Ladle Tilt Control via Servomotor Feedback and Flow Modeling
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Solution Overview
Problem
Existing tilting-type methods for automatically pouring molten metal into a mold lack precision in controlling the position where the molten metal drops, often resulting in it falling outside the pouring gate, which leads to inefficiencies and waste.
Innovation Solution
A method utilizing three servomotors to tilt, move back and forth, and move up and down a ladle, with a computer-controlled system that produces a mathematical model to estimate the molten metal's flow rate and drop position, adjusting input voltages to ensure accurate pouring by considering the effects of a contracted flow and guiding member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional tilting-type pouring methods are used, then the pouring process can be automated, but the position where molten metal drops cannot be accurately controlled
Solution Approach 1:
The system employs feedback control by continuously monitoring the actual drop position of molten metal and adjusting the ladle's tilt angle and position accordingly. Sensors detect the drop position and feed this information back to the control system, which then modifies the servomotor commands to correct any deviations from the target position, thereby achieving accurate control in the automated pouring process.
Solution Approach 2:
The system dynamically changes multiple parameters including the ladle's tilt angle, horizontal position, and vertical position during the pouring process. By independently controlling three servomotors that adjust these parameters in real-time, the system can precisely control where the molten metal drops while maintaining automated operation.
2Device complexity
If the drop position is not controlled, then the pouring process is simpler, but molten metal may drop outside the pouring gate causing waste
Solution Approach 1:
The feedback control system monitors the drop position and adjusts the pouring parameters in real-time to ensure molten metal lands precisely in the pouring gate. This prevents waste by correcting any deviations before they result in misplacement, maintaining system simplicity while eliminating material loss.
Solution Approach 2:
The system replaces manual pouring operations with an automated control system that uses sensors and servomotors to precisely control the ladle's position and tilt. This substitution of mechanical control with automated feedback control ensures accurate drop positioning without requiring complex manual operations, thereby preventing molten metal waste.
3Manufacturing precision
If multiple servomotors are used to control ladle position and tilt, then drop position accuracy is improved, but system complexity increases
Solution Approach 1:
The control system is segmented into three independent servomotor control units, each responsible for a specific degree of freedom (tilt angle, horizontal position, vertical position). This segmentation allows each motor to be controlled and monitored independently, simplifying the overall control architecture while achieving precise drop position accuracy through coordinated operation of the three segments.
Solution Approach 2:
The control system integrates multiple functions into a single unified controller that manages all three servomotors simultaneously. This universal control approach allows the system to coordinate tilt angle adjustment, horizontal positioning, and vertical positioning through one integrated control algorithm, reducing the apparent complexity while maintaining high drop position accuracy.
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 precise control of the molten metal's flow, ensuring it accurately drops into the mold's pouring gate, reducing waste and improving the efficiency of the casting process.
Implementation Method 1
controlling the respective input voltages transmitted to the three servomotors by means of a computer
Implementation Method 2
solving an inverse problem of the produced mathematical model in view of the effect of a contracted flow
Implementation Method 3
a mathematical model of an area on which the molten metal that flows from the ladle will drop
Data Source
AI summary
A method for controlling the respective input voltages transmitted to a servomotor that tilts the ladle such that the molten metal that flows from the ladle drops accurately into the pouring gate in the mold, a servomotor that moves the ladle back and forth, and a servomotor that moves the ladle up and down, by using a computer. In the method, a mathematical model of the area on which the molten metal that flows from the ladle will drop is produced, and then the inverse problem of the produced mathematical model is solved. In view of the effect of a contracted flow, the position on which molten metal drops is estimated by the estimating device for estimating the pouring rate and the estimating device for estimating the position on which molten metal will drop.