A device for improving the uniformity of zinc in cast aluminum alloys

Abstract

This utility model relates to the technical field of aluminum alloy smelting and purification equipment, and discloses a device for improving the uniformity of zinc element in cast aluminum alloys. It includes a base and an electronic weighing device, a servo motor, a lifting device, an aluminum molten liquid level measuring device, a controller, and a zinc ingot mounted on the base. The lifting device is movably mounted on the base and moves up and down under the drive of the servo motor. The zinc ingot, mounted on the lifting device, moves up and down accordingly. The electronic weighing device detects the weight change of the zinc ingot, the aluminum molten liquid level measuring device detects the aluminum molten liquid level, and the controller controls the action of the servo motor based on the signals fed back from the electronic weighing device and the aluminum molten liquid level measuring device, thereby adjusting the immersion depth of the zinc ingot in the aluminum molten liquid. This utility model achieves precise control of zinc element addition and automates the zinc element addition process, effectively improving the quality of aluminum alloy ingots, significantly improving the compositional consistency of 7-series aluminum alloys, and thus ensuring product performance consistency.

Description

Technical Field

[0001] This utility model relates to the field of aluminum alloy smelting and purification technology, specifically to a device for improving the uniformity of zinc composition in 7-series aluminum alloy castings. Background Technology

[0002] Aluminum alloys are an important industrial metallic material with wide applications in aerospace, automotive, machinery manufacturing, shipbuilding, and chemical industries. With the rapid development of my country's automotive and aerospace industries, the demand for ultra-high-strength aluminum alloys is increasing. However, some problems still need to be solved in the production process of aluminum alloys, especially in the smelting and casting stages.

[0003] In existing technologies, zinc is primarily added to the molten aluminum alloy during the smelting process by using a lifting assembly to introduce it into the molten metal, as described in Chinese invention patent applications CN103088224A and CN117109294A. However, existing technologies have the following problems: 1) When zinc is added, it tends to settle at the bottom during casting due to its greater weight than aluminum, leading to uneven composition in the cast aluminum rods or castings. 2) Directly adding large amounts of zinc ingots may cause excessive concentration of zinc in certain areas of the melt, increasing the difficulty of stirring and potentially causing excessive zinc segregation.

[0004] In view of this, developing a technical solution that can reduce the difference in zinc content before and after casting and improve the quality of aluminum alloy ingots is of great practical significance. Summary of the Invention

[0005] The purpose of this invention is to provide an automatic zinc replenishment device to improve the uniformity of zinc distribution in 7-series aluminum alloys, and to provide at least one beneficial option or create conditions to solve one or more technical problems existing in the prior art.

[0006] To achieve the above objectives, the present invention adopts the following technical solution.

[0007] A device for improving the uniformity of zinc in cast aluminum alloys includes a base and an electronic weighing device, a servo motor, a lifting device, an aluminum liquid level measuring device, a controller, and a zinc ingot mounted on the base. The lifting device is movably mounted on the base and is lifted and lowered under the drive of the servo motor. The zinc ingot is mounted on the lifting device and rises and falls accordingly. The electronic weighing device is used to detect the weight change of the zinc ingot. The aluminum liquid level measuring device is used to detect the height of the aluminum liquid level. The controller is used to control the action of the servo motor based on the signals fed back from the electronic weighing device and the aluminum liquid level measuring device, thereby realizing the adjustment of the immersion depth of the zinc ingot in the aluminum liquid.

[0008] More preferably, the base is made of steel, and the electronic weighing device includes a weighing sensor and a data processor, which weighs all devices installed on the base.

[0009] More preferably, the load cell is a tension load cell or a piezoelectric load cell.

[0010] More preferably, the servo motor has a servo driver, and the lifting device is a screw lifting mechanism. The lifting screw of the screw lifting mechanism is connected to the output shaft of the servo motor through a transmission mechanism, and then rotates down or up under the drive of the servo motor. The zinc ingot is fixed to the lifting screw.

[0011] More preferably, the lifting screw is made of stainless steel, with the lower end of the lifting screw connected to a zinc ingot via a thread, and the upper end of the lifting screw connected to a servo motor via a transmission mechanism.

[0012] More preferably, the lifting stroke range of the lifting screw is 0-500mm, and the lifting accuracy is ±0.5mm.

[0013] More preferably, the aluminum liquid level measuring device is an infrared-based liquid level detection device, including an emitting device for emitting infrared light, a receiving device for receiving infrared light, and a detection output circuit connected to the receiving device; the infrared light emitted by the emitting device is received by the receiving device after being reflected by the liquid surface, the receiving device converts the received infrared light signal into an electrical signal, and the detection output circuit processes the electrical signal and outputs the detection result signal.

[0014] More preferably, the zinc ingot is a rectangular ingot, with its length aligned with the direction of the flow channel. This provides a larger contact area between the zinc ingot and the molten aluminum, facilitating a more uniform distribution of zinc within the molten aluminum.

[0015] The technical solution provided by this utility model has at least the following technical effects or advantages.

[0016] The device provided by this utility model, by setting up a fixed upper and lower lifting device for zinc ingots, combined with an electronic weighing device, an aluminum liquid level measuring device and a controller, can monitor and adjust the lifting position of zinc ingots in real time, realizing precise control of zinc element addition and automating the zinc element addition process; moreover, different zinc elements can be added and supplemented according to different furnace types, effectively preventing uneven composition caused by zinc elements settling to the bottom, improving production efficiency and reducing human operation errors.

[0017] By comprehensively applying the above-mentioned technical solutions, this utility model effectively improves the quality of aluminum alloy ingots, significantly enhances the compositional consistency of 7-series aluminum alloys, and thus ensures the performance consistency of products.

[0018] Other beneficial effects or technical advantages of this invention will become more apparent in the following description or practice. Attached Figure Description

[0019] Figure 1 The diagram shown is a schematic of the device provided by this utility model for improving the uniformity of zinc element in cast aluminum alloys.

[0020] Explanation of the reference numerals in the attached figures.

[0021] 1: Base, 2: Electronic weighing device, 3: Servo motor, 4: Lifting device, 5: Aluminum liquid level measuring device, 6: Controller, 7: Zinc ingot, 8: Flow channel. Detailed Implementation

[0022] The specific embodiments of this utility model will be further described below with reference to the accompanying drawings, making the technical solution and beneficial effects of this utility model clearer and more explicit. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.

[0023] Additional aspects and advantages of this invention will become apparent in the description that follows, or may be learned by practice of this invention.

[0024] A method for improving the uniformity of zinc in cast aluminum alloys involves the following basic concept: A zinc ingot lifting device is installed on the smelting trough of the aluminum alloy smelting line. During operation, the zinc ingot is first immersed in the molten aluminum to a depth of 5mm-10mm using this device. Then, the height of the zinc ingot is automatically adjusted based on its real-time weight changes to maintain it in the optimal lifting position. By continuously monitoring the weight changes of the zinc ingot and adjusting its height, the stability and uniform distribution of zinc in the molten aluminum are ensured, thereby achieving uniform zinc distribution in the cast aluminum alloy.

[0025] This invention designs different lifting compensation logics for different types of smelting furnaces. For tilting smelting furnaces, since the molten aluminum in the furnace is poured out from the top, the contact volume between the zinc ingot and the molten aluminum in the trough gradually decreases. For ordinary smelting furnaces, since the molten aluminum in the furnace flows out from the bottom, the contact volume between the zinc ingot and the molten aluminum in the trough gradually increases.

[0026] Specifically, for tilting smelting furnaces, the following compensation logic is used to adjust the lifting position of zinc ingots based on real-time monitored changes in zinc ingot weight:

[0027] Lifting / lowering position = Initial position - α × Time + β × Temperature - θ × Pressure

[0028] Wherein, time is the smelting time of zinc ingots in the ladle, temperature is the smelting temperature of the ladle, and pressure is the smelting pressure of the ladle.

[0029] For conventional smelting furnaces, the following compensation logic is used to adjust the lifting and lowering positions of the zinc ingots based on the real-time monitored changes in zinc ingot weight:

[0030] Lifting / lowering position = Initial position + α × Time - β × Temperature + θ × Pressure.

[0031] Wherein, time is the smelting time of zinc ingots in the ladle, temperature is the smelting temperature of the ladle, and pressure is the smelting pressure of the ladle.

[0032] α, β, and θ are constants obtained through adjustments based on actual pre- and post-casting difference experiments. α, β, and θ are related to the tonnage of the smelting furnace, the weight of the zinc ingot, and also to the specific composition requirements of the casting alloy and the casting process. These parameters are derived based on different processes, equipment, and the measured changes in Zn content of the alloy. Specific experimental methods include existing single-factor experiments and orthogonal experiments, which will not be detailed here.

[0033] The above compensation logic effectively solves the problem of differences in zinc content inside molten aluminum in different types of smelting furnaces, ensuring the uniformity and stability of aluminum alloys.

[0034] Example 1.

[0035] A method for improving the uniformity of zinc in 7003 cast aluminum alloy comprises the following steps: 1) Alloy raw materials are prepared according to the following weight percentages: Zn 5.6%, Mg 0.8%, Zr 0.15%, with the balance being Al; 2) Alloy raw materials other than Zn are pre-added into a 20-ton non-tilting melting furnace for melting; 3) A zinc ingot (weighing 50kg) with a length of 200mm, a width of 120mm, and a thickness of 300mm is immersed in the molten aluminum for 5mm using a zinc ingot lifting device; then, the height of the zinc ingot is adjusted in real time according to the formula: lifting position = initial position + α × time - β × temperature + θ × pressure to keep the zinc ingot in the optimal lifting position; α = 0.0165, β = 0.0012, θ = 0.0005; 4) Refining, degassing, and filtering are performed to cast an aluminum rod with a diameter of 229mm.

[0036] Example 2.

[0037] A method for improving the uniformity of zinc in 7046 cast aluminum alloy comprises the following steps: 1) Alloy raw materials are prepared according to the following weight percentages: Zn 6.5%, Mg 1.4%, Zr 0.15%, with the balance being Al; 2) Alloy raw materials other than Zn are pre-added into a 25-ton tilting smelting furnace for melting; 3) A zinc ingot (weighing 50kg) with a length of 200mm, a width of 120mm, and a thickness of 300mm is immersed in molten aluminum for 10mm using a zinc ingot lifting device; then, the height of the zinc ingot is adjusted according to the formula: lifting position = initial position - α × time + β × temperature - θ × pressure to keep the zinc ingot in the optimal lifting position; α = 0.0108, β = 0.0009, θ = 0.0003; 4) Refining, degassing, and filtering are performed to cast an aluminum rod with a diameter of 229mm.

[0038] Comparative Example 1.

[0039] This comparative example is basically the same as Example 1, except that step 3 is removed, and all alloy raw materials are pre-added to a non-tilting melting furnace for melting.

[0040] Comparative Example 2.

[0041] This comparative example is basically the same as Example 2, except that step 3) is removed, and all alloy raw materials are pre-added to the tilting furnace for melting.

[0042] The distribution of Zn element in the aluminum rods prepared in each embodiment and comparative example is shown in Table 1.

[0043]

[0044] As can be seen from Table 1, the zinc ingot height adjustment technology of this invention can effectively improve the uniformity of Zn element distribution in the cast aluminum rod.

[0045] Example 3.

[0046] Reference Figure 1 As shown, a device for improving the uniformity of zinc in cast aluminum alloys includes a base 1, an electronic weighing device 2, a servo motor 3, a lifting device 4, an aluminum molten liquid level measuring device 5, a controller 6, and a zinc ingot 7. The lifting device 4 is movably mounted on the base 1 and is lifted and lowered under the drive of the servo motor 3. The zinc ingot 7 is mounted on the lifting device 4. The electronic weighing device 2 is used to detect the weight change of the zinc ingot 7. The aluminum molten liquid level measuring device 5 is used to detect the height of the aluminum molten liquid. The controller 6 is used to control the action of the servo motor 3 according to the signals fed back by the electronic weighing device 2 and the aluminum molten liquid level measuring device 5, thereby realizing the adjustment of the immersion depth of the zinc ingot 7 in the aluminum molten liquid.

[0047] The base 1 is made of high-temperature resistant steel plate, with dimensions of 400mm × 120mm × 50mm, and is used to install other components. The electronic weighing device 2 includes a weighing sensor and a data processor. The weighing sensor has an accuracy of ±1g; the weighing sensor is a tensile weighing sensor or a piezoelectric weighing sensor. The electronic weighing device 2 weighs all devices installed on the base 1, and then the mass of the non-zinc ingot devices is subtracted to obtain the mass of the zinc ingot. The servo motor 3 has a servo driver, and the maximum stroke of the servo motor is 500mm. The lifting device 4 is a screw lifting mechanism. The lifting screw of the screw lifting mechanism is connected to the output shaft of the servo motor 3 through a transmission mechanism, and thus rotates to descend or ascend under the drive of the servo motor 3. The zinc ingot 7 is fixed to the lifting screw. The aluminum molten liquid level measuring device 4 is an infrared-based liquid level detection device, including an infrared emitting device, an infrared receiving device, and a detection output circuit connected to the receiving device. The infrared light emitted by the emitting device is reflected by the liquid surface and received by the receiving device. The receiving device converts the received infrared light signal into an electrical signal, and the detection output circuit processes the electrical signal and outputs the detection result signal. The infrared-based liquid level detection device does not come into contact with the molten aluminum, has a simple structure, and is reliable. The controller 5 uses a known industrial control computer.

[0048] It should be noted that the electronic weighing device 2, servo motor 3, aluminum liquid level measuring device 5, and controller 6 are all commercially available products. The design of the connection circuit between these electronic components is determined by the product model used, which is common technical knowledge that is known to those skilled in the art, and will not be described in detail here.

[0049] In this embodiment, the lifting screw is made of 316 stainless steel, with a length of 300mm and a diameter of 20mm. The lower end is connected to a zinc ingot using threads. The upper end of the lifting screw is connected to the servo motor 3 through a transmission mechanism (such as a transmission gear, chain, etc.) to achieve lifting. The lifting stroke range is 0-500mm, and the lifting accuracy is ±0.5mm.

[0050] The controller 5 integrates a specific control algorithm. The specific integration method of the control algorithm is common technical knowledge for those skilled in the art and will not be elaborated here. The controller 5 also has communication capabilities, enabling it to connect with the electronic system for aluminum molten metal level in the flow channel, achieving data exchange and collaborative control.

[0051] In operation, the zinc ingot is first fixed to the lifting screw, then immersed in the molten aluminum in the flow channel 8 at a temperature of 720℃-750℃. The controller then automatically adjusts the servo motor's operation based on real-time weighing data and preset parameters, maintaining the zinc ingot in the optimal lifting position. Through continuous real-time monitoring and adjustment, the stability and uniform distribution of the zinc ingot in the molten aluminum are ensured, thereby achieving precise control over the zinc content.

[0052] It should also be noted that, unless otherwise explicitly specified and limited, the terms "assembly," "connection," and "joining" in this utility model should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can also refer to a mechanical connection; they can refer to a direct connection or a connection through an intermediate medium; or they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0053] In this utility model, unless otherwise specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "below," and "over" the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Above," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0054] Based on the above description of the structure and principle, those skilled in the art should understand that this utility model is not limited to the specific embodiments described above. Improvements and substitutions made using techniques known in the art based on this utility model all fall within the protection scope of this utility model, which should be defined by the claims and their equivalents. Parts not described in the specific embodiments are all prior art or common knowledge.

Claims

1. A device for improving the uniformity of zinc element in cast aluminum alloys, characterized in that, The device includes a base and an electronic weighing device mounted on the base, a servo motor, a lifting device, an aluminum liquid level measuring device, a controller, and a zinc ingot. The lifting device is mounted on the base and is lifted and lowered under the drive of the servo motor. The zinc ingot is mounted on the lifting device and rises and falls accordingly. The electronic weighing device is used to detect the weight change of the zinc ingot. The aluminum liquid level measuring device is used to detect the height of the aluminum liquid level. The controller is used to control the action of the servo motor based on the signals fed back from the electronic weighing device and the aluminum liquid level measuring device, thereby realizing the adjustment of the immersion depth of the zinc ingot in the aluminum liquid.

2. The device for improving the uniformity of zinc element in cast aluminum alloys according to claim 1, characterized in that, The base is made of steel, and the electronic weighing device includes a weighing sensor and a data processor. The electronic weighing device weighs all devices installed on the base.

3. The device for improving the uniformity of zinc element in cast aluminum alloys according to claim 2, characterized in that, The load cell is either a tension load cell or a piezoelectric load cell.

4. The device for improving the uniformity of zinc element in cast aluminum alloys according to claim 1, characterized in that, The servo motor has a servo driver, and the lifting device is a screw lifting mechanism. The lifting screw of the screw lifting mechanism is connected to the output shaft of the servo motor through a transmission mechanism, and then rotates down or up under the drive of the servo motor. The zinc ingot is fixed to the lifting screw.

5. The device for improving the uniformity of zinc element in cast aluminum alloys according to claim 4, characterized in that, The lifting screw is made of stainless steel. The lower end of the lifting screw is connected to a zinc ingot via a thread, and the upper end of the lifting screw is connected to a servo motor through a transmission mechanism.

6. The device for improving the uniformity of zinc element in cast aluminum alloys according to claim 4, characterized in that, The lifting stroke range of the lifting screw is 0-500mm, and the lifting accuracy is ±0.5mm.

7. The device for improving the uniformity of zinc element in cast aluminum alloys according to claim 1, characterized in that, The aluminum liquid level measuring device is an infrared-based liquid level detection device, including an infrared emitting device for emitting infrared light, a infrared receiving device for receiving infrared light, and a detection output circuit connected to the receiving device. The infrared light emitted by the emitting device is reflected by the liquid surface and received by the receiving device. The receiving device converts the received infrared light signal into an electrical signal. The detection output circuit processes the electrical signal and outputs the detection result signal.

8. The device for improving the uniformity of zinc element in cast aluminum alloys according to claim 1, characterized in that, The zinc ingot is a rectangular ingot.

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