CN103382522A - Method used for controlling roller rotary spray quenching technology - Google Patents
Method used for controlling roller rotary spray quenching technology Download PDFInfo
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- CN103382522A CN103382522A CN2013102734823A CN201310273482A CN103382522A CN 103382522 A CN103382522 A CN 103382522A CN 2013102734823 A CN2013102734823 A CN 2013102734823A CN 201310273482 A CN201310273482 A CN 201310273482A CN 103382522 A CN103382522 A CN 103382522A
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Abstract
The invention discloses a method used for controlling roller rotary spray quenching technology. A quenching temperature control device comprises an upper computer, wherein global control programs and ideal cooling curve data of rollers are stored in the upper computer; and temperature measuring units and a PLC which are both connected with the upper computer, wherein the output end of the PLC is connected to spray control units. In quenching processes, a real-time temperature determined by the temperature measuring units is received by the global control programs of the upper computer; and real-time regulation of air pressure and hydraulic pressure are performed by the global control programs of the upper computer according to the difference between the real-time temperature and an ideal temperature; so that the cooling speed is close to the cooling speed of the ideal cooling curve, temperature control precision of the quenching processes is ensured, and quenching efficiency is increased. In addition, the method possesses advantages that: cooling is uniform, quenching quality is stable, and the like.
Description
Technical field
The present invention relates to a kind of quenching technology control method, be specifically related to the temperature-controlled process of a kind of large-scale roller in the rotating spraying quenching process.
Background technology
Fog quenching is that a kind of nozzle that utilizes mixes swiftly flowing pressurized air with heat-eliminating medium, because compressed-air actuated high speed impact effect makes the cooling fluid atomizing, then a large amount of droplets is sprayed onto on high temperature workpiece to be quenched at high speed, makes workpiece fast cooling and complete the technology of quenching.This quenching technology have advantages of cooling evenly, other quenching modes such as controllability is strong, the cooling power variable range is large, safety non-pollution hardly match, thereby are widely used in the large-scale roller Field of Heat-treatment.
At present, the spraying heat treatment process of China's roll is all the method that the segmentation of employing is controlled, whole quenching process is divided into spraying stage and jet stage, the spraying stage comprises again some concrete stages, and set different atmospheric pressure value and hydraulic pressure value at stages, thereby control the speed of cooling of stages, complete the fog quenching of roll; Keep roll at the uniform velocity to rotate in the process of fog quenching, to guarantee the homogeneity of quenching effect.In operating process, the atmospheric pressure value of stages, hydraulic pressure value are all set by rule of thumb and be steady state value within a stage, can't regulate in real time according to the practical situation of production scene.In roll was produced, because dimension of roller, material are varied, so the air pressure that should adopt in quenching process, hydraulic pressure were also different.If air pressure, that the hydraulic pressure parameter arranges is improper, cooling intensity is excessive, may cause the roll cracking, brings financial loss to enterprise; If cooling intensity is too small, can cause again hardness not enough, need to reheat quenching, cause the wasting of resources.
Summary of the invention
The technical issues that need to address of the present invention are to provide a kind of roller rotational fog quenching process control method, the method can provide for the quenching of roll suitable speed of cooling, is difficult to control, be prone to the technical problem of quality accident to solve traditional fog quenching process cooling intensity.
For solving the problems of the technologies described above, the technical solution used in the present invention is as follows.
Roller rotational fog quenching process control method, the quenching temperature control device that uses comprises the upper computer of the desirable temperature lowering curve that stores overall sequence of control and multiple roll and all temps, time parameter, the input terminus of upper computer connects by signal wire the temperature measuring equipment that at least three groups axially are evenly arranged along roller surface, and the output terminal of upper computer is connected with the input terminus of PLC by signal wire; The output terminal of PLC is connected with spraying control device; Described spraying control device comprises the spraying plant corresponding with the position of temperature measuring equipment and quantity, and each spraying plant all is connected with total water pipe and total gas pipe line with the branch road pneumatic control valve by the branch road hydraulic control valve; On total water pipe, total hydraulic control valve is set, on total gas pipe line, the total gas pressure control valve is set;
The control method of described overall sequence of control order is as follows carried out:
A) before the quenching beginning, according to size and the material of pending roll, transfer the desirable temperature lowering curve that is complementary with pending roll;
When b) quenching beginning, at first start spraying control device and begin timing;
C) according to desirable temperature lowering curve, the ideal temperature Ta of current cool time of inquiry;
D) temperature measuring equipment detects the roller surface real time temperature and detected result is transferred to upper computer;
E) upper computer records the real time temperature of each point for measuring temperature, and calculates the mean value Tb of real time temperature;
Whether the mean value Tb that f) judges real time temperature is less than the air-cooled temperature of beginning, if Tb is not less than beginning air-cooled temperature, performing step i); If Tb is less than beginning air-cooled temperature, performing step g);
G) close total hydraulic control valve;
H) compare the mean value Tb of real time temperature and the size of the ideal temperature Ta of current cool time, if Tb greater than Ta, increases air pressure; If Tb less than Ta, reduces air pressure; If Tb equals Ta, keep air pressure constant, then performing step j);
I) relatively the mean value Tb of real time temperature and the size of the ideal temperature Ta of current cool time, if Tb greater than Ta, adjustable spraying control device increase hydraulic pressure and air pressure are if Tb less than Ta, reduces hydraulic pressure and air pressure; If Tb equals Ta, keep hydraulic pressure, air pressure constant;
J) judge whether the current cool time reach the concluding time of desirable temperature lowering curve, if the current time does not reach the quenching specific time, return to step c); If the current time has reached the concluding time of quenching curve, close spraying control device, quench and finish.
Further improvement of the present invention is: after recording the real time temperature of each point for measuring temperature in described step e), respectively the real time temperature of each point for measuring temperature is compared with ideal temperature Ta, according to comparative result adjustment branch road hydraulic control valve and branch road pneumatic control valve, hydraulic pressure, the air pressure of each branch road spraying plant are regulated.
Step I in the present invention) improvement is: described step I) if in Tb and Ta differ when default spraying error temperature value is above, total hydraulic control valve of adjustable spraying control device and total gas pressure control valve are to increase or to reduce hydraulic pressure and air pressure.
Step h in the present invention) improvement is: described step h) if in Tb and Ta differ when default air-cooled error temperature value is above, the total gas pressure control valve of adjustable spraying control device is to increase or to reduce air pressure.
Further improvement of the present invention is: described upper computer is provided with and makes overall sequence of control enter the segmentation trip switch of segmentation master mode, and the control method under the segmentation master mode is: according to knowhow, quenching process is divided into some stages; Input successively the target air pressure value, target hydraulic pressure value of stages and time length that should the stage in the overall sequence of control of upper computer; Upper computer sends steering order according to target air pressure value and target hydraulic pressure value to PLC, PLC sends electrical signal according to the steering order of upper computer each control valve aperture in spraying control device is regulated, its regulative mode is to adopt servo-actuated ratio to regulate in front 20 seconds that begin in each stage, and when servo-actuated ratio is regulated, the algorithm of the target valve place value of each control valve is:
Wherein, F1 is current hydraulic pressure (or air pressure) valve position value, and F is target hydraulic pressure (or air pressure) valve position value, and J is current hydraulic pressure (or air pressure) value, and M is target hydraulic pressure (or air pressure) value;
After servo-actuated ratio is regulated and finished, adopt PID to regulate to the adjusting of each pneumatic control valve and hydraulic control valve.
As preferably, in the present invention, total hydraulic control valve used, total gas pressure control valve, branch road hydraulic control valve and branch road pneumatic control valve are all motor-operated control valves.
As preferably, in the present invention, PLC used also is connected with display instrument.
Owing to having adopted technique scheme, the technical progress that the present invention obtains is as follows.
The present invention compares the parameters of actual quenching process and the data of desirable temperature lowering curve in real time by overall sequence of control, and by spraying control device, cooling intensity is adjusted, greatly improve handiness and the control accuracy of quenching process, improved quenching efficiency; Need not artificial input parameter in quenching thermometric and control process, level of automation is high, has reduced the error that causes because manual operation is improper; When processing the roll of plastics on new materials, need not according to experience, concrete atmospheric pressure value and hydraulic pressure value to be set, avoided parameter that the improper thermal treatment quality accident that causes is set.
The present invention is by comparing the real time temperature of each point for measuring temperature with ideal temperature, and by the control valve on each branch road, branch road air pressure, hydraulic pressure regulated, and further improved the homogeneity of quenching, and improved the quenching process control accuracy; The present invention is in quenching process, when the mean value of real time temperature and ideal temperature differ more than 30 ℃, total gas pressure, total hydraulic pressure are regulated, both guaranteed the speed of cooling of quenching, also avoided the frequent adjusting of control valve, in the situation that do not affect the quenching quality, the control process operation is more steady; The present invention is by arranging the segmentation trip switch, when breaking down, temperature measuring equipment can adopt the segmentation control method, and traditional segmentation control method has been made improvement, having adopted servo-actuated ratio to regulate the mode that combines with the PID adjusting regulates, have the advantages such as response is fast, steady-state error is little, improved fault-resistant of the present invention, made system performance more stable; In the present invention, each hydraulic control valve and pneumatic control valve all adopt motor-operated control valve, can carry out fine adjustment to flow and the pressure of gas and liquid; In the present invention, PLC used is connected with display instrument, and convenient operation personnel monitor quenching process, has further guaranteed Systems balanth.
Description of drawings
Fig. 1: the control device schematic diagram in the present invention;
Fig. 2: the control method schema in the present invention.
Wherein: 11. temperature measuring equipments, 2. upper computer, 3.PLC, 300. display instruments, 400. spraying plants, 410. total hydraulic control valves, 420. total gas pressure control valves, 411. branch road hydraulic control valves, 421. branch road pneumatic control valves.
Embodiment
Below in conjunction with the drawings and specific embodiments, the present invention is done further to describe in detail:
Roller rotational fog quenching process control method, quenching temperature control device used comprise the PLC of 2, one siemens S7-300 models of 11, one upper computers of three groups of temperature measuring equipments, a display instrument 300, and spraying control device as shown in Figure 1.Wherein, temperature measuring equipment 11 is a kind of infrared thermometers, and three groups of infrared thermometers are successively set on roll and wait front end, rear end and the middle part partly of quenching.The measuring result of infrared thermometer is transferred to the input terminus of upper computer 2 by signal wire.Store the desirable temperature lowering curve of overall sequence of control and multiple roll and all temps, time parameter in upper computer 2, these parameters comprise the air-cooled temperature of beginning, spraying error temperature value, air-cooled error temperature value etc.The output terminal of upper computer 2 is connected with the input terminus of PLC by signal wire.The output terminal of PLC is connected with spraying control device.Spraying control device comprises three spraying plants 400, the position of spraying plant 400 is corresponding with the position of three groups of infrared thermometers, each spraying plant 400 is connected with total water pipe by a branch road hydraulic control valve 411, also is connected with total gas pipe line by a branch road pneumatic control valve 421.Total water pipe is provided with total hydraulic control valve 410, and total gas pipe line is provided with total gas pressure control valve 420.These control valves are all motor-operated control valves, can carry out fine adjustment to air pressure and hydraulic pressure according to the electrical signal that PLC sends.The SM331 module of PLC also is connected with a display instrument 300, so that the technician monitors quenching process.
In the present embodiment, the control method of quenching process as shown in Figure 2.Quench before beginning, upper computer 2 transfers according to size and the material of pending roll the desirable temperature lowering curve that is complementary with this roll.When quenching beginning, open above-mentioned quenching temperature control device, open each hydraulic control valve and the pneumatic control valve of spraying control device, and the beginning timing.Then, overall situation sequence of control is according to the ideal temperature Ta of desirable temperature lowering curve current cool time of inquiry, receive again and record real time temperature T1, the T2, the T3 that are recorded by three temperature measuring equipments 11, and calculate the medial temperature Tb of three real time temperatures, whether the mean value Tb that then judges real time temperature reaches air-cooled temperature, and it is 200 ℃ that general roll is established this temperature.
If Tb is not less than 200 ℃, compare the size of Tb and Ta, whether the difference that judges Tb and Ta reaches spraying error temperature value, and spraying error temperature value is predefined, is generally 30 ℃, if Tb is higher more than 30 ℃ than Ta, send the instruction that total hydraulic pressure, total gas pressure increase, if Tb is lower more than 30 ℃ than Ta, send the instruction that total hydraulic pressure, total gas pressure reduce, be no more than 30 ℃ if Tb and Ta differ, keep total hydraulic pressure, total gas pressure is constant.Then respectively T1, T2, T3 are compared with Ta, if wherein the difference of some temperature and Ta is greater than 30 ℃, regulate branch road hydraulic control valve and the branch road pneumatic control valve of the corresponding spraying plant of point for measuring temperature therewith, regulate with hydraulic pressure, air pressure to this branch road, accelerate or reduction speed of cooling herein.
If Tb less than 200 ℃, needs to close total hydraulic control valve, carry out air-cooled, in order to avoid the too fast cracking that causes of speed of cooling.After closing total hydraulic control valve, then the size of Tb and Ta relatively, judge whether the difference of Tb and Ta reaches air-cooled error temperature value, air-cooled error temperature value is predefined, be generally 10 ℃, if Tb is higher more than 10 ℃ than Ta, send the instruction that total gas pressure increases; If Tb is lower more than 10 ℃ than Ta, send the instruction that total gas pressure reduces; Be no more than 10 ℃ if Tb and Ta differ, send the constant instruction of total gas pressure.Then, respectively T1, T2, T3 are compared with Ta, if wherein the difference of some temperature and Ta greater than 10 ℃, is regulated the branch road pneumatic control valve of the corresponding spraying plant of point for measuring temperature therewith, regulate with the air pressure to this branch road, accelerate or reduction speed of cooling herein.
At last, judge the no concluding time t2 that has reached desirable temperature lowering curve of current cool time t1, if current cool time t1 does not reach concluding time t2, return to the step of the current cool time ideal temperature Ta of inquiry; If cool time t1 has has met or exceeded the cool time t2 of desirable temperature lowering curve, send the instruction of closing each control valve, quench and finish.
In addition, also comprise a standby segmentation trip switch in upper computer, when opening the segmentation trip switch, can make overall sequence of control enter the segmentation master mode.When temperature measuring equipment 11 breaks down, open segmentation master mode switch, overall sequence of control is switched to the segmentation master mode, under this pattern, the method of work of system is: at first according to knowhow, quenching process is divided into some stages, inputs successively the target air pressure value, target hydraulic pressure value of stages and time length that should the stage in the overall sequence of control of upper computer; Upper computer sends steering order according to target air pressure value and target hydraulic pressure value to PLC, PLC sends electrical signal according to the steering order of upper computer, each control valve aperture in spraying control device is regulated, its regulative mode is: adopted servo-actuated ratio to regulate in front 20 seconds after each stage begins, the algorithm of the target valve place value of each control valve is:
Wherein, F is target hydraulic pressure (or air pressure) valve position value, and F1 is current hydraulic pressure (or air pressure) valve position value, and J is current hydraulic pressure (or air pressure) value, and M is target hydraulic pressure (or air pressure) value.
After servo-actuated ratio is regulated and finished, the regulate process of each pneumatic control valve and hydraulic control valve is adopted the method for PID control.After the stages operation is complete, close each control valve of spraying control device, quench and finish.
Claims (7)
1. roller rotational fog quenching process control method, it is characterized in that: the quenching temperature control device that uses comprises the upper computer (2) of the desirable temperature lowering curve that stores overall sequence of control and multiple roll and all temps, time parameter, the input terminus of upper computer connects by signal wire the temperature measuring equipment (11) that at least three groups axially are evenly arranged along roller surface, and the output terminal of upper computer is by signal wire and PLC(3) input terminus be connected; PLC(3) output terminal is connected with spraying control device; Described spraying control device comprises the spraying plant (400) corresponding with the position of temperature measuring equipment and quantity, and each spraying plant (400) all is connected with total water pipe and total gas pipe line with branch road pneumatic control valve (421) by branch road hydraulic control valve (411); On total water pipe, total hydraulic control valve (410) is set, on total gas pipe line, total gas pressure control valve (420) is set;
The control method of described overall sequence of control order is as follows carried out:
A) before the quenching beginning, according to size and the material of pending roll, transfer the desirable temperature lowering curve that is complementary with pending roll;
When b) quenching beginning, at first start spraying control device and begin timing;
C) according to desirable temperature lowering curve, the ideal temperature Ta of current cool time of inquiry;
D) temperature measuring equipment detects the roller surface real time temperature and detected result is transferred to upper computer;
E) upper computer records the real time temperature of each point for measuring temperature, and calculates the mean value Tb of real time temperature;
Whether the mean value Tb that f) judges real time temperature is less than the air-cooled temperature of beginning, if Tb is not less than beginning air-cooled temperature, performing step i); If Tb is less than beginning air-cooled temperature, performing step g);
G) close total hydraulic control valve;
H) compare the mean value Tb of real time temperature and the size of the ideal temperature Ta of current cool time, if Tb greater than Ta, increases total gas pressure; If Tb less than Ta, reduces total gas pressure; If Tb equals Ta, keep total gas pressure constant, then performing step j);
I) relatively the mean value Tb of real time temperature and the size of the ideal temperature Ta of current cool time, if Tb greater than Ta, the adjustable spraying control device total hydraulic pressure of increase and total gas pressure are if Tb less than Ta, reduces total hydraulic pressure and total gas pressure; If Tb equals Ta, keep total hydraulic pressure, total gas pressure constant;
J) judge whether the current cool time reach the concluding time of desirable temperature lowering curve, if the current time does not reach the concluding time of quenching curve, return to step c); If the current time has reached the concluding time of quenching curve, close spraying control device, quench and finish.
2. roller rotational fog quenching process control method according to claim 1, it is characterized in that: after recording the real time temperature of each point for measuring temperature in described step e), respectively the real time temperature of each point for measuring temperature is compared with ideal temperature Ta, according to comparative result adjustment branch road hydraulic control valve (411) and branch road pneumatic control valve (421), hydraulic pressure, the air pressure of each branch road spraying plant (400) are regulated.
3. roller rotational fog quenching process control method according to claim 1 and 2, it is characterized in that: described step I) if in Tb and Ta differ when default spraying error temperature value is above, total hydraulic control valve (410) of adjustable spraying control device and total gas pressure control valve (420) are with increase or reduce hydraulic pressure and air pressure.
4. roller rotational fog quenching process control method according to claim 1 and 2, it is characterized in that: described step h) if in Tb and Ta differ when default air-cooled error temperature value is above, the total gas pressure control valve (420) of adjustable spraying control device is to increase or to reduce air pressure.
5. roller rotational fog quenching process control method according to claim 1, it is characterized in that: described upper computer (2) is provided with and makes overall sequence of control enter the segmentation trip switch of segmentation master mode, and the control method under the segmentation master mode is: according to knowhow, quenching process is divided into some stages; Input successively the target air pressure value, target hydraulic pressure value of stages and time length that should the stage in the overall sequence of control of upper computer; Upper computer (2) sends steering order according to target air pressure value and target hydraulic pressure value to PLC, PLC sends electrical signal according to the steering order of upper computer each control valve aperture in spraying control device is regulated, its regulative mode is to adopt servo-actuated ratio to regulate in front 20 seconds that begin in each stage, and when servo-actuated ratio is regulated, the algorithm of the target valve place value of each control valve is:
Wherein, F1 is current hydraulic pressure (or air pressure) valve position value, and F is target hydraulic pressure (or air pressure) valve position value, and J is current hydraulic pressure (or air pressure) value, and M is target hydraulic pressure (or air pressure) value;
After servo-actuated ratio is regulated and finished, adopt PID to regulate to the adjusting of each pneumatic control valve and hydraulic control valve.
6. according to claim 1, the 2 or 5 described roller rotational fog quenching of any one process control methods, it is characterized in that: described total hydraulic control valve (410), total gas pressure control valve (420), branch road hydraulic control valve (411) and branch road pneumatic control valve (421) are all motor-operated control valves.
7. according to claim 1, the 2 or 5 described roller rotational fog quenching of any one process control methods, is characterized in that: described PLC(3) also be connected with display instrument (300).
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Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN104846169A (en) * | 2015-06-10 | 2015-08-19 | 唐山市裕龙冶金轧辊有限公司 | Roller spray quenching equipment |
| CN105349761A (en) * | 2015-11-10 | 2016-02-24 | 铜陵市明诚铸造有限责任公司 | Spray quenching process for alloy semi-steel roll |
| CN105950858A (en) * | 2016-07-05 | 2016-09-21 | 山东天海高压容器有限公司 | Automatic control method for steel cylinder heat treatment |
| CN106148675A (en) * | 2016-07-05 | 2016-11-23 | 山东天海高压容器有限公司 | Automatic control system for cast steel heat treating |
| CN107387184A (en) * | 2017-09-12 | 2017-11-24 | 柳州市隆兴模具技术有限公司 | A kind of Waste Heat Recovery accessory power system for quenching cooling oil |
| CN107401433A (en) * | 2017-09-12 | 2017-11-28 | 柳州市隆兴模具技术有限公司 | A kind of WHRS for quenching cooling oil |
| CN115253904A (en) * | 2022-07-29 | 2022-11-01 | 浙江铁狮高温材料有限公司 | Compact zirconia water gap core production equipment |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN104846169A (en) * | 2015-06-10 | 2015-08-19 | 唐山市裕龙冶金轧辊有限公司 | Roller spray quenching equipment |
| CN105349761A (en) * | 2015-11-10 | 2016-02-24 | 铜陵市明诚铸造有限责任公司 | Spray quenching process for alloy semi-steel roll |
| CN105950858A (en) * | 2016-07-05 | 2016-09-21 | 山东天海高压容器有限公司 | Automatic control method for steel cylinder heat treatment |
| CN106148675A (en) * | 2016-07-05 | 2016-11-23 | 山东天海高压容器有限公司 | Automatic control system for cast steel heat treating |
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| CN107387184A (en) * | 2017-09-12 | 2017-11-24 | 柳州市隆兴模具技术有限公司 | A kind of Waste Heat Recovery accessory power system for quenching cooling oil |
| CN107401433A (en) * | 2017-09-12 | 2017-11-28 | 柳州市隆兴模具技术有限公司 | A kind of WHRS for quenching cooling oil |
| CN115253904A (en) * | 2022-07-29 | 2022-11-01 | 浙江铁狮高温材料有限公司 | Compact zirconia water gap core production equipment |
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