. An excessively high gas-liquid ratio may lead to over-atomization, generating too many fine particles, while an excessively low gas-liquid ratio may lead to insufficient atomization, affecting the quality of the powder. At the same time, the selection of the gas-liquid ratio also directly affects the efficiency of the entire gas atomization powder making process.

[0004] Therefore, the gas-liquid ratio plays a crucial role in the gas atomization powder making process. It not only relates to the quality and stability of the powder, but also directly affects the efficiency and cost of the entire process. In the design and production process of the gas atomization powder making process, it is crucial to reasonably select and control the gas-liquid ratio.

[0005] Currently, in the gas atomization powder making process, a flowmeter is often used to monitor the gas flow rate, and the output signal is the gas volume flow rate signal. The influence of gas temperature on volume is not considered, and there is little monitoring of the melt mass flow rate, so the real-time monitoring and adjustment of the gas-liquid ratio cannot be realized. Content of the Utility Model

[0006] The purpose of the utility model is to provide a real-time feedback and control system for gas-liquid ratio of a gas atomization device, which can solve the technical problems mentioned in the above background technique.

[0007] To achieve the above object, the present utility model provides the following technical solutions: A real-time feedback and control system for the gas-liquid ratio of an air atomization device, characterized in that it is used in a tilting pouring type air atomization device, and includes a controller and a melt monitoring module, a gas monitoring module, a gas regulating module and / or a melting crucible tilting regulating module connected to the controller: The melt monitoring module includes an angular displacement sensor and a distance sensor. The angular displacement sensor is used to monitor the tilting angle of the melting crucible, and the distance sensor is used to monitor the liquid level height of the melt in the heat preservation crucible; The gas monitoring module includes a gas flow sensor connected to the atomizing gas pipeline; The gas regulating module is used to adjust the pressure and flow rate of the atomizing gas, and the melting crucible tilting regulating module is used to control the tilting angular velocity of the pouring drive system.

[0008] In a preferred embodiment, the gas monitoring module further includes a gas temperature sensor connected to the atomizing gas pipeline, and the gas temperature sensor is used to monitor the temperature of the atomizing gas.

[0009] In a preferred embodiment, the gas regulating module is connected to the gas pipeline and is arranged at the front end of the gas flow sensor and the gas temperature sensor.

[0010] In a preferred embodiment, the gas regulating module adopts an electric or pneumatic proportional valve, which can precisely control the flow rate and pressure of the gas.

[0011] In a preferred embodiment, the distance sensor adopts a vision sensor or a laser / ultrasonic rangefinder.

[0012] In a preferred embodiment, the real-time feedback and control system for the gas-liquid ratio further includes an alarm connected to the controller, which is used to give an alarm prompt in case of abnormal conditions.

[0013] In a preferred embodiment, the alarm adopts an audible alarm device and / or a visual alarm device.

[0014] On the other hand, the present utility model also provides a technical solution for a tilting pouring type air atomization device, including the real-time feedback and control system for the gas-liquid ratio described in any of the above solutions.

[0015] Compared with the prior art, the beneficial effects of the present utility model are as follows: The real-time feedback and control system for the gas-liquid ratio of the gas atomization device provided by the present utility model can monitor the states of the casting melt and the atomization gas in real time by setting a controller and connected melt monitoring module, gas monitoring module, and adjustment module, and can display the gas-liquid ratio parameters in real time. By comparing the real-time gas-liquid ratio parameters with the set gas-liquid ratio parameters, it can automatically detect and prompt equipment abnormalities or perform automatic feedback adjustment to achieve real-time monitoring and adjustment of the gas-liquid ratio, improve the quality and efficiency of gas atomization powder making, and effectively ensure process stability at the same time. Description of the Drawings

[0016] Figure 1 It is a schematic diagram of the real-time feedback and control system for the gas-liquid ratio of the gas atomization device in the embodiment of the present utility model.

[0017] The meanings of each label in the figure are as follows:

[0018] 1. Angular displacement sensor; 2. Distance sensor; 3. Gas flow sensor; 4. Gas temperature sensor; 5. Gas adjustment module; 6. Melting crucible; 7. Heat preservation crucible; 8. Gas pipeline. Specific Embodiments

[0019] Next, the technical solutions in the embodiments of the present utility model will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present utility model. Obviously, the described embodiments are only a part of the embodiments of the present utility model, rather than all the embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present utility model.

[0020] In the description of the present utility model, it should be understood that the orientation or positional relationships indicated by the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. are based on the orientation or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present utility model and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation to the present utility model.

[0021] See Figure 1, this embodiment discloses a real-time feedback and control system for the gas-liquid ratio of an air atomization device, which is mainly used in a tilting-pouring type air atomization device. The tilting-pouring type is the most widely used pouring method in the current vacuum / non-vacuum air atomization powder-making process. The main working process is to place metal or alloy raw materials in the melting crucible 6, and use induction heating or other heating methods to melt the raw materials and form a liquid metal or alloy melt. Then, the melting crucible 6 is tilted to pour the alloy liquid into the heat-insulating crucible 7, and the alloy melt enters the atomization zone through the diversion hole at the bottom of the heat-insulating crucible 7, and is impacted and broken by the high-pressure and high-speed gas ejected from the atomization nozzle to form fine metal droplets. The fine metal droplets are cooled and solidified inside the device to form spherical or quasi-spherical powders.

[0022] In this embodiment, the real-time feedback and control system for the gas-liquid ratio includes a controller and a melt monitoring module, a gas monitoring module, a gas regulation module 5, and a tilting adjustment module of the melting crucible connected to the controller. The melt monitoring module is used to monitor the state of the liquid melt in the melting crucible 6 and the heat-insulating crucible 7, and feed the monitoring data back to the controller. The gas monitoring module is used to monitor the state of the gas in the atomizing gas pipeline 8, and feed the monitoring data back to the controller. The controller is used to receive the data fed back by the melt monitoring module and the gas monitoring module, calculate the gas-liquid ratio, and compare the calculated gas-liquid ratio value with the set gas-liquid ratio parameter value, and control the gas regulation module 5 or the tilting adjustment module of the melting crucible to make adaptive adjustments according to the comparison results.

[0023] Specifically, the melt monitoring module includes an angular displacement sensor 1 connected to the melting crucible 6 and a distance sensor 2 connected to the heat-insulating crucible 7. Among them, the angular displacement sensor 1 is used to monitor the tilting angle of the melting crucible 6 in real time and feed the tilting angle signal back to the controller. The angular displacement sensor 1 can be installed in a contact or non-contact manner. Exemplarily, it can be installed on the tilting axis of the melting crucible 6 or on the outer shell of the air atomization device. The distance sensor 2 is installed on the inner wall of the outer shell of the air atomization device, corresponding to the top position of the heat-insulating crucible 7, and is used to monitor the liquid level height of the melt in the heat-insulating crucible 7. Exemplarily, the distance sensor 2 can adopt a vision sensor or a distance detection device such as a laser / ultrasonic rangefinder. When a vision sensor is used, the vision sensor can obtain the melt image in the heat-insulating crucible 7 in real time and feed the melt image information back to the controller. The controller calculates the liquid level height of the melt in the heat-insulating crucible 7 through calculation. The calculation method can adopt calculating the distance through different imaging angles. When a laser / ultrasonic rangefinder is used, it can directly feed the measured distance information back to the controller.

[0024] Exemplarily, the mass flow rate of the metal melt can be obtained by differential processing of the signal of the angular displacement sensor 1. The mass of the melt in the crucible can be obtained by corresponding calculations based on the signal of the angular displacement sensor 1. The calculation process is as follows:

[0025] Let the diameter of the melting crucible 6 be d and its internal depth be h. In the initial state, it is in a vertical state. When tilted to a certain angle, the atomization operation starts. When the time is t1, the tilt angle of the melting crucible 6 is α. At this time, the volume of the alloy melt in the melting crucible 6 is V = πd 2 (d * tanα) / 8 + πd 2 (h - d * tanα) / 4. The density of the alloy melt is ρ. Then, the mass of the alloy melt in the melting crucible 6 at this time is m1 = ρπd 2 (d * tanα) / 8 + ρπd 2 (h - d * tanα) / 4. Let the diameter of the heat - preservation crucible 7 be d1. Assuming that at time t1, the liquid - level height of the alloy melt in the heat - preservation crucible 7 is h3, then the mass of the alloy melt m2 in the heat - preservation crucible 7 is m2 = ρπd1 2 h3 / 4; where the angle α can be obtained in real - time through the angle displacement sensor 1, and h3 can be obtained in real - time through the distance sensor 2. By the above calculations, the mass change of the alloy melt in the melting crucible 6 and the heat - preservation crucible 7 is obtained. The mass flow rate of the alloy melt can be obtained by the difference method, that is, m l = dm / dt.

[0026] The gas monitoring module includes a gas flow sensor 3 and a gas temperature sensor 4 respectively connected to the gas pipeline 8. The gas flow sensor 3 is used to monitor the volume flow rate of the atomizing gas and feedback the volume flow rate data of the atomizing gas to the controller. The gas temperature sensor 4 is used to monitor the temperature of the atomizing gas and feedback the temperature data of the gas to the controller.

[0027] Exemplarily, during the powder - making process, assuming that the parameter transmitted by the gas flow sensor 3 to the controller is Q1 and the parameter transmitted by the gas temperature sensor 4 to the controller is T1. According to the gas state equation P1*V1 / T1 = P2*V2 / T2, the volume flow rate Q2 of the gas under standard conditions is deduced as: Q2 = Q1*T1 / T2. Then the gas mass flow rate m g = ρ*Q2, where ρ is the gas density under standard conditions and T2 is the standard gas temperature.

[0028] The gas regulation module 5 is connected to the gas pipeline 8 and is arranged at the front end of the gas flow sensor 3 and the gas temperature sensor 4. That is, the atomizing gas first passes through the gas regulation module 5 for flow regulation, and then passes through the gas flow sensor 3 and the gas temperature sensor 4 for volume flow rate and temperature detection. The gas regulation module 5 is used to regulate the pressure and flow rate of the atomizing gas. Regulation devices such as proportional valves and ball valves can be used. In practical applications, in order to ensure the accurate calculation of the gas - liquid ratio, an electric or pneumatic proportional valve capable of high - precision control of the gas flow rate and pressure is preferably used.

[0029] The tilting adjustment module of the melting crucible is connected to the pouring drive system of the melting crucible 6, and a hydraulic or electric proportional adjustment device can be used, such as an electro-hydraulic proportional control valve. The controller can control the tilting angular velocity of the pouring drive system by outputting an adjustment signal to the hydraulic or electric proportional adjustment device, thereby increasing or decreasing the mass flow rate of the melt.

[0030] The cooperation between the gas adjustment module 5 and the gas pipeline 8, as well as the cooperation between the tilting adjustment module of the melting crucible and the pouring drive system, all belong to the prior art, and the principle thereof will not be elaborated herein.

[0031] Preferably, in this embodiment, the gas-liquid ratio real-time feedback and control system further includes an alarm, and the alarm can adopt a sound or light alarm device, or a sound and light alarm device, which is connected to the controller and is used for alarm prompts in abnormal situations.

[0032] The controller adopts a PLC control system with a display interface, which can set the gas-liquid ratio parameters, gas parameters, and melt parameters on the display interface, and can output control signals for the gas adjustment module 5, the tilting adjustment module of the melting crucible, and the alarm. By setting the controller, automatic monitoring and adjustment of the gas-liquid ratio can be achieved. While achieving automatic and precise control, it can also avoid the safety hazards brought by on-site personnel control.

[0033] Specifically, the controller includes two processing processes: data reception and processing, and feedback adjustment and processing:

[0034] The content of data reception and processing includes:

[0035] 1. Setting parameter verification: The gas-liquid ratio set value, set gas parameters, and melt parameters are set in advance. The controller calculates the set gas parameters and melt parameters to obtain the calculated gas-liquid ratio value, and compares this calculated value with the gas-liquid ratio set value. If the gas-liquid ratio set value is inconsistent with the calculated value based on the set gas and melt parameters, the controller outputs a prompt or signal and displays it on the display interface, indicating that the parameter setting is incorrect, and prompting the operator to reset appropriate parameters;

[0036] 2. Calculating the actual gas mass flow rate;

[0037] 3. Calculating the actual melt mass flow rate;

[0038] 4. Calculating the real-time gas-liquid ratio parameter: The real-time gas-liquid ratio parameter can be calculated by m g / m l and can be transmitted through a signal to the display interface and storage hardware of the controller for reference by process personnel;

[0039] The content of the feedback adjustment and processing of the controller includes:

[0040] 1. Comparison between real-time gas-liquid ratio and set gas-liquid ratio parameter: The set gas-liquid ratio parameter and the allowable deviation are set by the process personnel in advance on the display interface of the controller. The controller compares the data by taking the difference or ratio between the real-time gas-liquid ratio signal and the set gas-liquid ratio signal. When within the allowable deviation range, the controller does not perform control operations;

[0041] 2. When the real-time gas-liquid ratio parameter and the set gas-liquid ratio parameter are outside the allowable deviation range, adjustment can be carried out through the following two implementation methods:

[0042] In one implementation method, the controller outputs a signal to output an adjustment signal to the gas adjustment module 5 of the gas pipeline 8 or the tilting adjustment module of the melting crucible of the pouring system to adjust the gas flow rate or the melt flow rate to make the real-time gas-liquid ratio parameter appropriate.

[0043] In another more precise implementation method:

[0044] 2.1 The controller first compares the real-time mass flow rate of the gas and the set gas flow rate. If outside the allowable deviation range, the controller outputs a signal to output an adjustment signal to the proportional valve of the gas pipeline 8; if within the allowable deviation range, the controller continues to compare the real-time mass flow rate of the melt and the set mass flow rate;

[0045] 2.2 The controller compares the real-time mass flow rate of the melt and the set mass flow rate. If within the allowable deviation range, it gives a prompt through the alarm and prompts the operator on the display interface of the controller that the parameter setting is unreasonable or the device is abnormal, and inspection or shutdown treatment is required; if outside the allowable deviation range, the controller outputs a signal to output an adjustment signal to the proportional valve of the pouring system to increase or decrease the tilting angular velocity of the pouring drive system, thereby increasing or decreasing the mass flow rate of the melt.

[0046] The real-time feedback and control system for gas-liquid ratio provided in this embodiment for the gas atomization device can monitor the states of the pouring melt and the atomizing gas in real time, and display the gas-liquid ratio parameter in real time. By comparing the real-time gas-liquid ratio parameter and the set gas-liquid ratio parameter, it can automatically detect and prompt equipment abnormalities or perform automatic feedback adjustment to achieve real-time monitoring and adjustment of the gas-liquid ratio, improve the quality and efficiency of gas atomization powder making, and effectively ensure process stability at the same time.

[0047] The above has shown and described the basic principles, main features and advantages of the present utility model. Those skilled in the art should understand that the present utility model is not limited by the above embodiments. The above embodiments and the descriptions in the specification are only preferred examples of the present utility model and are not used to limit the present utility model. Without departing from the spirit and scope of the present utility model, the present utility model will have various changes and improvements, and these changes and improvements all fall within the scope of the present utility model claimed. The scope of protection claimed by the present utility model is defined by the appended claims and their equivalents.

Claims

1. A gas-liquid ratio real-time feedback and control system for an aerosolization device, characterized in that: Used in a tilting casting type gas atomization device, including a controller and: A melt monitoring module, comprising an angle displacement sensor (1) and a distance sensor (2), wherein the angle displacement sensor (1) is used to monitor the tilting angle of a melting crucible (6), and the distance sensor (2) is used to monitor the liquid level of the melt in a heat-insulating crucible (7); A gas monitoring module, comprising a gas flow sensor (3) connected to an atomizing gas pipeline (8); A gas regulating module (5) and / or a melting crucible tilt regulating module, wherein the gas regulating module (5) is used to regulate the pressure and flow of the atomizing gas, and the melting crucible tilt regulating module is used to control the tilting angular velocity of the pouring drive system.

2. The gas-liquid ratio real-time feedback and control system for a gas atomization device according to claim 1, characterized in that: The gas monitoring module also includes a gas temperature sensor (4) connected to the atomizing gas pipeline (8).

3. The gas-liquid ratio real-time feedback and control system for a gas atomization device according to claim 2, characterized in that: The gas regulating module (5) is connected to the gas pipeline (8) and is arranged at the front end of the gas flow sensor (3) and the gas temperature sensor (4).

4. The gas-liquid ratio real-time feedback and control system for a gas atomization device according to claim 1, characterized in that: The gas regulating module (5) adopts an electric or pneumatic proportional valve.

5. The gas-liquid ratio real-time feedback and control system for a gas atomization device according to claim 1, characterized in that: The distance sensor (2) is a visual sensor or a laser / ultrasonic rangefinder.

6. The gas-liquid ratio real-time feedback and control system for a gas atomization device according to claim 1, characterized in that: The gas-liquid ratio real-time feedback and control system also includes an alarm connected to the controller.

7. The gas-liquid ratio real-time feedback and control system for a gas atomization device according to claim 6, characterized in that: The alarm device adopts an acoustic alarm device and / or a light alarm device.

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