Online detection device for molten aluminum alloy

Abstract

The utility model relates to the technical field of quality detection, and discloses an aluminum alloy melt online detection device which comprises a supporting frame, a control system is arranged on one side of the supporting frame, the supporting frame comprises two supports arranged in parallel and a cross beam jointly connected between the tops of the two supports, and a furnace body is rotationally arranged between the two supports; a furnace nozzle is arranged at the trimming position of one side, parallel to the length direction of the cross beam, of the top of the furnace body, a heating element and a stirring rod which are electrically connected to a control system are arranged in the furnace body, a detection head is arranged at an opening, located in the top of the furnace body, of the supporting frame, and a transmission mechanism for driving the detection head to ascend and descend is arranged on the supporting frame; the bottom of the detection head is provided with a camera used for capturing an image of the surface condition of the aluminum alloy melt and a temperature sensor responsible for measuring the internal temperature of the melt, and the supporting frame is further provided with a cooling mechanism used for protecting the detection head from being damaged by high temperature. The method has the effect of improving the timeliness and accuracy of the quality detection result of the aluminum alloy melt.

Description

Technical Field

[0001] The present application relates to the technical field of quality inspection, and in particular to an online inspection device for aluminum alloy melt. Background Art

[0002] Aluminum alloy, an indispensable foundational material for modern industry, is widely used in fields such as aerospace and automotive manufacturing. The smelting process is not only a crucial component of aluminum product production but also a crucial step in determining the quality and performance of the finished product. With the advancement of Industry 4.0 and technological advancements, automation and intelligent manufacturing are becoming increasingly important trends in the manufacturing industry. However, despite the emergence of advanced testing equipment such as laser scanners, aluminum alloy quality inspection remains largely limited to finished or semi-finished products, leaving molten aluminum alloy quality monitoring technology relatively underdeveloped.

[0003] Existing methods for testing aluminum alloy melts primarily include manual sampling and offline instrument measurement. Manual sampling involves periodically extracting samples from the furnace and sending them to a laboratory for composition analysis and appearance inspection. While simple and easy to implement, this method lacks real-time monitoring, which can lead to unstable product quality. Offline instrument measurement involves installing specialized testing equipment next to the production line, measuring various indicators after the melt cools. While this method improves detection accuracy, it still suffers from lags and cannot promptly reflect changes in the melting process.

[0004] The above commonly used aluminum alloy melt detection methods generally have the problem of being unable to achieve real-time monitoring, which makes it difficult to detect and deal with possible product quality problems early during the entire smelting process, thereby affecting the qualification rate and stability of the final product. Utility Model Content

[0005] In order to improve the timeliness and accuracy of the quality detection results of aluminum alloy melt, the present application provides an online detection device for aluminum alloy melt.

[0006] The present application provides an online detection device for aluminum alloy melt using the following technical solutions:

[0007] An online detection device for aluminum alloy melt, comprising a support frame, a control system is provided on one side of the support frame, the support frame comprises two parallel brackets and a crossbeam connected between the tops of the two brackets, a furnace body is rotatably arranged between the two brackets, and a furnace nozzle is provided at a cut edge on one side of the top of the furnace body parallel to the length direction of the crossbeam, a heating element and a stirring rod electrically connected to the control system are provided in the furnace body, a detection head is provided at an opening on the support frame at the top of the furnace body, and a transmission mechanism for driving the detection head to rise and fall is provided on the support frame, a camera for capturing images of the surface condition of the aluminum alloy melt and a temperature sensor for measuring the internal temperature of the melt are provided at the bottom of the detection head, and a cooling mechanism for protecting the detection head from damage by high temperature is also provided on the support frame.

[0008] Using this technical solution, before testing begins, a transmission mechanism lowers the detection head until it reaches the surface of the melt. At this point, a camera, located 5 cm above the melt, begins operating and continuously records image data. Simultaneously, a temperature sensor, inserted 10 cm below the melt surface, measures the current melt temperature and transmits the value to the control system. The control system receives this data in real time and automatically determines whether it exceeds the permitted range based on preset standards. If any abnormality is detected, an alarm is immediately triggered on the control system, adjusting the heating element power and stirring rod speed. After testing is complete, the transmission mechanism raises the detection head and resets it. This online aluminum alloy melt inspection device monitors the quality of the melt in real time. The camera captures images of the melt surface and the temperature sensor measures the internal temperature, enabling real-time monitoring of the melt quality and improving the timeliness and accuracy of test results. A cooling mechanism on the support frame protects the detection head from high-temperature damage, ensuring stable operation of the device.

[0009] Optionally, a guide groove is opened on the crossbeam along its own length direction, and the transmission mechanism includes two driving blocks relatively slidingly arranged in the guide groove, a bidirectional cylinder connected between the two driving blocks, and a connecting rod hinged between the single driving block and the side wall of the detection head. The bidirectional cylinder is located in the guide groove and fixedly set on the inner wall of the guide groove. The detection head is located directly below the bidirectional cylinder, and the bottom ends of the two connecting rods are hinged on the opposite side walls of the detection head, and the top ends are hinged on the bottom wall of the corresponding driving block.

[0010] By adopting this technical solution, before testing begins, the control system precisely controls the bidirectional cylinder, causing the piston rods at both ends of the bidirectional cylinder to retract synchronously, allowing the two drive blocks to slide relative to each other. This, in turn, causes the connecting rod to move the test head downward, while the connecting rod drives the test head upward. This allows for precise positioning of the test head above the molten metal and stable lifting and lowering, ensuring that the test head can accurately capture images of the aluminum alloy melt's surface conditions and measure its internal temperature, improving the accuracy and reliability of the test results. Furthermore, the transmission mechanism ensures the smoothness and repeatability of the test head's lifting and lowering motion, further enhancing the device's practicality.

[0011] Optionally, the interior of the detection head is hollow, and the cooling mechanism includes a circulating liquid cooling component connected to the internal cavity of the detection head. The circulating liquid cooling component includes a cooling pump arranged on the crossbeam, and a cooling liquid pipe connecting the cooling pump and the detection head. The cooling liquid pipe passes through the chamber and is connected to the cooling pump to form a closed circulation cooling circuit.

[0012] By adopting the above technical solution, the coolant pipe passes through the chamber and is connected to the cooling pump to form a closed circulation cooling circuit, thereby effectively reducing the possibility of the detection head being damaged by high temperature, increasing the service life of the detection device, and ensuring its stable operation in a high temperature environment.

[0013] Optionally, the cooling mechanism further includes an air-cooled radiator, which is located directly above the detection head and is arranged on the bottom wall of the beam.

[0014] By adopting the above technical solution, an air-cooled radiator is added and set directly above the detection head and on the bottom wall of the beam, which can further enhance the cooling effect of the detection head and further improve the stability of the detection head in long-term operation in a high-temperature environment, thereby improving the reliability of the entire aluminum alloy melt online detection device.

[0015] Optionally, the coolant pipe adopts a high-temperature resistant, retractable universal bamboo tube, and the coolant pipe is arranged through a guide groove.

[0016] By adopting the above technical solution, the coolant pipe adopts a high-temperature resistant, retractable universal bamboo-joint pipe. Its "bamboo-joint structure" enhances the bending resistance and structural stability of the pipe, and also improves the stability and durability of the coolant pipe in high-temperature environments. At the same time, it also reduces the impact of the stretching of the coolant pipe on the movement of the drive block during the operation of the transmission mechanism, thereby effectively ensuring the cooling protection effect of the detection head and further improving the reliability of the entire detection device.

[0017] Optionally, grooves are provided on the opposite side walls of the two connecting rods, and the coolant pipes are inserted into the grooves and are plug-fitted with the grooves.

[0018] By adopting the above technical solution, the coolant pipe is inserted into the groove and plugged into the groove, which improves the stability of the coolant pipe during the movement of the connecting rod and reduces the possibility of poor cooling effect of the detection head due to shaking of the coolant pipe, thereby improving the reliability and cooling efficiency of the detection device.

[0019] Optionally, chamfers are provided at the corners of the driving block and the connecting rod for tightening the coolant pipe.

[0020] By adopting the above technical solution, the chamfer can reduce the friction between the coolant pipe and the drive block and connecting rod during movement, thereby reducing the risk of coolant pipe wear, extending the service life of the coolant pipe, and improving the stability of the cooling system operation.

[0021] Optionally, the surfaces of the driving block and the connecting rod are coated with a wear-resistant polytetrafluoroethylene coating.

[0022] By adopting the above technical solution, a wear-resistant polytetrafluoroethylene coating is applied to the surface of the drive block and the connecting rod, which can significantly improve the wear resistance of the drive block and the connecting rod, and enhance the stability of the coolant pipe during stretching and bending, thereby extending the service life of the coolant pipe and extending the maintenance cycle, thereby effectively improving the durability and reliability of the detection device.

[0023] In summary, this application includes at least one of the following beneficial technical effects:

[0024] 1. Before starting the inspection, the transmission mechanism drives the detection head to move downward until the detection head drops to near the surface of the melt. At this time, the camera is located at a height of 5 cm above the melt and starts working and continuously records image information. At the same time, the temperature sensor is plugged into the melt 10 cm below the liquid surface to measure the current melt temperature and transmit the value to the control system. The control system receives this data in real time and automatically determines whether it exceeds the allowable range based on the preset standard value. If there is an abnormality, it immediately triggers the alarm unit on the control system and adjusts the power of the heating element and the speed of the stirring rod. After the inspection is completed, the transmission mechanism lifts the detection head to reset. The online detection device for aluminum alloy melt can monitor the quality of aluminum alloy melt in real time, capture the surface condition image of aluminum alloy melt through the camera, and measure the internal temperature of the melt through the temperature sensor, thereby realizing real-time monitoring of the melt quality and improving the timeliness and accuracy of the detection results. In addition, the cooling mechanism on the support frame protects the detection head from damage by high temperature, ensuring the stable operation of the detection device;

[0025] 2. Before testing begins, the control system precisely controls the bidirectional cylinder, causing the piston rods at both ends of the bidirectional cylinder to retract synchronously, allowing the two drive blocks to slide relative to each other. This, in turn, causes the test head to move downward under the action of the connecting rod; conversely, it drives the test head upward, enabling precise positioning of the test head above the molten metal and stable lifting and lowering. This ensures that the test head can accurately capture images of the aluminum alloy melt's surface conditions and measure its internal temperature, improving the accuracy and reliability of the test results. Furthermore, the transmission mechanism ensures the smoothness and repeatability of the test head's lifting and lowering motion, further enhancing the device's practicality.

[0026] 3. The coolant pipe passes through the chamber and is connected to the cooling pump to form a closed circulation cooling circuit, which effectively reduces the possibility of the detection head being damaged by high temperature, increases the service life of the detection device, and ensures its stable operation in high temperature environments. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic diagram of the overall structure of an embodiment of the present application.

[0028] Figure 2 It is a cross-sectional view showing the internal structure of the furnace body in the embodiment of the present application.

[0029] Figure 3 It is a schematic diagram showing the positional relationship between the bidirectional cylinder, the drive block and the crossbeam in the embodiment of the present application.

[0030] Figure 4 It is a schematic diagram showing the positional relationship among the connecting rod, the driving block and the crossbeam in the embodiment of the present application.

[0031] Description of reference numerals:

[0032] 1. Support frame; 11. Bracket; 12. Crossbeam; 121. Guide groove; 2. Control system; 3. Furnace body; 31. Furnace nozzle; 4. Rotating assembly; 41. Rotating rod; 42. Brake motor; 5. Heating element; 6. Stirring assembly; 61. Stirring rod; 62. Rotating motor; 7. Detection head; 71. Camera; 72. Temperature sensor; 8. Transmission mechanism; 81. Drive block; 82. Bidirectional cylinder; 83. Connecting rod; 831. Groove; 9. Cooling mechanism; 91. Air-cooled radiator; 92. Circulating liquid cooling assembly; 921. Cooling pump; 922. Cooling liquid pipe. DETAILED DESCRIPTION

[0033] The following is combined with Figure 1-4 This application is described in further detail.

[0034] The embodiment of the present application discloses an online detection device for aluminum alloy melt.

[0035] Reference Figure 1 and Figure 2 An online detection device for aluminum alloy melt includes a support frame 1, a control system 2 is fixedly installed on one side of the support frame 1, the support frame 1 includes a bracket 11 and a crossbeam 12, two brackets 11 are arranged in parallel, the crossbeam 12 is located between the two brackets 11 and is fixedly connected to the top of the two brackets 11. A furnace body 3 is rotatably arranged between the two brackets 11, a furnace nozzle 31 is provided at a cut edge on one side of the top of the furnace body 3 parallel to the length direction of the crossbeam 12, and a rotating component 4 for driving the furnace body 3 to rotate is provided on the bracket 11. Annular heating elements 5 are fixedly distributed on the inner wall of the furnace body 3, and a stirring component 6 for stirring the aluminum alloy melt inside the furnace body 3 is rotatably provided inside the furnace body 3. A detection head 7 is provided at the opening on the top of the furnace body 3 on the support frame 1, and a camera 71 and a temperature sensor 72 are installed at the bottom of the detection head 7. A transmission mechanism 8 and a cooling mechanism 9 are also provided on the support frame 1.

[0036] Reference Figure 1 and Figure 2 Before testing begins, transmission mechanism 8 drives detection head 7 downward until it reaches the surface of the melt. Camera 71, located 5 cm above the melt, begins operating and continuously records image data. Simultaneously, temperature sensor 72, inserted 10 cm below the melt surface, measures the current melt temperature and transmits the value to control system 2. Control system 2 receives this data in real time and automatically determines whether it exceeds the allowable range based on preset standard values. If any abnormality is detected, the alarm unit on control system 2 is immediately triggered, adjusting the power of heating element 5 and the speed of stirring rod 61. After testing is complete, transmission mechanism 8 raises detection head 7 and resets it.

[0037] Reference Figure 1 The rotating assembly 4 includes a rotating rod 41 and a brake motor 42. The rotating rod 41 is coaxially fixed on the side walls on both sides of the furnace body 3 in an axially symmetrical manner with the furnace nozzle 31 as the center line. The end of the rotating rod 41 facing away from the furnace body 3 is rotatably set on the bracket 11, and the brake motor 42 is fixed on the side of the bracket 11 facing away from the furnace body 3, and the rotating bracket 11 is coaxially fixedly connected to one of the rotating rods 41.

[0038] Reference Figure 2 The heating element 5 can be a resistance wire, an infrared heater or other types of electric heating elements 5. The heating element 5 in this embodiment uses a resistance wire wrapped in a well-insulated heat-conducting plastic tube.

[0039] Reference Figure 2 The stirring assembly 6 includes a stirring rod 61 and a rotating motor 62. The stirring rod 61 is located inside the furnace body 3 and is coaxially arranged with the furnace body 3. The rotating motor 62 is fixedly arranged on the bottom wall of the furnace body 3. Its output shaft rotates through the bottom wall of the furnace body 3 and extends into the furnace body 3 to be coaxially fixedly connected with the stirring rod 61.

[0040] Reference Figure 2 、 Figure 3 and Figure 4 The crossbeam 12 has a guide groove 121 extending along its length. The transmission mechanism 8 includes a drive block 81, a bidirectional cylinder 82, and a connecting rod 83. The drive block 81 is slidingly limited within the guide groove 121, and there are two of them. The two drive blocks 81 are arranged to slide relative to each other. The bidirectional cylinder 82 is located between the two drive blocks 81 within the guide groove 121 and is fixedly mounted on the inner side wall of the guide groove 121. The piston rod of the bidirectional cylinder 82 extends and contracts in a direction parallel to the length of the guide groove 121 and is fixedly mounted on the side wall of the drive block 81. A connecting rod 83 is provided for each drive block 81, and a single connecting rod 83 is connected between the corresponding drive block 81 and the detection head 7. The detection head 7 is located directly below the bidirectional cylinder 82. The bottom ends of the two connecting rods 83 are hinged to the opposite side walls of the detection head 7, and their top ends are hinged to the bottom wall of the corresponding drive block 81.

[0041] Reference Figure 4 The camera 71 used in this embodiment is a CMOS high-definition industrial camera with good heat resistance; the temperature sensor 72 is a K-type thermocouple with a wide temperature measurement range and high accuracy.

[0042] Reference Figure 2 、 Figure 3 and Figure 4 The cooling mechanism 9 includes an air-cooled radiator 91 and a circulating liquid cooling assembly 92. The air-cooled radiator 91 is located directly above the detection head 7 and is fixedly mounted on the bottom wall of the crossbeam 12. The interior of the detection head 7 is hollow. The circulating liquid cooling assembly 92 includes a cooling pump 921 and a cooling liquid pipe 922. The cooling pump 921 is fixedly mounted on the top wall of the two-way cylinder 82 at the top of the crossbeam 12. The cooling liquid pipe 922 is made of a high-temperature resistant, retractable universal bamboo tube. The cooling liquid pipe 922 passes through the chamber and is connected to the cooling pump 921 to form a closed-loop cooling circuit. In this circuit, the cooling liquid pipe 922 passes through the guide groove 121 and is in conflict with the driving block 81 and the connecting rod 83.

[0043] Reference Figure 3 and Figure 4 To ensure smooth and stable coolant delivery during stretching and bending of the coolant tube 922, grooves 831 are defined on the opposing sidewalls of the two connecting rods 83. The coolant tubes 922 are inserted into and engage with the grooves 831. Furthermore, the corners of the drive block 81 and connecting rod 83 where the coolant tubes 922 are tensioned are chamfered and coated with a wear-resistant polytetrafluoroethylene.

[0044] Reference Figures 1 to 4 , all electrical components in this application are electrically connected to the control system 2.

[0045] The implementation principle of an online detection device for aluminum alloy melt in the embodiment of the present application is as follows: before starting the detection, the control system 2 controls the two-way cylinder 82 to operate precisely, so that the piston rods at both ends of the two-way cylinder 82 are synchronously retracted, causing the two drive blocks 81 to slide relative to each other. Under the action of the connecting rod 83, the detection head 7 moves downward until the detection head 7 is lowered to near the surface of the melt. At this time, the camera 71 is located at a height of 5 cm above the melt and begins to work and continuously records image information. At the same time, the temperature sensor 72 is inserted into the melt 10 cm below the liquid surface to measure the current melt temperature and transmit the value to the control system 2. The control system 2 receives this data in real time and automatically determines whether it exceeds the allowable range based on the preset standard value. If there is any abnormality, the alarm unit on the control system 2 is immediately triggered and the power of the heating element 5 and the speed of the stirring motor are adjusted. After the detection is completed, the two-way cylinder 82 drives the detection head 7 to reset.

[0046] The above are all preferred embodiments of the present application, and are not intended to limit the scope of protection of the present application. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the scope of protection of the present application.

Claims

1. An online detection device for aluminum alloy melt, characterized in that , comprising a support frame (1), a control system (2) being provided on one side of the support frame (1), the support frame (1) comprising two parallel brackets (11) and a crossbeam (12) connected between the tops of the two brackets (11), a furnace body (3) being rotatably provided between the two brackets (11), and a furnace nozzle (31) being provided at a cut edge on one side of the top of the furnace body (3) parallel to the length direction of the crossbeam (12), a heating element ( 5) and a stirring rod (61), a detection head (7) is provided on the support frame (1) at an opening at the top of the furnace body (3), and a transmission mechanism (8) is provided on the support frame (1) for driving the detection head (7) to rise and fall, a camera (71) for capturing an image of the surface condition of the aluminum alloy melt and a temperature sensor (72) for measuring the internal temperature of the melt are provided at the bottom of the detection head (7), and a cooling mechanism (9) is also provided on the support frame (1) for protecting the detection head (7) from damage due to high temperature.

2. The online detection device for aluminum alloy melt according to claim 1, characterized in that The crossbeam (12) is provided with a guide groove (121) along its length direction. The transmission mechanism (8) includes two driving blocks (81) relatively slidingly arranged in the guide groove (121), a bidirectional cylinder (82) connected between the two driving blocks (81), and a connecting rod (83) hinged between a single driving block (81) and a side wall of the detection head (7). The bidirectional cylinder (82) is located in the guide groove (121) and fixedly arranged on the inner side wall of the guide groove (121). The detection head (7) is located directly below the bidirectional cylinder (82), and the bottom ends of the two connecting rods (83) are hinged on the opposite side walls of the detection head (7), and the top ends are hinged on the bottom wall of the corresponding driving block (81).

3. The online detection device for aluminum alloy melt according to claim 2, characterized in that The interior of the detection head (7) is hollow, and the cooling mechanism (9) includes a circulating liquid cooling component (92) connected to the internal cavity of the detection head (7). The circulating liquid cooling component (92) includes a cooling pump (921) arranged on the crossbeam (12), and a cooling liquid pipe (922) connecting the cooling pump (921) and the detection head (7). The cooling liquid pipe (922) passes through the chamber and is connected to the cooling pump (921) to form a closed circulation cooling circuit.

4. The online detection device for aluminum alloy melt according to claim 3, characterized in that The cooling mechanism (9) further includes an air-cooled radiator (91), which is located directly above the detection head (7) and is arranged on the bottom wall of the crossbeam (12).

5. The online detection device for aluminum alloy melt according to claim 4, characterized in that The cooling liquid pipe (922) is made of a high-temperature resistant, retractable universal bamboo tube, and the cooling liquid pipe (922) is arranged through the guide groove (121).

6. The online detection device for aluminum alloy melt according to claim 5, characterized in that The two connecting rods (83) have side walls facing away from each other with grooves (831), and the coolant pipe (922) is inserted into the groove (831) and is plugged into and fitted with the groove (831).

7. The online detection device for aluminum alloy melt according to claim 6, characterized in that The corners of the driving block (81) and the connecting rod (83) for tightening the coolant pipe (922) are both chamfered.

8. The online detection device for aluminum alloy melt according to claim 7, characterized in that The surfaces of the driving block (81) and the connecting rod (83) are coated with a wear-resistant polytetrafluoroethylene coating.

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