Tilting Ladle Pouring Control via Flow Model
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Solution Overview
Problem
Conventional tilting-type automatic pouring methods face challenges in achieving speedy and accurate pouring of molten metal into a mold, often requiring multiple backward tilting movements and being sensitive to load cell response characteristics, which complicates the control of the desired weight and increases the time required for pouring.
Innovation Solution
The method involves calculating the height and weight of molten metal during backward tilting using a model expression for the flow of molten metal, allowing for precise estimation and control of the final weight poured by summing the weight from forward and backward tilting phases, and using a computer system to determine if the estimated weight meets the desired target, thereby optimizing the tilting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional tilting-type automatic pouring methods control the tilting speed to maintain constant flow rate, then the flow rate control is improved, but the accuracy of the desired weight of molten metal poured deteriorates
Solution Approach 1:
The patent employs feedback control by continuously monitoring the weight of molten metal poured using a load cell and comparing it with the target weight. The control system adjusts the tilting speed based on the difference between actual and target weight, ensuring both constant flow rate and accurate weight control. This closed-loop feedback mechanism resolves the contradiction by dynamically adjusting parameters to satisfy both requirements simultaneously.
Solution Approach 2:
The patent dynamically adjusts the tilting speed during the pouring process rather than maintaining a fixed speed. By making the tilting speed variable and adaptive to real-time weight measurements, the system can maintain constant flow rate while also achieving accurate weight control. This dynamic approach allows the system to respond to changing conditions and resolve the contradiction between flow rate control and weight accuracy.
2Productivity
If the pouring method pours the predetermined weight of molten metal in the shortest time, then the productivity is improved, but the device complexity increases due to multiple separate backward tilting movements
Solution Approach 1:
The patent performs preliminary calculation of the required tilting speed profile before pouring begins, based on the target weight and desired pouring time. By pre-calculating the optimal tilting trajectory and incorporating it into the control system, the method achieves fast pouring without requiring complex real-time adjustments or multiple separate backward tilting movements. This preliminary planning simplifies the control logic while maintaining high productivity.
3Measurement precision
If the load cell response characteristics are considered for accurate weight measurement, then the measurement precision is improved, but the pouring time increases due to slower response
Solution Approach 1:
The patent pre-calculates the relationship between load cell output and actual molten metal weight, accounting for the load cell's response characteristics. By establishing this calibration curve beforehand, the system can accurately determine the poured weight from load cell measurements without requiring prolonged measurement times. This preliminary calibration enables both accurate weight measurement and rapid pouring execution.
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 enables speedy and accurate pouring of molten metal to the desired weight, reducing the time required and improving the accuracy by using a computer-controlled system that accounts for the flow dynamics and load cell measurements.
Implementation Method 1
the fact that the response characteristics of a load cell that meaures the weight of the molten metal that is poured greatly affects the accuracy of the weight
Implementation Method 2
a model expression for the flow of the molten metal, which expression defines the weight of the molten metal that flows from the ladle into the mold
Data Source
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AI summary
The present invention provides a tilting-type automatic pouring method wherein a very speedy and highly accurate pouring can be realized, which method pours molten metal into a mold by tilting a ladle that holds the molten metal, and the present invention also provides the storage medium for programs used for the method. The tilting-type automatic pouring method of the present invention uses a) the relationship of (1) the height of the molten metal during backward tilting of the ladle, which height is calculated from the height of the molten metal above the outflow position, which height decreases, when the forward tilting of the ladle stops and from the height of the molten metal that is above the outflow position and that decreases after the backward tilting of the ladle starts, and (2) the weight of the molten metal poured from the ladle into the mold, and b) the model expression for the flow of the molten metal, which expression defines the weight of the molten metal that flows from the ladle into the mold. In the tilting-type automatic pouring method of the present invention, the final weight of the molten metal that is poured is estimated by assuming that the final weight of the molten metal that is poured from the forward tilting of the ladle to its backward tilting is equal to the sum of the weight of the molten metal that is poured at the start of the backward tilting and the weight of the molten metal that is poured after the start of the backward tilting,