CN105478737A - Automatic pouring method and system for heat preserving furnace pouring platform - Google Patents
Automatic pouring method and system for heat preserving furnace pouring platform Download PDFInfo
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- CN105478737A CN105478737A CN201510933422.9A CN201510933422A CN105478737A CN 105478737 A CN105478737 A CN 105478737A CN 201510933422 A CN201510933422 A CN 201510933422A CN 105478737 A CN105478737 A CN 105478737A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D37/00—Controlling or regulating the pouring of molten metal from a casting melt-holding vessel
Abstract
The present invention relates to the production field of casting technique, in particular to an automatic pouring method and system for a heat preserving furnace pouring platform. By collecting an inclined effluent angle of a heat preserving furnace of the heat preserving furnace pouring platform, a pouring reference datum angle of the heat preserving furnace satisfying the pouring amount is obtained. If the inclined angle of the heat preserving furnace is equal to the pouring reference datum angle, the heat preserving furnace stops inclining. After a predetermined time, a molten steel image from a diversion trench discharge hole to a pouring mold gate is collected, and a molten steel flow velocity value is obtained according to the molten steel image. The extracted molten steel flow velocity value is compared with a corresponding predetermined velocity range. When the molten steel flow velocity value exceeds the corresponding predetermined velocity range, the inclined pouring angle of the heat preserving furnace is adjusted to control the flow velocity of the molten steel within the corresponding predetermined velocity range, so as to solve the problems of the existing technology that the inaccurate control on the pouring angle causes molten steel waste when the heat preserving furnace automatically pours, and the pouring efficiency is low.
Description
Technical field
The present invention relates to foundry engieering production field, particularly relate to a kind of holding furnace teeming stage automatic pouring method and system.
Background technology
Because the iron and steel production technology of China and developed country also have very large gap, this makes the bloom production efficiency of China only have external 1/3, and the low and energy shortage of production efficiency seriously governs the steel development of China.In the last few years, steel industry is round raising iron and steel production efficiency, reduce the aspect developings such as iron and steel energy consumption many new technologies, new technology, wherein die casting technology is a great energy conservation, and its level of application has become the important indicator weighing iron and steel production technology level.
At present, rapid shaping and the Rapid tooling field of domestic mould are also in the starting stage, lack advanced CAM technology (computerAidedManufacturing, computer-aided manufacturing).In iron and steel manufacturing industry, CAM technology is deficient especially, produces a large amount of molten steel wastes, and inefficiency.
Therefore, for above deficiency, need to provide a kind of novel heat insulation stove teeming stage automatic pouring method and system.
Summary of the invention
(1) technical problem that will solve
The cast Angle ambiguity of holding furnace automatic casting inaccurate, molten steel waste when the object of the invention is to solve industrial Mould Machining in prior art and the problem of cast inefficiency.
(2) technical scheme
In order to solve the problems of the technologies described above, one aspect of the present invention provides a kind of holding furnace teeming stage automatic pouring method, it is characterized in that, be included in casting process and perform following rate-determining steps: the inclination angle of water of the holding furnace of S1.1, collection holding furnace teeming stage, transfer the cast reference data angle meeting and water fluence according to inclination angle of water; S1.2, when the inclined casting angle of holding furnace equals cast reference data angle, stop verting holding furnace; S1.3, after the scheduled time, gather the molten steel image of guiding gutter discharging opening to casting mold mouth, and according to molten steel image zooming-out molten steel flow speed value; S1.4, the molten steel flow speed value of extraction and corresponding predetermined speed interval to be compared, when molten steel flow speed value is outside corresponding predetermined speed interval, the inclined casting angle of holding furnace is adjusted, is positioned at corresponding predetermined speed interval with the flow velocity controlling molten steel.
According to the present invention, while execution rate-determining steps, perform following detection and retract step: S2.1, from molten steel image, extract liquid steel level marginal arc long value, the marginal arc long value of extraction and predetermined value are compared; S2.2, when extract marginal arc long value be more than or equal to predetermined value time, holding furnace is retracted predetermined angle, with stop cast.
According to the present invention, in rate-determining steps S1.1: according to inclination angle of water, obtain vert velocity amplitude, the scheduled time and holding furnace of the holding furnace suitable with holding furnace inclination angle of water to need to continue the angle value of inclination, wherein, this angle value and inclination angle of water sum are for pour into a mould reference data angle.
According to the present invention, in rate-determining steps S1.2: when making holding furnace vert to cast reference data angle with holding furnace pitch velocity, stop verting holding furnace.
According to the present invention, in rate-determining steps S1.3: image procossing is carried out to molten steel image, and extract molten steel flow speed value; Wherein, molten steel image adopts maximum variance between clusters to calculate the dynamic brightness segmentation threshold of molten steel image, by dynamic brightness segmentation threshold, binary conversion treatment is carried out to molten steel image, extract molten steel flow speed value according to left and right edges width value on the molten steel liquid column level direction of molten steel image after binary conversion treatment.
According to the present invention, controlling in step S1.4: when molten steel flow speed value exceedes corresponding predetermined speed interval, reduce the inclined casting angle of holding furnace; When molten steel flow speed value is less than corresponding predetermined speed interval, increase the inclined casting angle of holding furnace.
The present invention provides a kind of running gate system on the other hand, and comprise holding furnace teeming stage, guiding gutter and casting mold, it also comprises: angular transducer, camera head, image procossing decision making device and execution control device; The angle of inclination of detection for detecting the angle of inclination of the holding furnace of holding furnace teeming stage, and is sent to execution control device by angular transducer; Camera head is for gathering the molten steel image of guiding gutter discharging opening to casting mold mouth, and the molten steel image of collection is sent to image procossing decision making device by camera head; Image procossing decision making device is for receiving molten steel image, extract the molten steel flow speed value of liquid steel level and the molten steel flow speed value of extraction is sent to execution control device, and extract marginal arc long value, and predetermined value in the marginal arc long value of extraction and image procossing decision making device is compared, make and holding furnace retracted predetermined angle to stop the decision-making of pouring into a mould and decision-making is sent to execution control device; Perform control device transfer the cast reference data angle of holding furnace in response to the angle of inclination of holding furnace when water outlet and control the inclination of holding furnace, perform the inclined casting angle of control device in response to molten steel flow speed value adjustment holding furnace, and execution control device retracts holding furnace in response to decision-making with predetermined angle.
According to the present invention, also comprise automatic adjustable optical filter device, described automatic adjustable optical filter device filters in response to the camera of switching signal to camera head that image procossing decision making device sends or stops filtering.
According to the present invention, guiding gutter is the downward infundibulate of osculum.
According to the present invention, also comprise mould and transmit the horizontal pusher of guide rail, described mould transmits the horizontal pusher of guide rail and is transported to below guiding gutter by casting mold in response to the signal performing the conveying casting mold that control device sends.
(3) beneficial effect
Technique scheme of the present invention compared with prior art tool has the following advantages:
One aspect of the present invention provides a kind of holding furnace teeming stage automatic pouring method, by gathering the inclination angle of water of the holding furnace of holding furnace teeming stage, transfer the cast reference data angle meeting and water the holding furnace of fluence, holding furnace is poured into a mould to pour into a mould reference data angle, molten steel flow speed value is extracted by gathering guiding gutter discharging opening to the molten steel image of casting mold mouth, the inclined casting angle of holding furnace is adjusted, to ensure that molten steel flow speed value is in corresponding predetermined speed interval, accurately to control cast, molten steel is avoided to waste; Method of the present invention improves the automation of whole casting process and ensures that molten steel is accurately poured into a mould, and casting process meets technological requirement, and product percent of pass is high, improves enterprises production efficiency, reduces production cost, meets the requirement of industrial production mould greatly.
The present invention provides a kind of system of holding furnace teeming stage automatic casting on the other hand, system provided by the invention adopts camera head to monitor the molten steel image of guiding gutter discharging opening to casting mold mouth in real time, by image procossing decision making device image processed and extract correlation values, perform the action in conjunction with the drive unit of the angle of inclination Shared Decision Making holding furnace teeming stage of current angular sensor Real-Time Monitoring of numerical value that control device extracts according to image procossing decision making device, ensure that whole casting process molten steel flow speed is adjustable, to reach the object of precisely cast; System provided by the invention detects the guiding gutter discharging opening molten steel image to casting mold mouth based on the principle of machine vision, indirectly control the angle of inclination of the holding furnace of holding furnace teeming stage thus reach feedback, control casting process more accurately and pour into a mould time molten steel do not overflow the object of casting mold; System provided by the invention is achieving non-contact measurement, while Measurement accuracy, realizes again the separation of detection and control, accomplishes distribute control; Native system can be stablized, automatically carry out production and processing continuously, efficiently, can Quick pouring shaping and reuse, substantially increase the accuracy and efficiency of detection, save molten steel, reduce the cost of production mould, equipment investment is few, and product percent of pass is high, improve enterprises production efficiency, reduce production cost.
The technical characteristic of the technical problem solved except the present invention described above, the technical scheme of formation and have the technical characteristic of these technical schemes to bring advantage except, the advantage that other technologies feature of the present invention and these technical characteristics bring, will further illustrate by reference to the accompanying drawings.
Accompanying drawing explanation
Fig. 1 is embodiment of the present invention holding furnace teeming stage cast automated system schematic diagram;
Fig. 2 is the holding furnace angle of inclination schematic diagram of embodiment of the present invention holding furnace teeming stage cast automated system;
Fig. 3 is guiding gutter and the mould structure schematic diagram of embodiment of the present invention holding furnace teeming stage cast automated system;
Fig. 4 is the camera detection figure of embodiment of the present invention holding furnace teeming stage cast automated system.
In figure, 1: the holding furnace of holding furnace teeming stage; 2: angular transducer; 3: guiding gutter; 4: casting mold; 5: camera head; 6: adjustable optical filter device automatically; 7: image procossing decision making device; 8: perform controlling organization; 9: the minimum liquid level that camera can detect.
Detailed description of the invention
Below in conjunction with drawings and Examples, the specific embodiment of the present invention is described in further detail.Following examples for illustration of the present invention, but are not used for limiting the scope of the invention.
Because the inclined casting angle of the holding furnace of holding furnace teeming stage is with to pour into a mould out water speed relevant, so within certain duration of pouring, between different inclination water outlet angular interval, the velocity amplitude that verts of holding furnace hydraulic pressure teeming stage should be differentiated.The excessive velocities if holding furnace verts, the molten steel of cast can be assembled at the water outlet that guiding gutter is less, even if when detecting that the molten steel in mould mouth arrives the moment of critical point (when being namely more than or equal to predetermined value when the marginal arc long value extracted), holding furnace is pulled back, but the molten steel hoarded because of guiding gutter inside can continue to be guided to below mould, molten steel is overflowed, so too much molten steel can not be hoarded in guiding gutter.If holding furnace pitch velocity is excessively slow, after detecting that in mould mouth, molten steel reaches critical point (when being namely more than or equal to predetermined value when the marginal arc long value extracted), the whole duration of pouring exceeds standard.
Along with the change of the holding furnace inclined casting angle of holding furnace teeming stage, the horizontal cross-section size of toppling over molten steel can change, and under same platform verts speed, cross section is larger, and the flow velocity of molten steel is faster, more easily causes guiding gutter molten steel to hoard; Same cross section is less, and the flow velocity of molten steel is slower, can extend the duration of pouring.In order to make the poring rate of molten steel moderate, neither fast nor slow, need to carry out meticulous control to pouring molten steel.
Therefore, the invention provides a kind of holding furnace teeming stage automatic pouring method that accurately can control pouring molten steel, specific as follows.
As Figure 1-Figure 4, a kind of holding furnace teeming stage automatic pouring method, it is included in casting process and performs following rate-determining steps:
The inclination angle of water of the holding furnace of S1.1, collection holding furnace teeming stage, transfers the cast reference data angle meeting and water fluence according to inclination angle of water;
S1.2, when the inclined casting angle of holding furnace equals cast reference data angle, stop verting holding furnace;
S1.3, after the scheduled time, gather the molten steel image of guiding gutter discharging opening to casting mold mouth, and according to molten steel image zooming-out molten steel flow speed value;
S1.4, the molten steel flow speed value of extraction and corresponding predetermined speed interval to be compared, when molten steel flow speed value is outside corresponding predetermined speed interval, the inclined casting angle of holding furnace is adjusted, is positioned at corresponding predetermined speed interval with the flow velocity controlling molten steel.
Can understand, above-mentioned steps S1.1 is the collection carried out when the beginning of casting process inclination angle of water, and step S1.2-S1.4 continues to control building along with building.
Method of the present invention improves the automation of whole casting process and ensures that molten steel is accurately poured into a mould, and avoid molten steel to waste, casting process meets technological requirement, product percent of pass is high, improve enterprises production efficiency, reduce production cost, meet the requirement of industrial production mould greatly.
Further, in the present embodiment, be also included in while performing rate-determining steps, perform following detection and retract step:
S2.1, from molten steel image, extract liquid steel level marginal arc long value, the marginal arc long value of extraction and predetermined value are compared;
S2.2, when extract marginal arc long value be more than or equal to (being namely more than or equal to) predetermined value time, holding furnace is retracted predetermined angle, with stop cast.
Can understand, above-mentioned steps S2.1 carries out after acquisition molten steel image.
Step is retracted specifically with regard to above-mentioned rate-determining steps and detection, because the molten steel amount (namely watering fluence) of each cast is identical, it is also then identical that molten steel amount is converted into volume, so the holding furnace inclination angle when knowing that molten steel flows out from holding furnace converter nose, namely after knowing inclination angle of water (angle between the direction turned over vertical direction to holding furnace), can predict that needing the amount continuing through the outflow of how many angle molten steel to meet waters fluence, this inclination angle of water adds needs the angle continued through to be exactly reference data angle.Those skilled in the art are repeatedly debugged by scene, by debug results determination reference data angle parameter.Holding furnace motion, within the scope of 0-90 degree, is divided into multiple interval, when inclination angle of water is in a certain interval, calls the reference data angle parameter in this interval parameter group.Again because the reference data angle of prediction can not meet the accurate requirement that industrialized standard is produced, camera head is now needed to monitor the molten steel image of guiding gutter discharging opening to casting mold mouth in real time, by image procossing decision making device image processed and extract correlation values, perform numerical value that control device extracts according to image procossing decision making device in conjunction with the action of the drive unit of current inclination Shared Decision Making holding furnace teeming stage, ensure that stage guarantee molten steel flow speed suitable in casting process is moderate.Those skilled in the art repeatedly debug at the scene according to inclination angle of water, determine by debug results the predetermined speed interval (namely corresponding predetermined speed is interval) that different inclination angle of water is corresponding.Particularly, holding furnace motion is within the scope of 0-90 degree, be divided into multiple interval, when inclination angle of water is in a certain interval, call the predetermined speed interval parameter in this interval parameter group, then monitor molten steel flow speed in real time, ensure that molten steel flow speed is in the predetermined speed interval that this inclination angle of water is corresponding.Now can either meet technological requirement (namely mould there will not be condensation), when also ensureing cast final position to be detected under this speed simultaneously, holding furnace of can pulling back in time.
Thus, this method not only accurately can control molten steel flow speed by the inclined casting angle controlling holding furnace, and automatically can also stop the cast of holding furnace, the automaticity of method is high, simple to operate, controls precisely.
Further, in rate-determining steps S1.1: according to inclination angle of water, obtain vert velocity amplitude, the scheduled time and holding furnace of the holding furnace suitable with holding furnace inclination angle of water to need to continue the angle value of inclination, wherein, this angle value and inclination angle of water sum are for pour into a mould reference data angle.Obtaining three suitable with it numerical value by inclination angle of water, is follow-up ready for operation.
Further, in rate-determining steps S1.2: when making holding furnace vert to cast reference data angle with holding furnace pitch velocity, stop verting holding furnace.By holding furnace with the holding furnace that inclination angle of water is suitable vert velocity amplitude vert can dope this moment molten steel to reference data angle water fluence, so that subsequent process steps realizes carrying out to the inclined casting angle of holding furnace the object that accurately controls.
Further, in rate-determining steps S1.3: image procossing is carried out to molten steel image, and extract molten steel flow speed value.Particularly, maximum variance between clusters is adopted to calculate the dynamic brightness segmentation threshold of molten steel image molten steel image, by dynamic brightness segmentation threshold, binary conversion treatment is carried out to molten steel image, extract molten steel flow speed value according to left and right edges width value on the molten steel liquid column level direction of molten steel image after binary conversion treatment.
Further, controlling in step S1.4: when molten steel flow speed value exceedes corresponding predetermined speed interval, reduce the inclined casting angle of holding furnace; When molten steel flow speed value is less than corresponding predetermined speed interval, increase the inclined casting angle of holding furnace.So, be when molten steel flow speed value is outside corresponding predetermined speed interval, the inclined casting angle of holding furnace is adjusted, be positioned at corresponding predetermined speed interval with the flow velocity controlling molten steel; When molten steel flow speed value both do not exceeded be not less than yet corresponding predetermined speed interval time, namely when molten steel flow speed value is in corresponding predetermined speed interval, keep current tilt cast angle.In this stage by the real-time monitoring of molten steel flow speed and adjustment, realize accurately controlling the inclined casting angle of holding furnace.
As shown in Figure 1, the present invention provides a kind of running gate system on the other hand, comprises holding furnace teeming stage, guiding gutter 3, casting mold 4, angular transducer 2, camera head 5, image procossing decision making device 7 and performs control device 8.
The angle of inclination of detection for detecting the angle of inclination of the holding furnace 1 of holding furnace teeming stage, and is sent to execution control device 8 by angular transducer 2.
Camera head 5 is for gathering the molten steel image of guiding gutter discharging opening to casting mold cast gate, and the molten steel image of collection is sent to image procossing decision making device 7 by camera head 5.
Image procossing decision making device 7 is for receiving molten steel image, extract the molten steel flow speed value of liquid steel level and the molten steel flow speed value of extraction is sent to execution control device, and extract marginal arc long value and predetermined value in the marginal arc long value of extraction and image procossing decision making device compared, make holding furnace 1 is retracted predetermined angle to stop the decision-making of pouring into a mould, and decision-making is sent to execution control device 8.
Perform control device 8 transfer the cast reference data angle of holding furnace in response to the angle of inclination of holding furnace 1 when water outlet and control the inclination of holding furnace 1, perform the inclined casting angle of control device 8 in response to molten steel flow speed value adjustment holding furnace 1, and execution control device 8 retracts holding furnace in response to above-mentioned decision-making with predetermined angle.
System provided by the invention adopts camera head to monitor the molten steel image of guiding gutter discharging opening to casting mold mouth in real time, by image procossing decision making device image processed and extract correlation values, perform the action in conjunction with the drive unit of the inclination angle Shared Decision Making holding furnace teeming stage of current angular sensor Real-Time Monitoring of numerical value that control device extracts according to image procossing decision making device, ensure that whole casting process molten steel flow speed is adjustable, to reach the object of precisely cast; System provided by the invention detects the guiding gutter discharging opening molten steel image to casting mold mouth based on the principle of machine vision, indirectly control the dump angle of the holding furnace of holding furnace teeming stage thus reach feedback, control casting process more accurately and pour into a mould time molten steel do not overflow the object of casting mold; System provided by the invention is achieving non-contact measurement, while Measurement accuracy, realizes again the separation of detection and control, accomplishes distribute control; Native system can be stablized, automatically carry out production and processing continuously, efficiently, can Quick pouring shaping and reuse, substantially increase the accuracy and efficiency of detection, save molten steel, reduce the cost of production mould, equipment investment is few, and product percent of pass is high, improve enterprises production efficiency, reduce production cost.
Particularly, also comprise automatic adjustable optical filter device 6, this automatic adjustable optical filter device 6 filters in response to the camera of switching signal to camera head 5 that image procossing decision making device 7 sends or stops filtering.Automatic adjustable optical filter device can the strong halation of the molten steel of elimination preferably surrounding, light pollution in elimination IMAQ, ensure the accuracy of the IMAQ in pouring molten steel process, change easy stained filter disc simultaneously and ensure that the image effect of making a video recording well is easy to process, thus the efficiency of raising detection, the error rate that reduces, minimizing molten steel are wasted.
Particularly, as shown in Figure 3, the density p=7*10 of molten steel in the present embodiment
3kg/m
3, mould regulation in below is m=43Kg after carrying out, the volume V=6.14*10 of calculation
-3m
3, the charging aperture bore of guiding gutter is 150mm to the distance of discharging opening bore, and guiding gutter is 75mm to the distance of mould mouth, by V=S*l=S*v*t, wherein
v=(g-K) t ' wherein K is relevant with the angle that the coefficient of friction molten steel of the inner surface of guiding gutter is toppled over.Through the setting t duration of pouring between 10s and 15s, ensure that the control of the effect and system that detection captured by camera head can be stablized and agree with.Above simultaneous, the span of the discharging opening bore d of the known guiding gutter of formula is 29.69mm≤d≤38.22mm.Guiding gutter adopts the funnel-shaped design downward in osculum, upper feed inlet bore 40mm, bottom discharging opening bore 32mm.Up big and down small funnel-shaped design can make the molten steel flowed out through guiding gutter more be condensed into fluid column, not easily disperses, and solves the control of mould and the measurement not problem accurately of cast critical end point; What guiding gutter adopted simultaneously is that (main material is C to amorphous refractory, and auxiliary material is SiO
2) as high temperature lining, this low cement high-strength castable is high temperature resistant (the highest can be resistance to 1650 DEG C ± 50 DEG C), can various site operation be adapted to, solve molten steel and easily adhere at guiding gutter, the fragile replacing of guiding gutter of processing and affect the problem of production operation.
Particularly, also comprise mould and transmit the horizontal pusher of guide rail, this mould transmits the horizontal pusher of guide rail and is transported to below guiding gutter by casting mold in response to the signal performing the conveying casting mold that control device sends.The horizontal supplying system of automatic control mould guide rail completes by performing control device the work pushed below next mould arrival guiding gutter, and automatically detects mould mouth and guiding gutter alignment result, for Mould Machining is prepared next time by camera head.
Particularly, in the present embodiment, holding furnace teeming stage can be preferably holding furnace potting syrup flattening bench, it comprise holding furnace and drive holding furnace vert with by pouring molten steel to the fluid pressure drive device of guiding gutter.Perform control device and can be preferably PLC.By the aperture of the hydraulic proportional valve of PLC hydraulic control drive unit, to control verting of holding furnace, finally reach and control cast angle of inclination object.Camera head is preferably the high definition industry camera from the horizontal by constant tilt angle, and black and white is imaged as preferred embodiment, and industrial camera adopts high speed processor and high-frequency of fixing a point captures molten steel image near guiding gutter discharging opening to casting mold mouth.Image procossing decision making device is preferably industrial computer.
During use, industry camera fixed point candid photograph guiding gutter discharging opening is transferred to industrial computer to the on-the-spot molten steel image of casting mold cast gate by gigabit Ethernet, industrial computer passes the photo of coming by the process that setting program continues, image analysis result is passed to PLC by fieldbus, according to image analysis result, PLC judges that whether current pouring molten steel flow velocity is suitable, adjust the dump angle of holding furnace; When PLC obtain industrial computer provide current cast reach cast terminal decision-making time, PLC drives the hydraulic drive mechanism of holding furnace hydraulic pressure teeming stage to pull back holding furnace, complete the pouring molten steel process of single mold, thus achieve the cast of industrial automatic die.The conveying of mould conveying controls corresponding motor conveying equipment by PLC, and guarantee accurate conveying, angular transducer and all kinds of executing agencies relaying are connected to PLC by the direct-connected mode of IO.
Particularly, the people-oriented interaction program interface that industrial computer is designed by VS2010+MFC+OpenCV, make the guiding gutter discharging opening of industrial camera collection to casting mold mouth molten steel image, the i.e. interested region of this method, the working condition of the long-range understanding production scene of handled easily personnel, and industrial production line operation can be changed flexibly by the interface operation PLC of industrial computer or amendment technological parameter.Simultaneously, industrial computer can also carry out record to some key parameters of Site Detection and store and statistical analysis, can wait statistical graph by formation curve figure, be beneficial to the Product Information Management of manufacturing enterprise, operating personnel can find the problem in production process from statistical information.
Industrial computer first carries out filtering to gathering the molten steel image come, and after denoising, then obtains with maximum variance between clusters (OSTU algorithm) the dynamic brightness segmentation threshold processing rear image, and carries out quick binaryzation with this threshold value to image.After binaryzation, be set to bright in image higher than the part of dynamic brightness threshold value, the part lower than dynamic brightness threshold value is set to secretly.After this series of processes, image gem-purely can demonstrate local edge.In the horizontal direction, the left and right edges width of image is exactly the width of molten steel fluid column in actual casting process, can mirror flow velocity size in pouring molten steel process by Fuzzy Anti.The molten steel flow speed value that industrial computer extracts issues PLC.As shown in Figure 4, because mould gate is circular, so the lower part of image after process, molten steel and mould gate are demarcated and to have an obviously arc edge, by calculating the length of this arc edge, marginal arc long value.Marginal arc long value accurately can reflect liquid steel level height in mould, i.e. the known terminal stopping cast.So, when the marginal arc long value extracted is more than or equal to predetermined value, holding furnace is retracted predetermined angle, to stop cast.
The step adopting above-mentioned running gate system to perform above-mentioned pouring procedure is described in detail in detail below, and the specific descriptions of control program are as follows:
The first step, first to each device startup self-detection.When guaranteeing that each device can normally work, industry camera first captures casting mold mouth, ensure that the position of casting mold mouth is correct, just in time drop on industrial computer area-of-interest, ensure the diversed groove pour steel that casting mold mouth can be stable, this is a critical step, if chute discharging opening and the alignment of casting mold mouth are forbidden, there will be the serious consequence that molten steel local leaks outside, after everything is ready, start cast order.
Second step, startup stage, gathered the inclination angle of water (angle of inclination namely during water outlet) of the holding furnace of holding furnace teeming stage by angular transducer.The inclination water outlet angle [alpha] of detection is sent to execution control device by angular transducer, performs control device and is applicable to the holding furnace of this inclination angle of water according to this inclination water outlet angle [alpha] Auto-matching and verts velocity amplitude V
0, holding furnace is with V
0speed of verting from molten steel flows out, continue to push through (continuing to tilt) one section of suitable angle φ, the value size of φ is relevant to the inclination water outlet angle [alpha] size of holding furnace, now basic guarantee molten steel can flow out the amount of about 40%, within this time period, the flow velocity of molten steel keeps continuing to increase.Inclination water outlet angle [alpha] adds that continuing to push through (continuing to tilt) one section of suitable angle φ is exactly reference data angle.Perform control device also according to inclination angle of water transfer reach reference data angle after holding furnace stop vert with reference data angle continue cast scheduled time T
1.Perform control device by above-mentioned V
0, φ and T
1send to the drive unit of holding furnace teeming stage.
3rd step, the drive unit of holding furnace teeming stage drives holding furnace with the speed V that verts
0vert to cast reference data angle, then stop verting holding furnace.
4th step, drive unit drives holding furnace to continue the scheduled time T of cast with reference data angle
1, molten steel flow speed is no longer increased and keeps its inertia to flow out, in this process, molten steel flow speed is by basicly stable, and steel flow output will reach about 70% simultaneously.Elapsed time T
1after, gather guiding gutter discharging opening to the molten steel image of casting mold mouth by camera head and the molten steel image of collection is sent to image procossing decision making device.Image procossing decision making device in response to the molten steel image gathered, and carries out image procossing to molten steel image in real time, then extracts molten steel flow speed value, the molten steel flow speed value of extraction is sent to execution control device.
5th step, perform control device the molten steel flow speed value of reception and corresponding predetermined speed interval are compared, when molten steel flow speed value is outside corresponding predetermined speed interval, perform control device and send the signal that adjusts the inclined casting angle value of the holding furnace drive unit to holding furnace teeming stage, drive unit is in response to the inclined casting angle of adjustment signal adjustment holding furnace.
Particularly, when molten steel flow speed value exceedes corresponding predetermined speed interval, slightly pulled back by holding furnace hydraulic platform, reduce holding furnace inclined casting inclination angle and be positioned at corresponding predetermined speed interval to make holding furnace inclined casting inclination angle, molten steel flow speed reduces; Otherwise when molten steel flow speed value is less than corresponding predetermined speed interval, pushes away to make holding furnace inclined casting inclination angle be positioned at corresponding predetermined speed interval before holding furnace is slight, increase holding furnace inclined casting inclination angle, allow molten steel flow speed increase; Inclined casting angle in this stage to holding furnace adjusts in real time.
In the above-mentioned stage, as long as the image procossing decision making device marginal arc long value detected in the liquid steel level image of camera head collection is more than or equal to the predetermined value in image procossing decision making device, namely image procossing decision making device makes the decision-making retracted by holding furnace, perform control device to pull back rapidly in response to the holding furnace of this Decision Control holding furnace teeming stage, cut off molten steel supply in time.
Particularly, liquid steel level marginal arc long value can be extracted after employing image procossing decision making device carries out image procossing to molten steel image, the action of extracting liquid steel level marginal arc long value can be carried out with the action of extracting molten steel flow speed simultaneously or successively carry out, predetermined value in the marginal arc long value of extraction and image procossing decision making device compares by image procossing decision making device, when the marginal arc long value extracted is more than or equal to predetermined value, image procossing decision making device is made and holding furnace is retracted predetermined angle, to stop the decision-making of pouring into a mould.Performing control device in response to decision-making sends and controls the signal that retracts of holding furnace, and the drive unit of holding furnace teeming stage controls holding furnace in response to this signal and retracts predetermined angle, to stop cast.
Particularly, when the drive unit of holding furnace receives the signal retracted by holding furnace, now, performing control device record current inclination is angle of pulling back, and to be pulled back holding furnace by the drive unit of holding furnace immediately, and holding furnace is retracted predetermined angle.
Being pulled back by holding furnace is not that holding furnace is forgotten about it zero degree from current inclination, but holding furnace is retracted predetermined angle, and a suitable angle of namely pulling back, this suitable angle depends on angle of water and/or angle of pulling back.The range value that the proper angle of pulling back and inclination angle are reduced, the range value that this inclination angle is reduced is relevant with angle of water and angle of pulling back.Get angle of water in the present embodiment, namely platform is pulled back to and angle of water from current angular.When the action that stopping is pulled back to holding furnace, namely current die casting operation completes, and waits for and pours into a mould order next time.
Particularly, each step of PLC all will could perform next step operation by the feedback of safety signal.If find that operating mode has potential safety hazard, do not receive safe index signal, just enter the anxious stop mode of safety, whole system enters halted state.
Data form is below the record data to certain cast.In form, flow velocity bound refers to maximum and the minimum of a value in the corresponding predetermined speed interval of molten steel flow speed in graphical analysis.Because the amount of each cast is all 43Kg, i.e. given volume, gather through test of many times and learn, under difference inclination water outlet angle [alpha] size, platform initial propulsion angle φ is also different.But the angular interval of closing on, each angle advanced is much the same, and angle of pulling back carries out revised value in the 5th step to platform inclination cast angle.
Table 1
From table 1, can know that the inclination water outlet angle [alpha] of holding furnace is larger, speed is faster, reaches cast terminal sooner, so large inclination angle of water will be pulled back at the platform increment more than 1 °.Accordingly, angle of water α is little, and arrive pulling back the moment of cast terminal, the angle [alpha] of platform can increase about 4 °.Whole consuming time, be wait for that in the complete groove of water conservancy diversion concentrated flow, molten steel just calculates cut-off time.Within operation normal and normal duration of pouring, obtain platform angle of water interval and corresponding retract angular interval:
Table 2
| Angle of water α | To pull back angle |
| 35.0°～45.0° | (α+4)±0.8 |
| 45.0°～60.0° | (α+1.5)±0.3 |
| 60.0°～75.0° | (α+1.0)±0.2 |
Method provided by the invention or system is adopted to be not limited to above-mentioned detailed description of the invention, any step of the inventive method all can use any device that can realize this step technique effect to complete, and the device in present system also can adopt any concrete equipment that can realize this device technique effect to replace.
To sum up, of the present inventionly propose a kind of die casting molten steel that is applicable to first and detect and the method for holding furnace hydraulic pressure teeming stage Angle ambiguity.Meanwhile, it is high that this invention additionally provides a kind of real-time, reacts closed-loop control system fast.Compared with prior art, not only real-time is high for this method and device, and reaction is fast, and prevents the substandard products of very few cast from generating, and detection efficiency is higher; Decrease the generation of slag, saved molten steel, increase the output of mould product.
Below be only the preferred embodiment of the present invention; it should be pointed out that for those skilled in the art, under the prerequisite not departing from the technology of the present invention principle; can also make some improvement and modification, these improve and modification also should be considered as protection scope of the present invention.
Claims (10)
1. a holding furnace teeming stage automatic pouring method, is characterized in that, is included in casting process and performs following rate-determining steps:
The inclination angle of water of the holding furnace of S1.1, collection holding furnace teeming stage, transfers the cast reference data angle meeting and water fluence according to described inclination angle of water;
S1.2, when the inclined casting angle of described holding furnace equals described cast reference data angle, stop verting described holding furnace;
S1.3, after the scheduled time, gather the molten steel image of described guiding gutter discharging opening to casting mold mouth, and according to described molten steel image zooming-out molten steel flow speed value;
S1.4, by extract described molten steel flow speed value and corresponding predetermined speed interval compare, when described molten steel flow speed value is outside corresponding predetermined speed interval, the inclined casting angle of holding furnace is adjusted, is positioned at corresponding predetermined speed interval with the flow velocity controlling molten steel.
2. holding furnace teeming stage automatic pouring method according to claim 1, is characterized in that, while the described rate-determining steps of execution, performs following detection and retracts step:
S2.1, from described molten steel image, extract liquid steel level marginal arc long value, the marginal arc long value of described extraction and predetermined value are compared;
S2.2, when extract described marginal arc long value be more than or equal to described predetermined value time, described holding furnace is retracted predetermined angle, with stop cast.
3. holding furnace teeming stage automatic pouring method according to claim 1, is characterized in that, in described rate-determining steps S1.1:
According to described inclination angle of water, obtain vert velocity amplitude, the described scheduled time and described holding furnace of the holding furnace suitable with described holding furnace inclination angle of water to need to continue the angle value of inclination, wherein, this angle value and described inclination angle of water sum are described cast reference data angle.
4. holding furnace teeming stage automatic pouring method according to claim 3, is characterized in that, in described rate-determining steps S1.2:
When described holding furnace is verted to described cast reference data angle with described holding furnace pitch velocity, stop verting described holding furnace.
5. holding furnace teeming stage automatic pouring method according to claim 1, is characterized in that, in described rate-determining steps S1.3:
Image procossing is carried out to described molten steel image, and extracts described molten steel flow speed value;
Wherein, described molten steel image adopts maximum variance between clusters to calculate the dynamic brightness segmentation threshold of described molten steel image, by described dynamic brightness segmentation threshold, binary conversion treatment is carried out to described molten steel image, extract described molten steel flow speed value according to left and right edges width value on the molten steel liquid column level direction of molten steel image described after described binary conversion treatment.
6. holding furnace teeming stage automatic pouring method according to claim 1, is characterized in that, in described control by described step S1.4:
When described molten steel flow speed value exceedes corresponding predetermined speed interval, reduce the inclined casting angle of described holding furnace;
When described molten steel flow speed value is less than corresponding predetermined speed interval, increase the inclined casting angle of described holding furnace.
7. a running gate system, comprises holding furnace teeming stage, guiding gutter and casting mold, it is characterized in that, also comprise: angular transducer, camera head, image procossing decision making device and execution control device;
The angle of inclination of detection for detecting the angle of inclination of the holding furnace of holding furnace teeming stage, and is sent to described execution control device by described angular transducer;
Described camera head is for gathering the molten steel image of described guiding gutter discharging opening to casting mold mouth, and the molten steel image of collection is sent to described image procossing decision making device by described camera head;
Described image procossing decision making device is for receiving described molten steel image, extract the molten steel flow speed value of liquid steel level and the molten steel flow speed value of described extraction is sent to described execution control device, and extract marginal arc long value and predetermined value in the marginal arc long value of described extraction and described image procossing decision making device is compared, make and described holding furnace retracted predetermined angle to stop the decision-making of pouring into a mould and described decision-making is sent to execution control device;
Described execution control device is transferred the cast reference data angle of holding furnace in response to the angle of inclination of holding furnace when water outlet and is controlled the inclination of holding furnace, described execution control device adjusts the inclined casting angle of described holding furnace in response to described molten steel flow speed value, and described execution control device retracts described holding furnace in response to described decision-making with predetermined angle.
8. holding furnace teeming stage Auto-pouring System according to claim 7, it is characterized in that: also comprise automatic adjustable optical filter device, described automatic adjustable optical filter device filters in response to the camera of switching signal to described camera head that described image procossing decision making device sends or stops filtering.
9. holding furnace teeming stage Auto-pouring System according to claim 7, is characterized in that: described guiding gutter is the downward infundibulate of osculum.
10. holding furnace teeming stage Auto-pouring System according to claim 7, it is characterized in that: also comprise mould and transmit the horizontal pusher of guide rail, described casting mold is transported to below described guiding gutter by the signal that described mould transmits the described casting mold of conveying that the horizontal pusher of guide rail sends in response to described execution control device.
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| CN110242326A (en) * | 2019-06-17 | 2019-09-17 | 中交第三公路工程局有限公司 | The grouting device of tunnel mud |
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| CN113600805A (en) * | 2021-08-30 | 2021-11-05 | 山东鲁豫阀门有限公司 | Emergency monitoring and releasing device for aluminum melting furnace casting system |
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| CN110722141A (en) * | 2019-11-27 | 2020-01-24 | 湖南江滨机器（集团）有限责任公司 | Method for inclined casting of ladle |
| CN111481971A (en) * | 2020-04-20 | 2020-08-04 | 徐州宏远通信科技有限公司 | Automatic control system and method for unloading of filter press based on image recognition |
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| CN112819749A (en) * | 2020-12-30 | 2021-05-18 | 中冶赛迪重庆信息技术有限公司 | Method, system, medium and terminal for identifying liquid level of tapping ladle of converter |
| CN113522802A (en) * | 2021-06-16 | 2021-10-22 | 无锡胜鼎智能科技有限公司 | Intelligent gate monitoring method and system |
| CN113600805A (en) * | 2021-08-30 | 2021-11-05 | 山东鲁豫阀门有限公司 | Emergency monitoring and releasing device for aluminum melting furnace casting system |
| CN114226658A (en) * | 2021-11-23 | 2022-03-25 | 大冶特殊钢有限公司 | Injection method for die casting |
| CN114226658B (en) * | 2021-11-23 | 2023-03-24 | 大冶特殊钢有限公司 | Injection method for die casting |
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