Monitoring device for zero point deviation of aluminum alloy rotary furnace

Abstract

The utility model discloses a monitoring device for zero point deviation of an aluminum alloy rotary furnace, which comprises a first detection element, a second detection element, a trigger element, a control element and an alarm element, the second detection element and the first detection element are fixedly installed in the same circumferential direction of the rotary furnace body in a spaced mode, the distance between the second detection element and the first detection element in the circumferential direction is matched with the distance of a theoretical angle of zero point positioning of the rotary furnace, and the trigger element is fixed to a rotating component of the rotary furnace and rotates along with the rotating component. The effective trigger width of the trigger element is smaller than the distance between the first detection element and the second detection element, and the control element is connected with the alarm element. The zero-point positioning deviation warning device can immediately give an alarm for zero-point positioning deviation to warn workers to pause production for maintenance, so that a series of production accidents and economic losses caused by continuous production under the condition that deviation is not known are avoided.

Description

Technical Field

[0001] This utility model relates to the technical field of aluminum alloy heating and heat treatment equipment, specifically to a monitoring device for zero-point deviation of aluminum alloy rotary furnace. Background Technology

[0002] The rotation angle of existing aluminum alloy rotary kilns is typically controlled by a servo motor and relies on pulse signal programs to calculate the kiln angle. However, under long-term continuous rotation conditions, angular positioning errors are easily generated due to mechanical wear or signal accumulation. Therefore, zero-point calibration using sensors is required within a certain rotation range. Currently, zero-point positioning of such equipment generally uses a single sensor (such as a limit switch) as the calibration element, but this technical solution has a significant drawback: when the calibration sensor fails due to malfunction or its position deviates due to mechanical installation deviation, the rotation zero point of the aluminum alloy rotary kiln will experience positioning deviation, leading to inaccurate workpiece positioning reference. This may result in safety accidents such as collisions between the robot and the kiln body, kiln supports, or other workpieces when the robot is grasping the workpiece.

[0003] The core deficiency of existing technology lies in the fact that it relies solely on servo motors for zero-point calibration, lacking an independent monitoring mechanism for zero-point positioning accuracy. A single sensor serves as both the positioning function and the sole detection element, making it impossible to verify the reliability of its own operational status. When the sensor malfunctions, the system cannot identify the zero-point deviation, causing the equipment to continue operating in an incorrect positioning state. This can lead to economic losses such as batch scrapping of workpieces and production line downtime for maintenance, and even more serious accidents such as equipment damage and personal injury due to mechanical collisions.

[0004] Therefore, how to design a safe and reliable device that can monitor the accuracy of zero-point positioning in real time and provide an immediate warning when the deviation exceeds a threshold has become a technical problem that urgently needs to be solved in this field. Utility Model Content

[0005] In view of this, the purpose of this utility model is to provide a monitoring device for zero-point deviation of aluminum alloy rotary furnace.

[0006] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0007] A monitoring device for zero-point deviation in an aluminum alloy rotary furnace, comprising:

[0008] The first detection element is fixedly installed at the theoretical zero point position of the rotary kiln body;

[0009] The second detection element is fixedly installed at a distance from the first detection element in the same circumferential direction of the rotary kiln body. The distance between the second detection element and the first detection element along the circumferential direction matches the theoretical angle distance for zero-point positioning of the rotary kiln.

[0010] A triggering element is fixed to the rotating part of the rotary kiln and rotates with it. The effective triggering width of the triggering element is less than the distance between the first detection element and the second detection element.

[0011] A control element is communicatively connected to the first detection element and the second detection element. The control element receives the detection signals from the first detection element and the second detection element in real time, and determines whether the zero-point deviation exceeds a preset threshold range based on the signal status.

[0012] An alarm element is connected to the control unit, and the alarm element triggers an alarm when the zero-point deviation exceeds a preset threshold range.

[0013] Furthermore, the first detection element and the second detection element are limit switches, photoelectric sensors, magnetic induction sensors or ultrasonic sensors.

[0014] Furthermore, the triggering element is a metal sheet, a reflector, or a magnetic body, and its shape is rectangular, arc-shaped, or an irregular structure that matches the rotation trajectory of the rotary kiln.

[0015] Furthermore, the preset threshold range of the first detection element and the second detection element is ±1°. When the detection value of the first detection element exceeds ±1° and the second detection element simultaneously exceeds ±1°, the alarm element is triggered to sound an alarm.

[0016] Furthermore, the first and second detection elements are fixed to the rotary kiln body via an adjustable angle base.

[0017] Furthermore, it also includes a calibration element connected to the control element and the adjustable angle base, wherein when a zero-point detection anomaly occurs, the calibration element corrects the position of the first detection element based on the detection value of the second detection element.

[0018] Furthermore, the alarm element includes an audible and visual alarm, an SMS alarm, or a network alarm module.

[0019] Compared with the prior art, the beneficial effects of this utility model are as follows: through the coordinated detection of two sets of detection elements, real-time monitoring and alarm of zero-point positioning deviation can be realized. When the zero-point detection fails due to the failure of the first detection element or mechanical offset, the synchronous out-of-tolerance signal of the second detection element will trigger an alarm, avoiding missed detection caused by the failure of a single sensor. It can immediately issue an alarm for zero-point positioning offset, alerting the staff to stop production for maintenance, and avoiding continued production without knowing that offset has occurred, thereby causing a series of production accidents and economic losses. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Appendix Figure 1 This is a schematic diagram of the structure of an embodiment of this application.

[0022] Explanation of reference numerals and components in the accompanying drawings:

[0023] 1. First detection element; 2. Second detection element; 3. Rotary furnace body. Detailed Implementation

[0024] The technical solution of this utility model will now be clearly and completely described through specific embodiments. Obviously, the described embodiments are only a part of the embodiments of this utility model, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the scope of protection of this utility model.

[0025] See appendix Figure 1 As shown, this application discloses a monitoring device for zero-point deviation of an aluminum alloy rotary furnace, comprising a first detection element 1, a second detection element 2, a trigger element, a control element, and an alarm element. The first detection element 1 is fixedly installed at the theoretical zero-point position of the rotary furnace body 3, and is used to output a first detection signal characterizing whether the rotary furnace has reached the zero-point position. The second detection element 2 is fixedly installed at a distance from the first detection element 1 along the same circumferential direction of the rotary furnace body 3. The distance between the second detection element 2 and the first detection element 1 along the circumferential direction matches the distance of the theoretical angle for zero-point positioning of the rotary furnace, and is used to output a second detection signal characterizing the position of the rotary furnace. Preferably, the first detection element 1 and the second detection element 2 sense the position or state change of the trigger element, convert the physical signal into an electrical signal, and transmit it to the control element to achieve quantitative monitoring of the zero-point deviation of the rotary furnace. The first detection element 1 and the second detection element 2 are any one or a combination of limit switches, photoelectric sensors, magnetic induction sensors, or ultrasonic sensors. Through the coordinated monitoring of the first detection element 1 and the second detection element 2, the failure of a single sensor to detect the zero-point deviation is avoided.

[0026] The triggering element is fixed to the rotating part of the rotary kiln and rotates with it. The effective triggering width of the triggering element is less than the distance between the first detection element 1 and the second detection element 2. Preferably, the triggering element is a metal sheet, a reflector, or a magnetic body, and its shape is rectangular, arc-shaped, or an irregular structure that matches the rotation trajectory of the rotary kiln. The metal sheet is suitable for magnetic induction sensors and limit switches, the reflector can achieve sensitive triggering in conjunction with a photoelectric sensor, and the magnetic body forms a high-efficiency sensing combination with the magnetic induction sensor. The control element is communicatively connected to the first detection element 1 and the second detection element 2 to receive the detection signals of the first detection element 1 and the second detection element 2 in real time, and to determine whether the zero-point deviation exceeds the preset threshold range based on the signal status. Preferably, the control element internally presets the preset threshold range of the first detection element 1 and the second detection element 2 to ±1°. When the rotary kiln is running, the control element collects the signal data of the two detection elements in real time and calculates the time difference and angular offset of the triggering element passing through the two detection elements through a built-in algorithm. If the value detected by the first detection element 1 exceeds ±1° and the value detected by the second detection element 2 simultaneously exceeds ±1°, the control element determines that the zero-point deviation of the rotary kiln exceeds the allowable range and immediately sends a trigger command to the alarm element, effectively avoiding false alarms caused by misjudgment of a single element.

[0027] The alarm element is connected to the control element and triggers an alarm and outputs a shutdown command to the rotary kiln control system when the zero-point deviation exceeds a preset threshold range. Preferably, the alarm element is a combination of an audible and visual alarm, an SMS alarm, or a network alarm module.

[0028] Preferably, in this embodiment, the first detection element 1 and the second detection element 2 are fixed to the rotary kiln body 3 by an adjustable angle base. The adjustable angle base allows installers to flexibly adjust the angles of the first detection element 1 and the second detection element 2 on-site according to the actual situation, without the need for repeated disassembly and repositioning of the detection components, which greatly shortens the installation time and reduces the installation difficulty and labor costs.

[0029] Preferably, it also includes a calibration element connected to the control element and the adjustable angle base. When the zero-point detection is abnormal, the calibration element generates a correction command based on the detection value of the second detection element 2, and drives the adjustable angle base to adjust the position of the first detection element 1 to achieve automatic calibration.

[0030] When the rotary kiln is operating normally and without zero-point deviation, the trigger element rotates past the first detection element 1 and the second detection element 2, triggering detection signals sequentially according to a preset timing sequence. The control element receives the signal status of the two detection elements in real time and analyzes the triggering sequence and time interval of the signals using an internal preset algorithm. Since the effective triggering width of the trigger element is less than the distance between the two detection elements, the two detection elements will not trigger simultaneously under normal circumstances, and the triggering sequence and time interval correspond to the standard operating angle of the rotary kiln. Once a zero-point deviation occurs in the rotary kiln, the positional relationship of the trigger element relative to the first and second detection elements will change, causing a change in the timing and time interval of the triggering detection signals. The control element calculates the deviation between the actual zero-point position and the theoretical zero-point position by comparing the real-time received signal status with the preset standard signal status. When this deviation exceeds a preset threshold, the control element immediately sends a command to the alarm element, which then triggers an audible and visual alarm, alerting the operator that the rotary kiln has a zero-point deviation and needs timely adjustment and calibration, thereby ensuring the operating accuracy and production quality of the aluminum alloy rotary kiln.

[0031] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A monitoring device for zero-point deviation in an aluminum alloy rotary furnace, characterized in that, include: The first detection element is fixedly installed at the theoretical zero point position of the rotary kiln body; The second detection element is fixedly installed at a distance from the first detection element in the same circumferential direction of the rotary kiln body. The distance between the second detection element and the first detection element along the circumferential direction matches the theoretical angle distance for zero-point positioning of the rotary kiln. A triggering element is fixed to the rotating part of the rotary kiln and rotates with it. The effective triggering width of the triggering element is less than the distance between the first detection element and the second detection element. A control element is communicatively connected to the first detection element and the second detection element. The control element receives the detection signals from the first detection element and the second detection element in real time, and determines whether the zero-point deviation exceeds a preset threshold range based on the signal status. An alarm element is connected to the control element, and the alarm element triggers an alarm when the zero-point deviation exceeds a preset threshold range.

2. The monitoring device for zero-point deviation of an aluminum alloy rotary furnace according to claim 1, characterized in that, The first detection element and the second detection element are limit switches, photoelectric sensors, magnetic induction sensors or ultrasonic sensors.

3. The monitoring device for zero-point deviation of an aluminum alloy rotary furnace according to claim 1, characterized in that, The triggering element is a metal sheet, a reflector, or a magnetic body, and its shape is rectangular, arc-shaped, or an irregular structure that matches the rotation trajectory of the rotary kiln.

4. The monitoring device for zero-point deviation of an aluminum alloy rotary furnace according to claim 1, characterized in that, The preset threshold range of the first detection element and the second detection element is ±1°. When the detection value of the first detection element exceeds ±1° and the second detection element simultaneously exceeds ±1°, the alarm element is triggered to sound an alarm.

5. The monitoring device for zero-point deviation of an aluminum alloy rotary furnace according to claim 1, characterized in that, The first and second detection elements are fixed to the rotary kiln body via an adjustable angle base.

6. The monitoring device for zero-point deviation in an aluminum alloy rotary furnace according to claim 5, characterized in that, It also includes a calibration element connected to the control element and the adjustable angle base, which corrects the position of the first detection element based on the detection value of the second detection element when a zero-point detection anomaly occurs.

7. The monitoring device for zero-point deviation of an aluminum alloy rotary furnace according to claim 1, characterized in that, The alarm components include audible and visual alarms, SMS alarms, or network alarm modules.

Images