Automatic Pouring Equipment Ladle Control via Acceleration Compensation
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Solution Overview
Problem
Conventional automatic pouring equipment fails to accurately measure the precise quantity of molten metal due to additional forces caused by accelerated ladle movement, leading to improper pouring sequences.
Innovation Solution
The method employs three servomotors controlled by a PLC to tilt, lift, and move the ladle relative to the mold, while disregarding weight measurement results during acceleration, using a load cell to calculate the change in molten metal weight and adjusting for acceleration forces, ensuring continuous and precise pouring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the ladle is moved with accelerated speed to improve pouring efficiency, then the productivity increases, but the measurement precision of the weight detection means deteriorates due to additional forces
Solution Approach 1:
The patent converts the harmful acceleration forces into a beneficial control signal by detecting them through the weight detection means. The control unit uses the detected weight changes during acceleration to calculate the actual molten metal weight more accurately, turning the previously harmful measurement error into a useful feedback for precise pouring control.
Solution Approach 2:
The patent implements a feedback mechanism where the weight detection means continuously monitors the ladle weight during movement, and the control unit uses this real-time feedback to calculate and adjust the pouring rate. The feedback loop compensates for acceleration forces by using the detected weight changes to determine the actual metal quantity being poured.
2Productivity
If the ladle is moved with accelerated speed to increase productivity, then the pouring rate increases, but the manufacturing precision of the poured metal quantity deteriorates
Solution Approach 1:
The patent replaces direct mechanical measurement of metal quantity with a sensor-based detection system. Instead of mechanically measuring the metal volume or weight directly, the system uses weight detection means to sense the total ladle weight including molten metal, and the control unit calculates the metal quantity by subtracting known constants (ladle weight, acceleration forces), achieving precise measurement through sensor data processing rather than mechanical measurement.
Solution Approach 2:
The patent changes the measurement parameter from direct mechanical weight measurement to a calculated parameter that compensates for acceleration forces. The control unit transforms the raw weight detection data into an accurate metal quantity parameter by mathematically correcting for the dynamic forces present during accelerated ladle movement, enabling precise control despite changing motion conditions.
3Device complexity
If the weight detection means is used to measure total weight including molten metal, then the device complexity is reduced, but the measurement precision deteriorates due to acceleration forces
Solution Approach 1:
The patent introduces the control unit as an intermediary that processes the raw weight detection data. Instead of directly interpreting the weight detection means output, the control unit acts as a mediator that calculates the actual metal weight by compensating for acceleration forces, bridging the gap between simple detection and precise measurement requirements.
Solution Approach 2:
The patent replaces direct mechanical measurement with a sensor-based system where the weight detection means measures total weight and the control unit calculates the metal quantity through computational correction. This substitution allows the use of simple mechanical sensors while achieving precise measurement through software-based compensation for acceleration effects.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for accurate and continuous pouring of molten metal into the mold with minimal error, disregarding acceleration-induced forces and mechanical noise, achieving an error rate of less than 3% in metal quantity.
Implementation Method 1
measuring the weight of the automatic pouring equipment, including the weight of the three servomotors, by a means to measure weight
Data Source
AI summary
The present invention provides a method to control automatic pouring equipment that can pour molten metal in a desired sequence, and it also provides the system therefor. The method to control the automatic pouring equipment comprises pouring the molten metal by three servomotors that are each driven and controlled by a PLC and that act to have the ladle tilted, hoisted, and move backward and forward, characterized in that the method comprises pouring the molten metal into the mold from the ladle by a continuous driving of the servomotors by the instructions given by the PLC, at the same time measuring the weight of the automatic pouring equipment, including the weight of the three servomotors by a means to measure the weight, and calculating the change of the weight of the molten metal in the ladle by the PLC, and in that the method comprises pouring the molten metal, disregarding the results of measurements obtained by the means to measure the weight of the automatic pouring equipment, including the weight of the three servomotors, when an acceleration force works on the ladle.