CN102441660B - Quantitative casting control system based on ultrasonic array and quantitative casting control method based on same - Google Patents
Quantitative casting control system based on ultrasonic array and quantitative casting control method based on same Download PDFInfo
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- 238000005266 casting Methods 0.000 title claims abstract description 110
- 238000000034 method Methods 0.000 title claims abstract description 33
- 239000007788 liquid Substances 0.000 claims abstract description 106
- 238000003723 Smelting Methods 0.000 claims abstract description 5
- 239000000872 buffer Substances 0.000 claims description 69
- 239000003990 capacitor Substances 0.000 claims description 26
- 108010076504 Protein Sorting Signals Proteins 0.000 claims description 20
- 230000008569 process Effects 0.000 claims description 14
- 230000036541 health Effects 0.000 claims description 6
- 238000007493 shaping process Methods 0.000 claims description 6
- 229910000831 Steel Inorganic materials 0.000 claims description 3
- 238000011217 control strategy Methods 0.000 claims description 3
- 238000012545 processing Methods 0.000 claims description 3
- 239000010959 steel Substances 0.000 claims description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 40
- 229910052802 copper Inorganic materials 0.000 description 39
- 239000010949 copper Substances 0.000 description 39
- 238000010586 diagram Methods 0.000 description 5
- 238000005303 weighing Methods 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 230000001133 acceleration Effects 0.000 description 2
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- 230000003321 amplification Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- PTVDYARBVCBHSL-UHFFFAOYSA-N copper;hydrate Chemical compound O.[Cu] PTVDYARBVCBHSL-UHFFFAOYSA-N 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
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- 229910052742 iron Inorganic materials 0.000 description 1
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Abstract
The invention discloses a quantitative casting control system based on an ultrasonic array, which comprises a die, a casting bath, a smelting furnace, a motor, an ultrasonic sensor array, a driver and a control unit, wherein the ultrasonic sensor array is arranged above the die, the driver is connected with the motor, and the control unit is connected with the ultrasonic sensor array and the driver. By the aid of the ultrasonic sensor array, the liquid level of casting liquid can be rapidly and accurately detected, precision of a detecting system is improved to a large extent, and accordingly control reliability of the quantitative casting control system is also improved. The invention further discloses a quantitative casting control method based on the ultrasonic array, which is used for precisely measuring the liquid level of the casting liquid and ensuring reliability and safety of quantitative casting control by means of ultrasonic ranging technique.
Description
Technical field
The invention belongs to metallurgical control technology field, be specifically related to a kind of quantitative casting control system and control method thereof based on ultrasonic array.
Background technology
The positive plate quantitative casting is one important procedure in the copper smelting process, need copper liquid be cast into the positive plate of profile unanimity by quantitative control, supplies with next process-electrolytic process.The uniformity of positive plate profile will directly influence the energy-saving effect of electrolytic process.The temperature that cast copper liquid is watered in strict control simultaneously, 20～30 ℃ of common high copper fusing points, promptly 1100～1130 ℃.The copper coolant-temperature gage is suitable, and dissolved gases is few in the copper liquid, the positive plate densification of output, and copper water mold can make whole copper ingot almost solidify simultaneously, thereby obtains the compact grained positive plate.The copper coolant-temperature gage is too high, not only increases burnup, increases the gas dissolving, makes positive plate pore occur, makes easily that also coating on the mold is rotten and comes off, so that the mould phenomenon that sticks together, can make also that mold is overheated and shortens useful life; The copper coolant-temperature gage is low excessively, and is mobile poor, copper continuously in the time of seriously, even set off an explosion.
Simultaneously, obtain high-quality cathode copper, the appearance and size of positive plate is extremely important, generally requires outward appearance level and smooth, smooth, and overlap, burr will lack, and the error of quality and thickness is the smaller the better, help reducing the electric energy loss of electrolytic process more.
At present, in the domestic copper liquid casting cycle, the capacity that the operator usually estimates copper liquid in the positive plate mould estimates whether to reach the thickness requirement of positive plate, manually control whether stop casting, this control method and workman's qualification, technical merit, sense of responsibility and duty have direct relation; So there is bigger error in the positive plate appearance and size that is cast into.
A kind of existing more advanced quantitative casting method is by adopting electronic scale to weigh to realize control, this weighing system by mechano-electronic claim, amplifier, digital to analog converter form.It is weighed is to utilize the mechanical lever principle, with balance weight iron installation weight is balanced, and the sensor load-bearing claims that with quilt weight in kind is suitable in 1: 8 ratio.This technical scheme need be transformed copper liquid casting equipment up hill and dale, and expense is higher, complex structure, and machined piece precision height especially, the lever material is strict; The casting that exists in the electronic scale dynamic weighing simultaneously starts and stops moment owing to acceleration change, and the electronic scale id reaction all can impact the check weighing precision slowly.
Summary of the invention
At the above-mentioned technological deficiency of existing in prior technology, the invention provides a kind of quantitative casting control system and control method thereof based on ultrasonic array, can realize accurate measurement to casting liquid liquid level, and then to the quantitative casting Instantaneous Control.
A kind of quantitative casting control system based on ultrasonic array comprises:
Mould;
Be used in mould, toppling over the casting groove of casting liquid;
Link to each other with the casting groove and be used for providing the smelting furnace of the liquid of casting to the casting groove;
The motor that links to each other with casting groove flow-guiding mouth end by steel wire rope;
Be located at the array of ultrasonic sensors of mould top, described array of ultrasonic sensors is rearranged by n ultrasonic sensor;
The driver that links to each other with motor;
The control module that links to each other with driver with array of ultrasonic sensors.
Described control module comprises: a controller, a ultrasonic wave transmitter module, a n channel switching module and n ultrasonic wave receiver module;
Described channel switching module and controller, ultrasonic wave transmitter module and corresponding ultrasonic sensor link to each other with the ultrasonic wave receiver module, and its switching signal according to controller makes ultrasonic sensor be communicated with the ultrasonic wave transmitter module or is communicated with corresponding ultrasonic wave receiver module;
Described ultrasonic wave transmitter module links to each other with channel switching module with controller, and its triggering signal to controller output is modulated, and to the ultrasonic sensor output drive signal, to drive ultrasonic sensor emission ultrasonic signal sequence;
Described ultrasonic wave receiver module links to each other with channel switching module with controller, and it nurses one's health shaping to the echo-signal that ultrasonic sensor receives, and to controller output square-wave signal;
Described controller is tried to achieve several transmitting-receiving time quantums according to the clock of triggering signal and the clock of several square-wave signals, calculates the liquid level and the temperature of current casting liquid according to these transmitting-receiving time quantums; And then according to the liquid level of casting liquid, to driver output control signal.
Preferably, described control module is connected with alarm, and control module is according to the temperature of casting liquid, to the alarm output alarm signal; To guarantee the security and the validity of production process.
Preferably, described array of ultrasonic sensors equidistantly is made of side by side n ultrasonic sensor; Make that to casting liquid level gauging calculate simply, precision is higher.
Preferably, described ultrasonic wave receiver module is made up of a comparator, two operational amplifiers, a diode, nine resistance and two electric capacity; Wherein: an end of the 18 resistance links to each other with an end of the 8th electric capacity and constitutes the receiving terminal of ultrasonic wave receiver module, the other end of the 18 resistance links to each other with the normal phase input end of second operational amplifier and ground connection, the other end of the 8th electric capacity links to each other with an end of the 16 resistance, the other end of the 16 resistance links to each other with the inverting input of an end of the 12 resistance and second operational amplifier, positive supply termination first supply voltage of second operational amplifier, the negative supply termination second source voltage of second operational amplifier, the other end of the 12 resistance links to each other with the output of second operational amplifier and the normal phase input end of first operational amplifier, the output of the inverting input of first operational amplifier and first operational amplifier, one end of the 7th electric capacity and an end of the 19 resistance link to each other, the other end of the 19 resistance links to each other with the anode of first diode and ground connection, the negative electrode of the other end of the 7th electric capacity and first diode, one end of the 14 resistance, one end of the 17 resistance and the first input end of comparator link to each other, the other end of the 17 resistance links to each other with an end of the 20 resistance and ground connection, the other end of the 20 resistance links to each other with second input of an end of the 15 resistance and comparator, the other end of the 14 resistance links to each other with the power end of an end of the 13 resistance and comparator and connects the 3rd supply voltage, the other end of the 13 resistance links to each other with the other end of the 15 resistance, the earth terminal ground connection of comparator, the output of comparator links to each other with controller and exports square-wave signal; Can improve precision to casting liquid level gauging.
Preferably, described ultrasonic wave transmitter module is made up of five reverse buffers, two forward buffers, two triodes, four electric capacity and six resistance; Wherein: an end of the 6th electric capacity constitutes the negative transmitting terminal of ultrasonic wave transmitter module, one end of the other end of the 6th electric capacity and the 6th resistance, one end of the tenth resistance, the output of the 4th reverse buffer links to each other with the output of the 5th reverse buffer, the input of the input of the 4th reverse buffer and the 5th reverse buffer, the input of first reverse buffer, one end of the output of the second forward buffer and the 9th resistance links to each other, power supply termination first supply voltage of first reverse buffer, the earth terminal ground connection of first reverse buffer, one end of the output of first reverse buffer and the 3rd resistance, the input of second reverse buffer links to each other with the input of the 3rd reverse buffer, the output of the output of second reverse buffer and the 3rd reverse buffer, one end of first resistance, one end of the 5th resistance links to each other with an end of the 3rd electric capacity, the other end of the 3rd electric capacity constitutes the positive transmitting terminal of ultrasonic wave transmitter module, the other end of the power end of the second forward buffer and the 9th resistance and an end of the 5th electric capacity link to each other and connect first supply voltage, the earth terminal ground connection of the second forward buffer, the input of the second forward buffer links to each other with the output of the first forward buffer, the other end of the 5th electric capacity links to each other with an end of the 4th electric capacity and ground connection, the other end of the 4th electric capacity links to each other with the power end of the first forward buffer and connects first supply voltage, the Enable Pin of the first forward buffer links to each other with the earth terminal of the first forward buffer and ground connection, the input of the first forward buffer links to each other with controller and receives triggering signal, the colelctor electrode of first triode connects first supply voltage, the base stage of first triode links to each other with controller and receives first amplitude-modulated signal, the emitter stage of second triode connects amplitude modulated voltage, the base stage of second triode links to each other with controller and receives second amplitude-modulated signal, the colelctor electrode of the emitter stage of first triode and second triode, the other end of the 3rd resistance, the other end of first resistance, the other end of the 5th resistance, the other end of the 6th resistance links to each other with the other end of the tenth resistance; Can improve precision to casting liquid level gauging.
Described controller is MCU (Micro Control Unit).
A kind of quantitative casting control method based on ultrasonic array comprises the steps:
(1) utilize the casting liquid emission ultrasonic signal sequence of control module Real Time Drive array of ultrasonic sensors in mould, and several echo-signals of reflecting via casting liquid of received ultrasonic signal sequence;
(2) described echo-signal is nursed one's health shaping, obtain square-wave signal; According to the clock of triggering signal and the clock of several square-wave signals, try to achieve several transmitting-receiving time quantums;
(3), try to achieve some groups of data about casting liquid liquid level and temperature according to described transmitting-receiving time quantum; After the processing of data equalization, obtain the liquid level and the temperature of current casting liquid;
(4) control module to driver output control signal, by drive motors work, is controlled the dump angle of casting groove according to the liquid level of casting liquid; Control module is according to the temperature of casting liquid, to the alarm output alarm signal.
Preferably, in the described step (1), control module is launched the ultrasonic signal sequence according to the casting liquid of work schedule driven array of ultrasonic sensors in mould: at first, make the most preceding ultrasonic sensor of arrangement in the array of ultrasonic sensors as the ultrasonic wave emission sensor and launch the ultrasonic signal sequence, make ultrasonic sensor in this ultrasonic wave emission sensor angle of departure coverage as the ultrasonic wave receiving sensor and receive echo-signal simultaneously; After receiving, ultrasonic wave emission sensor angle of departure coverage before making in the once transmitting-receiving process is outer arranges the most preceding ultrasonic sensor as the ultrasonic wave emission sensor in the current transmitting-receiving process and launch the ultrasonic signal sequence, make ultrasonic sensor in the current ultrasonic wave emission sensor angle of departure coverage as the ultrasonic wave receiving sensor and receive echo-signal simultaneously, according to this, finish the transmitting-receiving process of whole ultrasonic wave sensor array; Can avoid confusion, by repeatedly measuring the random disturbances of removing measuring process.
Preferably, in the described step (3), ask for some groups of methods and be about the data of casting liquid liquid level and temperature:
1) makes any two ultrasonic sensors in arbitrary ultrasonic wave emission sensor angle of departure coverage in the array of ultrasonic sensors as the combination of ultrasonic wave receiving sensor, solve the spread speed of ultrasonic wave in medium under the distance of array of ultrasonic sensors and casting liquid and the Current Temperatures according to following formula;
Wherein: i and j are the sequence number of ultrasonic sensor, i ultrasonic sensor and j ultrasonic sensor are the ultrasonic wave receiving sensor combination in the same ultrasonic wave emission sensor angle of departure coverage, v is the spread speed of ultrasonic wave in the Current Temperatures medium, h is the distance of array of ultrasonic sensors and casting liquid, d
iAnd d
jThe distance of difference i ultrasonic sensor and j ultrasonic sensor and ultrasonic wave emission sensor, t
iAnd t
jThe transmitting-receiving time quantum of difference i ultrasonic sensor and j ultrasonic sensor correspondence;
2), solve the liquid level and the temperature of casting liquid by following formula according to the distance and the spread speed of ultrasonic wave in the Current Temperatures medium of array of ultrasonic sensors with casting liquid;
H＝h′-h (2)
T＝kT′-Δ(4)
Wherein: H is the liquid level of casting liquid, and T is the temperature of casting liquid, and T ' is the Current Temperatures of ultrasonic wave propagation medium, and h ' is the distance of array of ultrasonic sensors and mould, v
0Be the spread speed of ultrasonic wave in 0 degree centigrade of medium, k is a calibrated error, and Δ is a calibrated error;
3) the ultrasonic wave receiving sensor combination in all ultrasonic wave emission sensor angle of departure coverages in the traversal array of ultrasonic sensors is according to step 1) and 2), try to achieve some groups of data about casting liquid liquid level and temperature.
Preferably, in the described step (4), control module adopts PID (proportional-integral-differential) control strategy to export control signal to driver according to the liquid level of casting liquid, by drive motors work, and the dump angle of control casting groove; Can improve the speed and the accuracy of casting.
Useful technique effect of the present invention is:
(1) the present invention controls the ultrasonic wave transmitter module by controller, can carry out the modulation of amplitude and phase place to the ultrasonic waves transmitted signal, and receives processing and found range, and can effectively improve the certainty of measurement of array of ultrasonic sensors.
(2) the present invention by array of ultrasonic sensors can measure simultaneously the casting liquid temperature and the height, reduced the complexity of scrap build and saved cost.
(3) the present invention can detect the liquid level of casting liquid fast and accurately by array of ultrasonic sensors, thereby effectively solves the casting startup that the electronic-weighing method exists in the prior art and stop moment the influence that the check weighing precision is caused because acceleration change and electronic scale id reaction are slow; Improve the precision of detection system to a great extent, thereby also improved the control reliability of quantitative casting system.
(4) the present invention carries out PID control by controller to quantitative casting, can improve the speed and the accuracy of casting; Detect the approximate temperature of casting liquid simultaneously by array of ultrasonic sensors, realized noncontacting measurement preferably to the casting liquid temp, the product quality of casting model be can effectively improve, and the life-span of mould, the security that has improved casting cycle simultaneously prolonged.
Description of drawings
Fig. 1 is the structural representation of control system of the present invention.
Fig. 2 is the structural principle schematic diagram of control module.
Fig. 3 is the circuit diagram of channel switching module.
Fig. 4 is the circuit diagram of ultrasonic wave transmitter module.
Fig. 5 is the circuit diagram of ultrasonic wave receiver module.
Fig. 6 is the transmitting-receiving schematic diagram of array of ultrasonic sensors.
The specific embodiment
In order more specifically to describe the present invention, control system of the present invention and control method thereof are elaborated below in conjunction with the drawings and the specific embodiments.
Present embodiment is cast into example with positive plate copper liquid; As shown in Figure 1, a kind of quantitative casting control system based on ultrasonic array comprises:
The positive plate mould;
Be used for toppling in the anode board mold casting groove of copper liquid;
Link to each other with the casting groove and be used for providing the smelting furnace of copper liquid to the groove of casting;
The motor that links to each other with casting groove flow-guiding mouth end by steel wire rope;
Be located at the array of ultrasonic sensors of positive plate mould top, array of ultrasonic sensors equidistantly is made of side by side 8 ultrasonic sensors; In the present embodiment, it is TCF1M-21T/R1 that ultrasonic sensor adopts model, and centre frequency is 40kHz, and maximum emission angle is 60 ° a ultrasonic sensor.
The driver that links to each other with motor;
The control module that links to each other with driver with array of ultrasonic sensors; Driver carries out power amplification with the control signal of control module output, and then the control drive motors;
The alarm that links to each other with control module.
As shown in Figure 2, control module comprises MCU, ultrasonic wave transmitter module, eight channel switching module and eight ultrasonic wave receiver modules;
Channel switching module and MCU, ultrasonic wave transmitter module and corresponding ultrasonic sensor link to each other with the ultrasonic wave receiver module, and its switching signal according to MCU makes ultrasonic sensor be communicated with the ultrasonic wave transmitter module or is communicated with corresponding ultrasonic wave receiver module.As shown in Figure 3, the channel switching module in the present embodiment is made up of two relays, two triodes, two diodes and two resistance; Wherein: the negative electrode of the second diode D2 links to each other with the end of the first relay coil K1 and connect+supply voltage of 5V, the anode of the second diode D2 links to each other with the other end of the first relay coil K1 and the colelctor electrode of the 5th triode Q5, the base stage of the 5th triode Q5 links to each other with an end of the 28 resistance R 28, the other end of the 28 resistance R 28 links to each other with MCU and the receiving key signal, the grounded emitter GND of the 5th triode Q5, one end ground connection GND of first relay K, 1 normally-closed contact, one end of first relay K, 1 normally opened contact links to each other with the negative transmitting terminal Emit-of ultrasonic wave transmitter module, and the other end of first relay K, 1 normally-closed contact and normally opened contact links to each other with the first sending and receiving end A of corresponding ultrasonic sensor; The negative electrode of the 3rd diode D3 links to each other with an end of second relay K, 2 coils and connect+supply voltage of 5V, the anode of the 3rd diode D3 links to each other with the other end of second relay K, 2 coils and the colelctor electrode of the 6th triode Q6, the base stage of the 6th triode Q6 links to each other with an end of the 29 resistance R 29, the other end of the 29 resistance R 29 links to each other with MCU and the receiving key signal, the grounded emitter GND of the 6th triode Q6, one end of second relay K, 2 normally-closed contacts links to each other with the receiving terminal Receiver of corresponding ultrasonic wave receiver module, one end of second relay K, 2 normally opened contacts links to each other with the positive transmitting terminal Emit+ of ultrasonic wave transmitter module, and the other end of second relay K, 2 normally-closed contacts and normally opened contact links to each other with the second sending and receiving end B of corresponding ultrasonic sensor.
The ultrasonic wave transmitter module links to each other with channel switching module with MCU, and its triggering signal to MCU output is modulated, and to the ultrasonic sensor output drive signal, to drive ultrasonic sensor emission ultrasonic signal sequence.As shown in Figure 4, the ultrasonic wave transmitter module in the present embodiment is made up of five reverse buffers, two forward buffers, two triodes, four electric capacity and six resistance; Wherein: an end of the 6th capacitor C 6 constitutes the negative transmitting terminal Emit-of ultrasonic wave transmitter module, one end of the other end of the 6th capacitor C 6 and the 6th resistance R 6, one end of the tenth resistance R 10, the output of the 4th reverse buffer Y4 links to each other with the output of the 5th reverse buffer Y5, the input of the input of the 4th reverse buffer Y4 and the 5th reverse buffer Y5, the input of the first reverse buffer Y1, the output of the second forward buffer U2 links to each other with an end of the 9th resistance R 9, the supply voltage of power supply termination+5V of the first reverse buffer Y1, the earth terminal ground connection GND of the first reverse buffer Y1, one end of the output of the first reverse buffer Y1 and the 3rd resistance R 3, the input of the second reverse buffer Y2 links to each other with the input of the 3rd reverse buffer Y3, the output of the output of the second reverse buffer Y2 and the 3rd reverse buffer Y3, one end of first resistance R 1, one end of the 5th resistance R 5 links to each other with an end of the 3rd capacitor C 3, the other end of the 3rd capacitor C 3 constitutes the positive transmitting terminal Emit+ of ultrasonic wave transmitter module, the power end of the second forward buffer U2 links to each other with an end of the other end of the 9th resistance R 9 and the 5th capacitor C 5 and connect+supply voltage of 5V, the earth terminal ground connection GND of the second forward buffer U2, the input of the second forward buffer U2 links to each other with the output of the first forward buffer U1, the other end of the 5th capacitor C 5 links to each other with an end of the 4th capacitor C 4 and ground connection GND, the other end of the 4th capacitor C 4 links to each other with the power end of the first forward buffer U1 and connect+supply voltage of 5V, the Enable Pin of the first forward buffer U1 links to each other with the earth terminal of the first forward buffer U1 and ground connection GND, the input of the first forward buffer U1 links to each other with MCU and receives triggering signal, the colelctor electrode of the first triode Q1 connects+supply voltage of 5V, the base stage of the first triode Q1 links to each other with MCU and receives the first amplitude-modulated signal AM1, the emitter stage of the second triode Q2 connects+amplitude modulated voltage of 12V, the base stage of the second triode Q2 links to each other with MCU and receives the second amplitude-modulated signal AM2, the colelctor electrode of the emitter stage of the first triode Q1 and the second triode Q2, the other end of the 3rd resistance R 3, the other end of first resistance R 1, the other end of the 5th resistance R 5, the other end of the 6th resistance R 6 links to each other with the other end of the tenth resistance R 10.
The ultrasonic wave receiver module links to each other with channel switching module with MCU, and it nurses one's health shaping to the echo-signal that ultrasonic sensor receives, and to MCU output square-wave signal.As shown in Figure 5, the ultrasonic wave receiver module in the present embodiment is made up of a comparator, two operational amplifiers, a diode, nine resistance and two electric capacity; Wherein: an end of the 18 resistance R 18 links to each other with an end of the 8th capacitor C 8 and constitutes the receiving terminal Receiver of ultrasonic wave receiver module, the other end of the 18 resistance R 18 links to each other with the normal phase input end IN+ of second operational amplifier A 2 and ground connection GND, the other end of the 8th capacitor C 8 links to each other with an end of the 16 resistance R 16, the other end of the 16 resistance R 16 links to each other with an end of the 12 resistance R 12 and the inverting input IN-of second operational amplifier A 2, the supply voltage of the positive supply termination+5V of second operational amplifier A 2, the supply voltage of the negative supply termination-5V of second operational amplifier A 2, the other end of the 12 resistance R 12 links to each other with the output of second operational amplifier A 2 and the normal phase input end IN+ of first operational amplifier A 1, the inverting input IN-of first operational amplifier A 1 and the output of first operational amplifier A 1, one end of the 7th capacitor C 7 links to each other with an end of the 19 resistance R 19, the other end of the 19 resistance R 19 links to each other with the anode of the first diode D1 and ground connection GND, the negative electrode of the other end of the 7th capacitor C 7 and the first diode D1, one end of the 14 resistance R 14, one end of the 17 resistance R 17 links to each other with the first input end IN1 of comparator Z, the other end of the 17 resistance R 17 links to each other with an end of the 20 resistance R 20 and ground connection GND, the other end of the 20 resistance R 20 links to each other with an end of the 15 resistance R 15 and the second input IN2 of comparator Z, one end of the other end of the 14 resistance R 14 and the 13 resistance R 13 and the power end VCC of comparator Z link to each other and connect+supply voltage of 3.3V, the other end of the 13 resistance R 13 links to each other with the other end of the 15 resistance R 15, the earth terminal ground connection GND of comparator Z, the output of comparator Z links to each other with MCU and exports square-wave signal.
MCU tries to achieve several transmitting-receiving time quantums according to the clock of triggering signal and the clock of several square-wave signals, calculates the height and the temperature of current copper liquid according to these transmitting-receiving time quantums; And then according to the height of copper liquid, to driver output control signal; According to the temperature of copper liquid, to the alarm output alarm signal; In the present embodiment, it is the fpga chip of XC3S250E-4FTG256C that MCU adopts the model of Xilinx company.
The control method based on the quantitative casting control system of ultrasonic array of present embodiment comprises the steps:
(1) utilize copper liquid emission ultrasonic signal sequence in the control module Real Time Drive array of ultrasonic sensors anode board mold, and several echo-signals of reflecting via copper liquid of received ultrasonic signal sequence.
As shown in Figure 6, in the present embodiment, control module is launched the ultrasonic signal sequence according to the copper liquid in the work schedule driven array of ultrasonic sensors anode board mold: at first, make the most preceding ultrasonic sensor 1 of arrangement in the array of ultrasonic sensors as the ultrasonic wave emission sensor and launch the ultrasonic signal sequence, make ultrasonic sensor 2, ultrasonic sensor 3 in this ultrasonic wave emission sensor angle of departure coverage simultaneously, ultrasonic sensor 4 is as the ultrasonic wave receiving sensor and receive echo-signal; After receiving, ultrasonic wave emission sensor angle of departure coverage before making in the once transmitting-receiving process is outer arranges the most preceding ultrasonic sensor 5 as the ultrasonic wave emission sensor in the current transmitting-receiving process and launch the ultrasonic signal sequence, make ultrasonic sensor 6, ultrasonic sensor 7 in the current ultrasonic wave emission sensor angle of departure coverage simultaneously, ultrasonic sensor 8 is as the ultrasonic wave receiving sensor and receive echo-signal, to finish the transmitting-receiving process of whole ultrasonic wave sensor array.
(2) echo-signal is nursed one's health shaping, obtain square-wave signal; According to the clock of triggering signal and the clock of several square-wave signals, try to achieve several transmitting-receiving time quantums.
It was first moment that note MCU triggers the moment that drives ultrasonic sensor 1 emission ultrasonic signal sequence, the moment that MCU receives the square-wave signal of ultrasonic sensor 2 is second constantly, then first is the corresponding transmitting-receiving time quantum t of ultrasonic sensor 2 with second constantly time interval constantly
2Try to achieve the transmitting-receiving time quantum t of ultrasonic sensor 3 and ultrasonic sensor 4 according to this
3And t
4MCU is triggered drive ultrasonic sensor 5 emission ultrasonic signal sequences, in like manner try to achieve ultrasonic sensor 6, ultrasonic sensor 7 and the corresponding respectively transmitting-receiving time quantum t of ultrasonic sensor 8
6, t
7And t
8
(3) according to the transmitting-receiving time quantum, by the following method, try to achieve some groups of data about copper liquid height and temperature.
1) makes any two ultrasonic sensors in ultrasonic sensor 1 angle of departure coverage receive combination, solve the spread speed of ultrasonic wave in medium under the distance of array of ultrasonic sensors and copper liquid and the Current Temperatures according to following formula as ultrasonic wave;
Wherein: i and j are the sequence number of ultrasonic sensor, ultrasonic sensor i and ultrasonic sensor j are that the ultrasonic wave in ultrasonic sensor 1 angle of departure coverage receives combination, v be ultrasonic wave in the airborne spread speed of Current Temperatures, h is the distance of array of ultrasonic sensors and copper liquid, d
iAnd d
jThe distance of difference ultrasonic sensor i and ultrasonic sensor j and ultrasonic sensor 1, t
iAnd t
jThe transmitting-receiving time quantum of difference ultrasonic sensor i and ultrasonic sensor j correspondence; Because in the present embodiment, array of ultrasonic sensors equidistantly is made of side by side 8 ultrasonic sensors, then d
i=(i-1) d, d
j=(j-1) d, d is the spacing of adjacent two ultrasonic sensors in the array of ultrasonic sensors.
2), find the solution the height and the temperature of copper liquid by following formula according to h and v;
H＝h′-h (2)
T＝kT′-Δ(4)
Wherein: H is the height of copper liquid, and T is the temperature of copper liquid, and T ' is the Current Temperatures of air, and h ' is the distance of array of ultrasonic sensors and positive plate mould, v
0For ultrasonic wave 0 degree centigrade of airborne spread speed, k is a calibrated error, Δ is a calibrated error; Formula 4 is for recording the actual temperature T of one group of copper liquid according to thermocouple
0, T
1, T
2, T
3... T
n, and the temperature T of trying to achieve one group of air according to the present embodiment correspondence
0', T
1', T
2', T
3' ... T
n', obtain by least square fitting.
3) make any two ultrasonic sensors in ultrasonic sensor 5 angle of departure coverages receive combination, according to step 1) and 2 as ultrasonic wave), find the solution the height and the temperature of copper liquid; For whole ultrasonic wave sensor array, can try to achieve six groups of data altogether about copper liquid height and temperature.
After at last the data equalization being handled, obtain the height and the temperature of current copper liquid.
(4) control module to driver output control signal, by drive motors work, is controlled the dump angle of casting groove according to the height of copper liquid.
Wherein, control module utilizes the PID control strategy, by drive motors work, and the dump angle of control casting groove, concrete grammar is as follows; The thickness requirement of positive plate is 50mm in the present embodiment.
When a. just having begun to cast,, will control parameter P and transfer big (increasing the dump angle of casting groove), accelerate the response speed of casting cycle because the copper liquid height in the positive plate mould is far smaller than 50mm;
B. proceeds to a half when casting, the height of copper liquid is approximately 25mm, will control parameter P and turn the dump angle of groove (reduce cast) down, and the assurance system is being unlikely to overshoot in the response fast, the stability of raising control system transition;
C. when casting when being near completion, the height of copper liquid is approximately 40mm, will control parameter P and further turn the dump angle of groove (further reduce cast) down, and the stable state that carries out the transition to comparatively level and smooth with the assurance system prevents the overshoot appearance;
D. when casting was finished, the height of copper liquid reached 50mm, made control parameter P be adjusted to 0 (mention the casting groove, making dump angle is negative angle), stopped casting.
Control module, is realized reporting to the police to the alarm output alarm signal according to the temperature of copper liquid simultaneously; The temperature requirement of casting process is 1100 ° in the present embodiment, and when copper liquid temperature surpassed 1100 °, the alarm signal of control module output was the signal of telecommunication of high level.
Claims (6)
1. the quantitative casting control system based on ultrasonic array is characterized in that, comprising:
Mould;
Be used in mould, toppling over the casting groove of casting liquid;
Link to each other with the casting groove and be used for providing the smelting furnace of the liquid of casting to the casting groove;
The motor that links to each other with casting groove flow-guiding mouth end by steel wire rope;
Be located at the array of ultrasonic sensors of mould top, described array of ultrasonic sensors is rearranged by n ultrasonic sensor;
The driver that links to each other with motor;
The control module that links to each other with driver with array of ultrasonic sensors; Described control module comprises: a controller, a ultrasonic wave transmitter module, a n channel switching module and n ultrasonic wave receiver module;
Described channel switching module and controller, ultrasonic wave transmitter module and corresponding ultrasonic sensor link to each other with the ultrasonic wave receiver module, and its switching signal according to controller makes ultrasonic sensor be communicated with the ultrasonic wave transmitter module or is communicated with corresponding ultrasonic wave receiver module;
Described ultrasonic wave transmitter module links to each other with channel switching module with controller, and its triggering signal to controller output is modulated, and to the ultrasonic sensor output drive signal, to drive ultrasonic sensor emission ultrasonic signal sequence;
Described ultrasonic wave receiver module links to each other with channel switching module with controller, and it nurses one's health shaping to the echo-signal that ultrasonic sensor receives, and to controller output square-wave signal;
Described controller is tried to achieve several transmitting-receiving time quantums according to the clock of triggering signal and the clock of several square-wave signals, calculates the liquid level and the temperature of current casting liquid according to these transmitting-receiving time quantums; And then according to the liquid level of casting liquid, to driver output control signal;
Described ultrasonic wave receiver module is made up of a comparator, two operational amplifiers, a diode, nine resistance R 12～R20 and two capacitor C 7～C8; Wherein: an end of resistance R 18 links to each other with an end of capacitor C 8 and constitutes the receiving terminal of ultrasonic wave receiver module, the other end of resistance R 18 links to each other with the normal phase input end of second operational amplifier and ground connection, the other end of capacitor C 8 links to each other with an end of resistance R 16, the other end of resistance R 16 links to each other with an end of resistance R 12 and the inverting input of second operational amplifier, positive supply termination first supply voltage of second operational amplifier, the negative supply termination second source voltage of second operational amplifier, the other end of resistance R 12 links to each other with the output of second operational amplifier and the normal phase input end of first operational amplifier, the output of the inverting input of first operational amplifier and first operational amplifier, one end of capacitor C 7 links to each other with an end of resistance R 19, the other end of resistance R 19 links to each other with the anode of first diode and ground connection, the negative electrode of the other end of capacitor C 7 and first diode, one end of resistance R 14, one end of resistance R 17 and the first input end of comparator link to each other, the other end of resistance R 17 links to each other with an end of resistance R 20 and ground connection, the other end of resistance R 20 links to each other with an end of resistance R 15 and second input of comparator, one end of the other end of resistance R 14 and resistance R 13 and the power end of comparator link to each other and connect the 3rd supply voltage, the other end of resistance R 13 links to each other with the other end of resistance R 15, the earth terminal ground connection of comparator, the output of comparator links to each other with controller and exports square-wave signal.
2. the quantitative casting control system based on ultrasonic array according to claim 1, it is characterized in that: described control module is connected with alarm, and control module is according to the temperature of casting liquid, to the alarm output alarm signal.
3. the quantitative casting control system based on ultrasonic array according to claim 1 is characterized in that: described array of ultrasonic sensors equidistantly is made of side by side n ultrasonic sensor.
4. the quantitative casting control system based on ultrasonic array according to claim 1 is characterized in that: described ultrasonic wave transmitter module is made up of five reverse buffers, two forward buffers, two triodes, four capacitor C 3～C6 and six resistance R 1～R6; Wherein: an end of capacitor C 6 constitutes the negative transmitting terminal of ultrasonic wave transmitter module, one end of the other end of capacitor C 6 and resistance R 6, one end of resistance R 4, the output of the 4th reverse buffer links to each other with the output of the 5th reverse buffer, the input of the input of the 4th reverse buffer and the 5th reverse buffer, the input of first reverse buffer, one end of the output of the second forward buffer and resistance R 2 links to each other, power supply termination first supply voltage of first reverse buffer, the earth terminal ground connection of first reverse buffer, one end of the output of first reverse buffer and resistance R 3, the input of second reverse buffer links to each other with the input of the 3rd reverse buffer, the output of the output of second reverse buffer and the 3rd reverse buffer, one end of resistance R 1, one end of resistance R 5 links to each other with an end of capacitor C 3, the other end of capacitor C 3 constitutes the positive transmitting terminal of ultrasonic wave transmitter module, the other end of the power end of the second forward buffer and resistance R 2 and an end of capacitor C 5 link to each other and connect first supply voltage, the earth terminal ground connection of the second forward buffer, the input of the second forward buffer links to each other with the output of the first forward buffer, the other end of capacitor C 5 links to each other with an end of capacitor C 4 and ground connection, the other end of capacitor C 4 links to each other with the power end of the first forward buffer and connects first supply voltage, the Enable Pin of the first forward buffer links to each other with the earth terminal of the first forward buffer and ground connection, the input of the first forward buffer links to each other with controller and receives triggering signal, the colelctor electrode of first triode connects first supply voltage, the base stage of first triode links to each other with controller and receives first amplitude-modulated signal, the emitter stage of second triode connects amplitude modulated voltage, the base stage of second triode links to each other with controller and receives second amplitude-modulated signal, the colelctor electrode of the emitter stage of first triode and second triode, the other end of resistance R 3, the other end of resistance R 1, the other end of resistance R 5, the other end of resistance R 6 links to each other with the other end of resistance R 4.
5. the control method of the quantitative casting control system based on ultrasonic array as claimed in claim 1 comprises the steps:
(1) utilize the casting liquid emission ultrasonic signal sequence of control module Real Time Drive array of ultrasonic sensors in mould, and several echo-signals of reflecting via casting liquid of received ultrasonic signal sequence; Wherein, control module is launched the ultrasonic signal sequence according to the casting liquid of work schedule driven array of ultrasonic sensors in mould: at first, make the most preceding ultrasonic sensor of arrangement in the array of ultrasonic sensors as the ultrasonic wave emission sensor and launch the ultrasonic signal sequence, make ultrasonic sensor in this ultrasonic wave emission sensor angle of departure coverage as the ultrasonic wave receiving sensor and receive echo-signal simultaneously; After receiving, ultrasonic wave emission sensor angle of departure coverage before making in the once transmitting-receiving process is outer arranges the most preceding ultrasonic sensor as the ultrasonic wave emission sensor in the current transmitting-receiving process and launch the ultrasonic signal sequence, make ultrasonic sensor in the current ultrasonic wave emission sensor angle of departure coverage as the ultrasonic wave receiving sensor and receive echo-signal simultaneously, according to this, finish the transmitting-receiving process of whole ultrasonic wave sensor array;
(2) described echo-signal is nursed one's health shaping, obtain square-wave signal; According to the clock of triggering signal and the clock of several square-wave signals, try to achieve several transmitting-receiving time quantums;
(3), try to achieve some groups of data by the following method about casting liquid liquid level and temperature according to described transmitting-receiving time quantum; After the processing of data equalization, obtain the liquid level and the temperature of current casting liquid;
A. make any two ultrasonic sensors in arbitrary ultrasonic wave emission sensor angle of departure coverage in the array of ultrasonic sensors as the combination of ultrasonic wave receiving sensor, solve the spread speed of ultrasonic wave in medium under the distance of array of ultrasonic sensors and casting liquid and the Current Temperatures according to following formula;
Wherein: i and j are the sequence number of ultrasonic sensor, i ultrasonic sensor and j ultrasonic sensor are the ultrasonic wave receiving sensor combination in the same ultrasonic wave emission sensor angle of departure coverage, v is the spread speed of ultrasonic wave in the Current Temperatures medium, h is the distance of array of ultrasonic sensors and casting liquid, d
iAnd d
jThe distance of difference i ultrasonic sensor and j ultrasonic sensor and ultrasonic wave emission sensor, t
iAnd t
jThe transmitting-receiving time quantum of difference i ultrasonic sensor and j ultrasonic sensor correspondence;
B. according to distance and ultrasonic wave the spread speed in Current Temperatures medium of array of ultrasonic sensors, solve the liquid level and the temperature of casting liquid by following formula with casting liquid;
H=h'-h （2）
T=kT'-△ （4）
Wherein: H is the liquid level of casting liquid, and T is the temperature of casting liquid, and T ' is the Current Temperatures of ultrasonic wave propagation medium, and h ' is the distance of array of ultrasonic sensors and mould, v
0Be the spread speed of ultrasonic wave in 0 degree centigrade of medium, k is a calibrated error, and Δ is a calibrated error;
C. travel through the combination of the ultrasonic wave receiving sensor in all ultrasonic wave emission sensor angle of departure coverages in the array of ultrasonic sensors,, try to achieve some groups of data about casting liquid liquid level and temperature according to step a and b;
(4) control module to driver output control signal, by drive motors work, is controlled the dump angle of casting groove according to the liquid level of casting liquid; Control module is according to the temperature of casting liquid, to the alarm output alarm signal.
6. control method according to claim 5, it is characterized in that: in the described step (4), control module adopts the PID control strategy to export control signal to driver according to the liquid level of casting liquid, by drive motors work, the dump angle of control casting groove.
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| CN104325113A (en) * | 2014-10-10 | 2015-02-04 | 镁联科技（芜湖）有限公司 | Automatic material locking structure of mold and compression molding die |
| CN106180667B (en) * | 2016-08-23 | 2019-02-12 | 北方工业大学 | Method for quantitatively casting anode plate |
| CN110695348A (en) * | 2019-12-03 | 2020-01-17 | 邳州市政隆建设有限公司 | Multifunctional casting machine |
| CN111957936A (en) * | 2020-08-24 | 2020-11-20 | 江西台德智慧科技有限公司 | Production process control system based on intelligent manufacturing |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5012855A (en) * | 1987-09-30 | 1991-05-07 | Mitsubishi Denki Kabushiki Kaisha | Industrial robot |
| CN101041177A (en) * | 2007-03-21 | 2007-09-26 | 鞍钢股份有限公司 | Automatic stable accurate control device for liquid level of continuous casting tundish |
| CN101254533A (en) * | 2008-03-18 | 2008-09-03 | 中南大学 | Constant fluid level control device of fused mass box for casting |
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Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5012855A (en) * | 1987-09-30 | 1991-05-07 | Mitsubishi Denki Kabushiki Kaisha | Industrial robot |
| CN101041177A (en) * | 2007-03-21 | 2007-09-26 | 鞍钢股份有限公司 | Automatic stable accurate control device for liquid level of continuous casting tundish |
| CN101254533A (en) * | 2008-03-18 | 2008-09-03 | 中南大学 | Constant fluid level control device of fused mass box for casting |
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