CN100507533C - Metal liquid integrative performance on-line intelligent checking system - Google Patents
Metal liquid integrative performance on-line intelligent checking system Download PDFInfo
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Abstract
The invention relates to an on-line detection system for molten metal integration property, which includes a signal collection device for generating electric signal correlated with molten metal temperature change, a data processing main frame, a thermoemf combination measuring interface device for carrying amplification and analog/digital conversion of the electric signal, which is convenient for processing digital signal by the data processing main frame, and a data output device including a data remote transmission device, a storage device, a display device and a printing device. The detection system is adapted for eighteen kinds of designation molten iron and nineteen kinds of key parameter fast detection prescribed by national standard and international standard, and has high detection accuracy and good stability.
Description
Technical field
The present invention relates to a kind of metal liquid integrative performance on-line intelligent checking system, this system adopts heat to analyze coupling technique, can be at the various physical and chemical parameters of stokehold fast detecting molten metal, so that before casting, control casting quality by the composition adjustment and the technology adjustment of molten metal.
Background technology
Foundry industry is the basis of machinery manufacturing industry, and in order to improve casting quality, the detection of foundry goods combination property is a critical process.The detection of combination property not only should comprise such as the detection of chemical constitutions such as carbon content, silicone content, also should comprise such as physical parameters such as intensity, hardness, length growth rate, nodularization rate, carbonide and detecting.It is after casting is finished sample or foundry goods to be carried out (section) analysis that traditional foundry goods detects, and this detection is called offline inspection.Offline inspection comprises optics metallographic detection method or scanning electron microscope detection method, electron probe detection method, transmission electron microscope detection method etc., and these methods exist the shortcoming of low precision or narrow range, expense height, length consuming time.Development along with thermoanalysis technology, realize the stokehold fast detecting of metal liquid comprehensive performance all sidedly, active demand and development trend that foundry goods detects have been become, because the every index that can in time judge molten metal is detected in this stokehold, thereby by composition adjustment control casting quality, therefore this stokehold is detected and is called online detection before casting.Online detection obtains various physicochemical property data and only needs a few minutes from being sampled to, and has good application prospects.
Existing metal liquid comprehensive performance on-line detecting system can not realize really that still combination property detects, for example Japanese this NSP-510 of detection instrument company type stokehold hot metal composition analyzer of spreading wave, the PQ-DIT detection system of Sweden Novacast company, the Detal-CII detection system of Germany etc., though detection speed is faster many than offline inspection, but identification, sensing range is less, the parameter that can test is less, can not detect gray iron simultaneously, magnesium iron, multiple molten iron such as agate iron and high-carbon, and antijamming capability, detect stability, reappearance and accuracy of detection also are difficult to satisfy requirements at the higher level.
Summary of the invention
The objective of the invention is in order to overcome the shortcoming of existing metal liquid comprehensive performance on-line detecting system, the combination property that a kind of sensing range is big, precision is high on-line detecting system is provided, this system is suitable for gray iron, magnesium iron, agate iron (and high-carbon) four big classifications, 18 kinds of trade mark molten iron (HT100～HT350 of national standard and international standard defined, QT400～QT900, the fast detecting of 19 kinds of key parameters of KTH300-6～KTH370-12).
The object of the present invention is achieved like this: a kind of metal liquid comprehensive performance on-line detecting system, comprise: signal pickup assembly, thermoelectrical potential is united the metering interface arrangement, data processing main frame and data output apparatus, signal pickup assembly comprises sensor, sensor comprises cup and thermopair, be used to pour into molten metal to be detected, and by the thermopair generation electric signal relevant with the temperature variation of molten metal, thermoelectrical potential is united the metering interface arrangement and is comprised signal amplification circuit and A/D mould/number conversion circuit, signal amplification circuit is used for the electric signal of receiving sensor output, and this electric signal is amplified, the analog signal conversion through amplifying that A/D mould/number conversion circuit is used for signal amplification circuit output is a digital signal, so that the data processing main frame is handled this digital signal, data output apparatus comprises the data remote device, memory storage, display device, printing equipment; It is characterized in that:
Signal pickup assembly is by the sampling ware; sensor and integrated filter assembly constitute; the sampling ware is made by lightweight flame-proof thermal insulation material; sensor is selected high-precision galvanic couple silk for use; galvanic couple silk outside is with protective casing; place the cup middle part; temperature change value before and after being used for solidifying accurately is converted to and is easy to discern; the thermoelectrical potential value that 0～60mv changes; the square cup of sensor meets newton's cooling condition; it is made to be narrower than 20 purpose precoated sands; can guarantee that molten iron is by Fe-FeC3 stability series mode crystallization; the integrated filter assembly is the copper-constantan signal transmssion line of overcoat protection tube; it causes signal in the sensing chamber by the stokehold, can get rid of the various interference to sampled signal.
In metal liquid comprehensive performance on-line detecting system of the present invention, comprise a dope layer on the cup inwall of sensor and the bottom surface, the powder of dope layer tellurium Te, bismuth Bi and aluminium Al be sprayed at the cup inner chamber after bonding agent mixes and form, wherein, total addition of tellurium, bismuth and aluminium is no less than 0.02% of the molten metal weight of containing in the cup, and tellurium, bismuth and aluminium separately the ratio of weight and three's sum be tellurium 〉=60%, bismuth≤30%, aluminium≤10%.Cup is that raw material adopts core shooter to make with the precoated sand.The thermopair overcoat is with resistant to elevated temperatures protective casing, and level places 1/2～2/3 place of cup height.
In metal liquid comprehensive performance on-line detecting system of the present invention, the data processing main frame adopts industry control embedded main board and (SuSE) Linux OS, analyze coupling technique based on the heat that comprises Multi-Component Phase Diagram, nonlinear multivariable recurrence etc., the data that receive are handled, to obtain the relevant physical and chemical parameter of tested molten metal.For this reason, the data processing main frame also comprises with regard to its processing capacity: data acquisition module, molten metal unique point identification module, parameter acquisition module and various output modules etc. except comprising linux kernel, RTLinux kernel, MiniGUI figure support storehouse etc.
The invention has the beneficial effects as follows: this system is suitable for 18 kinds of trade mark molten iron of national standard and international standard defined, the fast detecting of 19 kinds of key parameters, that is: 1), can measure 12 key parameters of gray iron " the whole six kinds of trades mark in HT100～350 " in three minutes, comprise as the trade mark in the physical property, tensile strength sigma b, hardness HB the carbon equivalent C in the chemical constitution
EL, carbon C, silicon Si and maximum temperature T
M, liquidus temperature T
L, solidus temperature T
S, degree of supercooling Δ T, maloperation prompting, save the technology prompting of waste product etc.; 2), measured 11 key parameters of agate iron " KTH300～370 4 kind of the trade mark " in three minutes, comprise the trade mark, tensile strength sigma b, length growth rate δ, carbon equivalent C
EL, carbon C, silicon Si and maximum temperature T
M, liquidus temperature T
L, solidus temperature T
S, maloperation prompting, save the technology prompting of waste product etc.; 3), one fen half can measure 13 key parameters of magnesium iron " QT400～900 8 kind of the trade mark ", comprises the trade mark, tensile strength sigma b, length growth rate δ, nodularization rate Ds, nodulizing grade, carbide content K, maximum temperature T
M, spheroidal graphite liquidus temperature T
N, spheroidal graphite supercooling temperature T
U, spheroidal graphite rise temperature T
R, maloperation prompting, save the technology prompting of waste product etc.; 4), measured 9 key parameters of high-carbon molten iron (comprise magnesium iron base iron, the iron base iron of wriggling), high silicon iron water, hot metal containing low silicon in three minutes, comprise the trade mark, tensile strength sigma b, Brinell hardness HB in the physical property, the carbon equivalent C in the chemical constitution
EL, carbon C, silicon Si and maximum temperature T
M, liquidus temperature T
L, solidus temperature T
SDeng.
Owing to have above-mentioned advantage, the present invention has really realized instructing the target of execute-in-place, because the tensile strength sigma b of the tensile strength sigma b of gray iron, Brinell hardness HB and magnesium iron, agate iron and length growth rate δ are the useless indexs of declaring of national standard and international standard defined, if can not fast it be measured, then do not reach the basic goal of the online detection of quality; In addition, if can not measure nodularization rate Ds, the carbide content K of magnesium iron in the half fast, before the molten iron cooling, just can not effectively instruct cast to prevent nodularization and inoculation fade at one minute.
Description of drawings
The present invention will be further described below in conjunction with drawings and Examples.
Fig. 1 is the Fe-C binary phase diagraml that existing molten metal (molten iron) combination property on-line detecting system is adopted;
Fig. 2 is the casting pig cooling curve corresponding with Fig. 1;
Fig. 3 is liquid, the solidus temperature T that the conventional online detection system exists
L, T
SThe synoptic diagram of value erroneous judgement;
Fig. 4 is the Fe-C-Si ternary phase diagram that metal liquid comprehensive performance on-line detecting system of the present invention is adopted;
Fig. 5 is the synoptic diagram of the non-linear correction of metal liquid comprehensive performance on-line detecting system employing of the present invention;
Fig. 6 is the measured magnesium iron cooling curve of metal liquid comprehensive performance on-line detecting system of the present invention;
Fig. 7 is the composition block scheme of metal liquid comprehensive performance on-line detecting system of the present invention;
Fig. 8 is that thermoelectrical potential is united the circuit theory diagrams that measure interface arrangement;
Fig. 9 is the schematic diagram of data processing main frame;
Figure 10 is the cut-open view of the sensor of metal liquid comprehensive performance on-line detecting system employing of the present invention.
Embodiment
Before metal liquid comprehensive performance on-line detecting system of the present invention is elaborated, at first analyze the reason of the technological deficiency generation of existing on-line detecting system from theoretical side, and the mechanism of characteristics that the present invention may be better understood thus and excellent effect generation.
Thermal analysis system be when utilizing alloy graining because of the state variation of each phase causes the crystallization latent heat difference that discharged, thereby on cooling curve, form the characteristics of flex point or platform, the chemical analysis of the counter thus gold of slippaging.
The existing single employing thermal analysis system of on-line detecting system is got the Binary Ideal state, and soon molten metal or cast iron are considered as the iron carbon bianry alloy under the perfect condition, so can only carbon determination equivalent C
EL, minority such as carbon C chemical analysis; Its test philosophy based on the Fe-C binary phase diagraml and typical molten steel solidification process temperature lowering curve (being cooling curve) as shown in Figure 1 and Figure 2.For the corresponding relation between clearer demonstration Fig. 1 and 2, in the accompanying drawings that these two figure are placed side by side.
Existing detection system is not considered the influence of solidus temperature Ts value usually, makes the accuracy of test silicon (Si) reduce greatly.Because when detecting,, just can obtain its carbon content x% (Fig. 1 horizontal ordinate) by corresponding Fe-C binary phase diagraml as long as find the liquidus temperature TL (according to the thinking of Fe-C binary phase diagraml, Ts is horizontal line, and its numerical value does not change) of cooling curve by existing method.The shortcoming of this method is: do not consider the influence of Ts value, and the silicon amount is exactly closely related with Ts, therefore causes the accuracy of test silicon to reduce greatly.In fact the effect of silicon is very big in the cast iron, and is very important, and Ts also is the non-constant value of fluctuation.Existing detection system was once attempted the Ts value the influence of silicon testing result as the factor of considering always, but still failed to solve the low problem of Ts value susceptibility so far, and promptly when in the molten iron during silicone content marked change, its measured Ts value is no change still.
In addition, when detecting, can not discern the unusual platform in the cooling curve, unusual spike or rise signal, make liquidus temperature T by existing method
LValue and solid-state temperature Ts value be erroneous judgement easily, as shown in Figure 3, so cause the detection accuracy of the basic function-carbon (C) of test also to reduce greatly.Moreover why existing detection system tests the narrow range of carbon, also is because liquidus temperature T
LValue has sample error, only adopts the linear regression data processing technique in addition, causes few, the low precision of parameter that records.
Detection system of the present invention has realized following innovation in the above-mentioned shortcoming at existing detection system aspect detection method and the system's composition.
At first, introduce Multi-Component Phase Diagram, the precision of test carbon, silicon is improved comprehensively.Engineering is material cylinder iron, and except that carbon containing, silicon content is also very high, should be considered as the Fe-C-Si ternary alloy three-partalloy, and the liquidus curve on its ternary alloy phase diagram, solidus have all correspondingly become curved surface (liquidus surface, sulidus face) like this, as shown in Figure 4.By finding the intersection point-liquidus temperature T of molten iron when cooling and two curved surfaces earlier
LAnd solid-state temperature Ts, contrast the Fe-C-Si ternary phase diagram again, can obtain its carbon content and silicon content more exactly.
In addition, improve the susceptibility of Ts temperature value, can make the precision of test carbon, silicon higher.For this reason, the present invention has taked a series of measures, comprising: 1) position in the cup of optimization thermocouple wire, and test is found to make thermocouple wire be in 1/2～2/3 place of cup height, can improve susceptibility; 2) formulation for coating material of optimization sensor cup by adding Al, Bi, can strengthen the amplitude that Ts changes; 3), can improve accuracy of identification by filtering algorithm and get sample mean.
Further, the present invention considers the influence factor to various physical and chemical parameters comprehensively, that is to say, the cooling curve that detects gained contains a large amount of thermodynamics of crystallization information, as difference between the temperature of each platform section on the curve, length, slope, each point etc., also has other factors simultaneously, as alloying elements such as Cu, Cr, Mo, Ni, trace elements such as Pb, As, Bi, and the height of oxygen, sulphur, manganese, phosphorus equal size, smelting technology condition etc., these information and factor must analysis-by-synthesis take in comprehensively, and this is that heat of the present invention is analyzed coupling technique.When above-mentioned factors has appreciable impact to physical and chemical parameter, just constituted one group of independent variable describing the cast iron characteristic, the size of its influence power must be done comprehensive judgement from molten alloy theory and correlation regression coefficient aspects.
Casting pig is a kind of in the cast iron quality, and its principal character is graphite (length breadth ratio 〉=50) in the form of sheets, and when cast iron solidified, carbon is separated out with the graphite state usually, comes in every shape.The different shape of graphite has determined the different classes of of cast iron.(length breadth ratio 2～10) was vermicular cast iron when graphite was the worm shape; (length breadth ratio=1) was spheroidal-graphite cast iron when graphite was spherical; Graphite (obtaining after the solid-state annealing) be group when cotton-shaped (length breadth ratio ≈ 1) be malleable cast iron (agate iron).Show that by curve among Fig. 1, Fig. 2 and test strength of gray cast iron is directly proportional with temperature T L on the cooling curve.Except temperature T
LOutside, the factor that influences intensity also has a lot, as the quantity of carbonide, pearlite, iron phosphide eutectic, undercooled graphite, the thickness of crystal grain, silicon carbon ratio etc., the result, the various physical and chemical parameters of molten metal and the relation of each independent variable of cooling curve are the funtcional relationships of a nonlinear multivariable.Based on this, the present invention is on the basis of multiple regression, take non-linear correction measure (existing detection system only adopts linear processing techniques), each principal element is taken all factors into consideration, realized gray iron GB whole six trades mark (HT100～intensity HT350), the tests of hardness HB.The synoptic diagram of non-linear correction, as shown in Figure 5.
What agate iron was different with gray iron is: agate iron is the air chill solidification mode, i.e. Fe-Fe3C dual mode, and it is cotton-shaped that graphite is group after the thermal treatment.
In the magnesium iron cooling curve of Fig. 6, be example with factors such as Δ T2, Δ T1 to the influence of magnesium iron performance parameter (as intensity σ b, length growth rate δ, nodularization rate Ds) only: T2 is more little for rise value Δ, illustrates that austenite shells is complete more, and nodularization is good more, and intensity is high more.Otherwise, when cooling curve rise value Δ T2 is big, illustrating that austenite shells breaks, spheroidal graphite distorts, nodularization is poor, and intensity degenerates.T1 is more little for the degree of supercooling Δ, and sphere diameter is even more, and length growth rate δ is high more.Iron liquid carbon content is high more, the liquid-solid phase line temperature difference is big more, " liquidus temperature TN " on the cooling curve is also big more with poor (being degree of supercooling Δ T1) of " the temperature T U of a large amount of eutectic crystallizations ", the sphere diameter that long, the nascent spheroidal graphite of time that nascent spheroidal graphite is grown up is described is just bigger, sphere diameter is totally inhomogeneous, causes poor toughness, length growth rate δ value to descend.Vice versa.In like manner, influence have that it's too late what, the omen of decline etc. of uniformity coefficient, the carbonide of quality, the sphere diameter of the various internal factors of magnesium iron performance such as nodularization, detailed reflection is all arranged on the cooling curve of magnesium iron in process of setting, in the influence of taking all factors into consideration all independents variable and after nonlinear multivariable returns, get final product speed and survey key parameters such as the intensity of magnesium iron, length growth rate, nodularization rate, carbonide.
The wriggle obvious good what gray iron of combination property of iron, its test philosophy is similar to magnesium iron, and key is the feature of the section of rise, and magnesium iron is different with the rise slope of the iron of wriggling.
It is ultimate principle that metal liquid comprehensive performance on-line detecting system of the present invention is analyzed coupling technique with above-mentioned heat, is hardware platform with the industry control embedded main board.This detection system comprises: signal pickup assembly, thermoelectrical potential are united metering interface arrangement, data processing main frame and data output apparatus.Signal pickup assembly comprises sensor, and sensor comprises cup and thermopair, is used to pour into molten metal to be detected, and produces the electric signal relevant with the temperature variation of molten metal by thermopair.Thermoelectrical potential is united the metering interface arrangement and is comprised signal amplification circuit and A/D (mould/number) change-over circuit, signal amplification circuit is used for the electric signal of receiving sensor output, and this electric signal is amplified, the analog signal conversion through amplifying that A/D (mould/number) change-over circuit is used for signal amplification circuit output is a digital signal, so that the data processing main frame is handled this digital signal.Data output apparatus comprises data remote device, memory storage, display device and/or printing equipment.
After the sampling molten metal pours into sensor, monitor its process of setting by the data processing main frame, therefrom obtain series of features information, judge also the various physics and chemistry key parameters of output molten metal fast through processing in time, can provide retrospective technology prompting according to quality objective simultaneously, thereby the production run of guidance, and for later closed loop automatically control the realization means are provided.Below in conjunction with Fig. 7 system of the present invention composition is described in detail as follows:
Signal pickup assembly: constitute by sampling ware, sensor and integrated filter assembly.Sampling ware (or claiming sample spoon) is made by lightweight flame-proof thermal insulation material.Sensor (or claiming the sample cup) is selected high-precision galvanic couple silk for use, and is all better to guarantee thermal stability and inoxidizability under its high temperature; Galvanic couple silk outside is with protective casing, and level places the cup middle part, so that its thermal inertia is very little; Temperature change value before and after solidifying can accurately be converted to the thermoelectrical potential value that is easy to discern, 0～60mv changes.Cup meets newton's cooling condition, and it is made to be narrower than 20 purpose precoated sands, can guarantee molten iron by Fe-FeC3 stability series mode crystallization, and guarantees " hardware and software platform " (promptly level and smooth and unique point remarkable) of cooling curve.The integrated filter assembly is the copper constantan signal transmssion line of overcoat protection tube etc., and it causes signal in the sensing chamber by the stokehold, can get rid of the various interference to sampled signal.
Thermoelectrical potential is united the metering interface arrangement: this device is directly changed into digital quantity with the molten metal temperature sensor through the millivolt signal of filtering unit output, sends data to the data processing main frame by for example RS-232 bus and standard communication protocol.As shown in Figure 8, in this device, gather and signal procedure by the CPLD operation, realize functions such as passage switching, ADC startup, image data, ambient temperature compensation, digital school zero, gamma correction and data processing, main frame sends the reading of data order, export linearization the digital quantity of temperature.Comprise a temperature collect module in this device, it can gather 4 road thermocouple signals simultaneously, analog switch CD4052 switches the multi way temperature sensor respectively, choose the temperature sensor measurement circuit of passage 0 by CPLD control sequence, amplify through two-stage and send into A/D converter (ADS976) after (ICL7652) superposes with the temperature collection signal to passage 3.After the logic device (CPLD) image data, be converted to corresponding temperature digital amount after school zero, filtering and linearization process, be sent to another piece CPLD, it mainly handles the serial communication with main frame.When host computer needs data, send out the order of fetching data by serial port, CPLD then sends current latest data to main frame.Also have an EEPROM in the acquisition module simultaneously, the main storage parameter relevant with operational model also is to send to main frame by CPLD by serial port when main frame needs.
Interface arrangement also can adopt the IC7650 two-stage to amplify cold junction compensation, AD574 modulus (A/D) conversion.
The data processing main frame comprises the industry control embedded main board, and wherein CPU is the 300MHz dominant frequency, and the 128M internal memory uses the Busybox running software in linux system; Peripheral interface comprises RS-232, RS-232/485, parallel port, 10/100M Ethernet interface, floppy drive, IDE hard-disk interface, USB mouth; Serial line interface can connect acquisition module and data remote; The parallel port connects prints; The USB mouth is used for the historical data unloading; Ethernet interface provides high-speed data channel, can be used for Process Control System; Hard-disk interface can connect the high capacity external memory.
The data processing main frame also can adopt single card microcomputer, for example the single card microcomputer of Z80 series.
Data output apparatus comprises data remote device, memory storage, display device and printing equipment.Display device can adopt LCD display, also can adopt the FIP fluorescence display board of low-power consumption, is used to show testing process and testing result; Printing equipment can adopt thermal printer, is used to print testing result; The data remote device comprises communication modes such as Ethernet, RS-232, RS-485, by FTP mode and zmodem agreement, externally can provide online data and analysis result, is convenient to user's remote real-time monitoring; Memory storage can be hard disk or USB mobile memory, with store historical data, is convenient to quality management.
In the data processing main frame, analyze coupling technique based on the heat that comprises Multi-Component Phase Diagram, nonlinear multivariable recurrence etc., the data that receive are handled, to obtain the relevant physical and chemical parameter of tested molten metal.For this reason, the data processing main frame also mainly comprises with regard to its processing capacity: data acquisition module, molten metal unique point identification module, parameter acquisition module and various output modules etc. except comprising linux kernel, RTLinux kernel, MiniGUI figure support storehouse etc.As shown in Figure 9, these modules are shown as: real-time 485 communication thread, real-time clock, data acquisition thread, fifo queue, temperature data reads with storage, history data store, technology remedy reminding module, gray iron/agate iron/base iron parameter acquisition module, magnesium iron parameter acquisition module, gray iron/agate iron/base iron unique point identification module, magnesium iron unique point identification module, printout module, parameter display module, data remote module, usb data memory module, function selecting module, printer and touch-screen driving etc.The RTLinux program run is in two spaces: user's space and kernel state.RTLinux provides application programming interfaces, by these api functions real-time processing section is written as kernel module, and is loaded in the RTLinux kernel, runs on the kernel state of RTLinux.The application program of non-real time portions is then carried out in the user's space under the Linux.
Data acquisition module regularly reads temperature information from the thermopair acquisition module by serial ports, and reading precision regularly directly influences result of calculation, so this module need be compiled into the Linux loadable module and runs on kernel state.Data acquisition module is carried out one and is closed circulation process, passes to master routine again read information from the thermopair acquisition module after.It comprises two interfaces, with the interface of thermopair acquisition module be hardware interface, by the RS-485 communication, agreement adopts the ADAM4000 agreement, with the interface of master routine be real-time pipeline (RT-FIFO).Because acquisition module runs on the different program space of priority with master routine, therefore carry out exchanges data by the RT-FIFO that RTLinux provided.
The data initialization module of detection system master routine realizes following function: configuration file and detected parameters data load; The data load relevant with man-machine interface comprises on-the-spot arrangenent diagram, instruction manual book, interface Background, button icon, multilingual dot matrix word library etc.; Peripherals detects the detection that comprises acquisition module, printer, touch-screen, USB memory device, bar code device etc.
Function selecting module mainly comprises following content: the kind of molten iron to be detected, target material etc.; When testing result is lower than the set target material trade mark, illustrate that molten iron is undesirable, at this moment the technology remedial measures can be reported to the police and point out to detection system.
The unique point judge module: with the gray iron is example, after the gray iron molten iron pours into sensor (sample cup), and be through heating up, arrive peak T
M, cooling, just analyse processes such as austenite, eutectic freezing, end of test (EOT); To produce heat release in the crystallization process, so the of short duration platform of temperature cooling curve appearance, to photographic view, can calculate parameters such as carbon content.But in actual detected, temperature variation and perfect condition have very big difference, and detection system will be carried out digitized filtered to the input temp curve, and multiple situation is carried out Intelligent Recognition, thereby obtain real characteristic information.In the ash iron test temperature changing process is divided into " wait that heats up, search TM, identification TL and associated eigenvalue, identification Ts and associated eigenvalue, collection finish " five states, under different conditions, carries out the corresponding state processing function.
Test processs such as agate iron, ferritic spheroidal graphite cast iron base iron, pearlitic ductile iron base iron, the iron base iron of wriggling and cooling curve are similar to gray iron.
Parameter acquisition module: the resulting data of identification module are carried out computing, and computing method are as follows:
Physical and chemical parameter A
i=∑ (B
i* X
i α+ C
i* Y
i β+ D
i)
Wherein, function A1, A2 ... Ai is physical and chemical parameters such as tensile strength sigma b, hardness HB, length growth rate, carbon equivalent ce L, carbon C, silicon Si, independent variable X
1, X
2, X
3... X
iBe curvilinear characteristic parameter (comprising TM, TL, Ts, differential, integration, rise etc.), Y
1, Y
2, Y
3... Y
iBe coupling technique parameter (Mn, P, alloying element and trace element etc.), B
1, B
2, B
3... B
iAnd C
1, C
2, C
3... C
iAnd α, β ... for returning nonlinear factor, D
1, D
2, D
3... D
iBe non-linear modified value.
The cooling curve of magnesium iron is different with gray iron etc., the physical and chemical parameter analysis of magnesium iron and maximum temperature T
M, liquidus temperature T
N, supercooling temperature TU, rise temperature T
R, many parameter correlations such as differential, integration.In the magnesium iron search temperature changing process is divided into and " heats up and wait for, search for T
M, identification T
NReach associated eigenvalue, identification T
UReach associated eigenvalue, identification T
RAnd associated eigenvalue, gather to finish " six states, under different conditions, carry out the corresponding state processing function.
Print module: comprise the printing (form, physical and chemical parameter and cooling curve) of online examining report, the state-detection of printer and the print routine of " technology prompting " etc.
Data remote module: two class communication interfaces are provided, 10/100M Ethernet interface and RS-232 serial line interface, and articulate on RS-232 interface that RS-232 changes the RS-485 module or RS-232 changes the CAN bus module, can make detection system possess 485 or the ability of CAN bus transfer simultaneously.The data remote module mainly is to provide the transmission service by network and serial port, detects data to client (as command centre) transmission history.Transport services adopts File Transfer Protocol, and service routine has adopted the open source software bftpd on the Linux.Serial-port communication has adopted the zmodem agreement, its data transmission rate height, good reliability, the bit error rate is low, and has the breakpoint transmission function, be very suitable for interference ratio at the scene bigger environment use.
Usb data memory module: utilize two USB mouths on the embedded main board,, be convenient to quality management by USB movable storage device unloading historical data.
Detection system of the present invention can also comprise gearing and output control circuit, as shown in Figure 7.
The sensor of metal liquid comprehensive performance on-line detecting system of the present invention as shown in figure 10.This sensor also is an importance that guarantees excellent effect of the present invention, and it comprises cup 101 and thermopair.Cup is cup-shaped, is used to pour into molten metal to be detected.The thermopair level is crossed cup, so that surrounded by the molten metal in the cup, thereby produces the electric signal relevant with the temperature variation of molten metal.Thermopair is by the accurate thermocouple wire 102,102 of K type ' be formed by connecting by high temperature spot welding, thermocouple wire 102,102 ' be respectively Ni-Cr and Ni-Si, and their free end is drawn by the locating slot of bottom of cup.Thermopair by resistant to elevated temperatures protective casing 103 around, one the test example in, the thermocouple wire diameter is less than 0.5mm, the internal diameter of protective casing is not more than 1.5mm, the position of thermopair in cup is in 2/3 place of cup height.In another test example, the position of thermopair in cup is in 1/2 place of cup height.Cup is that raw material adopts core shooter to make with the precoated sand, its tensile strength greater than 2.50Mpa, granularity less than 20 orders.On the inwall of cup and bottom surface, comprise a dope layer 104, dope layer is the powder of tellurium Te, bismuth Bi and aluminium Al with to be sprayed at cup after bonding agent evenly mixes inboard and form, wherein, total addition of tellurium, bismuth and aluminium is no less than 0.02% of the molten metal weight of containing in the cup, in a test example, tellurium, bismuth and the aluminium ratio of weight and three's sum separately are that tellurium is 60%, and bismuth is 30%, and aluminium is 10%.In another test example, tellurium, bismuth and the aluminium ratio of weight and three's sum separately are that tellurium is 70%, and bismuth is 25%, and aluminium is 5%.
The scope that detection system of the present invention can detect is: gray iron (can survey the whole six kinds of trades mark in HT100～350); Agate iron (can survey KTH300～370 4 kind of the trade mark); Magnesium iron (can survey QT400～900 8 kind of the trade mark); Ferritic spheroidal graphite cast iron base iron; Pearlitic ductile iron base iron; The iron base iron of wriggling; The inoculation cast iron degree of supercooling; And can expand to classifications such as cast steel, cast aluminium, cast copper; The gray iron test function be subdivided into again common gray iron, alloy gray iron, high-carbon gray iron, nickeliferous, add barium, contain arsenic, 19 subclasses such as roll, high-sulfur, high phosphorus; The magnesium iron test function is subdivided into 5 subclasses such as ferritic spheroidal graphite cast iron, pearlitic ductile iron, alloy normalizing magnesium iron, as-cast ball iron, hyperoxia low-sulfur magnesium iron again.19 parameters that can detect are: the trade mark, tensile strength sigma b, length growth rate δ, Brinell hardness HB, nodularization rate DS, nodulizing grade, carbide content K, carbon equivalent ce L, carbon C, silicon Si, maximum temperature T
M, liquidus temperature T
L, solidus temperature Ts, degree of supercooling Δ T, spheroidal graphite liquidus temperature T
N, spheroidal graphite supercooling temperature T
U, spheroidal graphite rise temperature T
R, maloperation prompting, save the technology prompting of waste product etc.
The speed of the detection that detection system of the present invention reaches is: magnesium iron-1.5 minute, gray iron, agate iron, magnesium iron base iron, the iron base iron of wriggling, high-carbon gray iron-3 minute.
The technology prompting that can provide according to testing result comprises: trade mark waste product not up to standard is reported to the police, intensity waste product not up to standard is reported to the police, length growth rate waste product not up to standard is reported to the police, hardness exceeds standard warnings, decaying spheroidisation is reported to the police, carbonide (spoken parts in traditional operas) exceeds standard warning etc.; Steel scrap should be added, answer carbon drop, should add copper, should add manganese, should add chromium, should add ferrosilicon, modulizer etc. should be added; , the sample cup do not install, signal wire does not connect, sample saucer frame need change, water the sample temperature too high, water the sample temperature low excessively, water sample slag inclusion arranged, water sample have overflow, sample cup thermo wires is thrust, changes cup and rob and water sample etc.
Can show, print following classification or full detail: the type of tested molten iron, all detect cooling curve, the technology prompting of physical and chemical parameter, molten iron, the management information (specimen coding, heat (batch) number, date, sample time) of test etc.; The online examining report list in stokehold that the same day is all; The online examining report list in stokehold of arbitrary sample in of that month; The online examining report list in stokehold of whole samples in of that month.Can pass through communication modes such as Ethernet, RS-232, RS-485, that the stokehold is detected, current or sample data in the past takes out from detection system, transfers to control center, is convenient to real-time multiple spot and commands the analysis-by-synthesis that reaches data.
With regard to the part important parameter, innovative point of the present invention also is: limit under the test specification of carbon is extended to 2.8% by common 3.0%, the upper limit extends to 4.2% by common 3.5%, limit under the test specification of silicon is extended to 0.6% by common 1.2%, the upper limit extends to 4.5% by common 2.7%, can fill up blank testing complicated, high-strength, Special Casting Iron spare.
Claims (1)
1, a kind of metal liquid comprehensive performance on-line detecting system, comprise: signal pickup assembly, thermoelectrical potential is united the metering interface arrangement, data processing main frame and data output apparatus, signal pickup assembly comprises sensor, sensor comprises cup and thermopair, be used to pour into molten metal to be detected, and by the thermopair generation electric signal relevant with the temperature variation of molten metal, thermoelectrical potential is united the metering interface arrangement and is comprised signal amplification circuit and A/D mould/number conversion circuit, signal amplification circuit is used for the electric signal of receiving sensor output, and this electric signal is amplified, the analog signal conversion through amplifying that A/D mould/number conversion circuit is used for signal amplification circuit output is a digital signal, so that the data processing main frame is handled this digital signal, data output apparatus comprises the data remote device, memory storage, display device, printing equipment; It is characterized in that:
Signal pickup assembly is by the sampling ware; sensor and integrated filter assembly constitute; the sampling ware is made by lightweight flame-proof thermal insulation material; sensor is selected high-precision galvanic couple silk for use; galvanic couple silk outside is with protective casing; place the cup middle part; temperature change value before and after being used for solidifying accurately is converted to and is easy to discern; the thermoelectrical potential value that 0～60mv changes; the square cup of sensor meets newton's cooling condition; it is made to be narrower than 20 purpose precoated sands; can guarantee that molten iron is by Fe-FeC3 stability series mode crystallization; the integrated filter assembly is the copper-constantan signal transmssion line of overcoat protection tube; it causes signal in the sensing chamber by the stokehold, can get rid of the various interference to sampled signal.
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| CN102645446B (en) * | 2012-05-17 | 2014-01-08 | 天津立中合金集团有限公司 | Online detection method of grain refinement and metamorphism effect of aluminum alloy melt |
| CN104019675A (en) * | 2014-06-25 | 2014-09-03 | 镇江新晔网络科技有限公司 | Temperature control system for smelter |
| CN109870552A (en) * | 2018-12-23 | 2019-06-11 | 合肥工业大学 | The comprehensive performances iron liquid intelligent detecting instrument such as elasticity modulus elongation, tensile yield strength |
| CN110018196B (en) * | 2019-04-26 | 2022-04-15 | 天津埃克申科技有限公司 | Multi-channel metal hot melt analysis system and method |
| CN111468346B (en) * | 2020-05-26 | 2021-11-05 | 山西圣士达铸业有限公司 | Nodular cast iron pipeline spraying device capable of being automatically positioned and adjusted by 360 degrees |
| JP2022041553A (en) * | 2020-09-01 | 2022-03-11 | ヤマハ株式会社 | Communication control method |
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