CN109195241B - Over-burning prevention method in electromagnetic induction heating process of aluminum alloy ingot - Google Patents
Over-burning prevention method in electromagnetic induction heating process of aluminum alloy ingot Download PDFInfo
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- CN109195241B CN109195241B CN201811283091.9A CN201811283091A CN109195241B CN 109195241 B CN109195241 B CN 109195241B CN 201811283091 A CN201811283091 A CN 201811283091A CN 109195241 B CN109195241 B CN 109195241B
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B6/00—Heating by electric, magnetic or electromagnetic fields
- H05B6/02—Induction heating
- H05B6/06—Control, e.g. of temperature, of power
Abstract
The invention discloses an anti-overburning method in an electromagnetic induction heating process of an aluminum alloy ingot, belonging to the technical field of aluminum alloy. The invention solves the problem of overburning in the electromagnetic induction heating process of the aluminum alloy cast ingot by controlling the operation of the overburning prevention device. The device for preventing the excessive burning comprises an ingot length measurement control system, an energy monitor, a plurality of side temperature control thermocouples, a plurality of side temperature measurement monitoring thermocouples, an end temperature measurement monitoring thermocouple, a furnace steel structure, an induction heating coil, an ingot in-and-out device, a water cooling system, a control system, an audible and visual alarm device and the like which are required by an electromagnetic induction heating furnace. The invention integrates various control methods such as ingot length measurement and control, energy input control, temperature measurement monitoring thermocouple comparison control and the like, achieves the effect of multiple over-burning prevention, and solves the problem of the over-burning of the ingot in the electromagnetic induction heating process.
Description
Technical Field
The invention belongs to the technical field of aluminum alloy heating, and particularly relates to an anti-overburning method in an electromagnetic induction heating process of an aluminum alloy ingot.
Background
The induction heating has the advantages of high heating speed, energy conservation, environmental protection, capability of realizing gradient heating and the like, and is widely applied to ingot heating before modern aluminum alloy extrusion. Because the ingot needs to continuously enter and exit the furnace, the existing ingot induction heating furnace adopts a contact thermocouple to measure and control the temperature, and the temperature measurement is inaccurate due to the influence of the surface quality condition of the ingot and the frequent occurrence of the unexpected conditions of poor contact between the thermocouple and the surface of the measured ingot and the like. The existing ingot induction heating furnace controls the start and stop of a heating coil according to the temperature detected by a thermocouple, the temperature control means is single, the reliability is poor, and when the temperature detected by the thermocouple is lower than the actual temperature of an ingot due to accidents such as poor contact, the heating coil can heat the ingot all the time, and finally serious quality accidents of overburning of the ingot are caused.
In addition, the thermocouple contact condition is influenced by the surface quality condition of the ingot, the thermocouple contact condition is also influenced by the length of the ingot, when one or more side thermocouples are just positioned at the critical position of the end part of the ingot due to the length value of the ingot, the thermocouple and the end part of the ingot can be in poor contact to cause the overburning of the ingot, and the existing equipment cannot avoid the condition.
Meanwhile, whether the cast ingot is over-burnt or not needs to be judged from the microstructure level of the cast ingot, and the over-burnt cast ingot can be seen by naked eyes only when the over-burning is serious and the cast ingot is partially melted, so that if the temperature abnormality of the induction heating furnace cannot be detected, the over-burnt cast ingot can possibly flow into the next procedure according to the normal flow, and serious quality accidents are caused.
Disclosure of Invention
The invention aims to solve the problems in the prior art and provides an anti-overburning method in the electromagnetic induction heating process of the aluminum alloy ingot.
In order to achieve the purpose, the technical scheme of the invention is as follows:
an anti-overburning method in the electromagnetic induction heating process of an aluminum alloy ingot comprises the steps of using an aluminum alloy ingot electromagnetic induction heating anti-overburning device to prevent overburning in the electromagnetic induction heating process of the aluminum alloy ingot;
the aluminum alloy ingot casting electromagnetic induction heating anti-overburning device comprises:
an electromagnetic induction heating furnace equipped with an induction heating coil;
the energy monitor is connected with the induction heating coil in series;
the temperature control assembly comprises a plurality of side temperature control thermocouples, a plurality of side temperature measuring thermocouples, an end temperature measuring monitoring thermocouple and an audible and visual alarm device; the side temperature control thermocouple and the side temperature thermocouple are symmetrically arranged on two different side surfaces of the electromagnetic induction heating furnace in pairs; the end temperature measuring and monitoring thermocouple is arranged at the central position of the opening end of the hearth of the electromagnetic induction heating furnace; the acousto-optic alarm device is respectively connected with the side temperature control thermocouple, the side temperature thermocouple, the end temperature monitoring thermocouple and the energy monitor;
the feeding and discharging device is arranged at an opening of the electromagnetic induction heating furnace, and a measuring device for measuring the length of the cast ingot is arranged on one side of the feeding and discharging device; the measuring device is connected with all the side temperature control thermocouples and all the side temperature measurement monitoring thermocouples, and the side temperature control thermocouples and the side temperature measurement thermocouples are started or stopped through the measuring device;
the specific over-burning prevention operation comprises the following steps: the ingot is standby at a feeding and discharging device → the measuring device measures and records the length of the ingot → the end temperature measurement monitoring thermocouple is moved out → the ingot is fed into the furnace → the side temperature measurement thermocouple and the side temperature control thermocouple are extended out, the end temperature measurement monitoring thermocouple is moved into contact with the surface of the ingot to carry out real-time temperature measurement and temperature control → the induction heating coil heats the ingot → the energy monitor carries out real-time monitoring on the electric energy in the heating process → the ingot is heated completely → the induction heating coil stops heating → the temperature measurement thermocouple and the temperature control thermocouple are retracted, the end temperature measurement monitoring thermocouple is moved out → the ingot is moved out;
in the heating process of the cast ingot, when the temperature detected by any one thermocouple is abnormal or the energy monitor detects that the total heat input is abnormal, the sound-light alarm device is immediately triggered to give an alarm.
Furthermore, the side temperature control thermocouple and the side temperature measurement thermocouple are telescopic thermocouples.
Furthermore, the end temperature measurement monitoring thermocouple is a movable thermocouple.
Furthermore, the electromagnetic induction heating furnace also comprises a steel structure for supporting the electromagnetic induction heating furnace, a control system and a water cooling system.
Furthermore, the energy monitor is respectively connected with the control system and the sound-light alarm device.
Further, the length measurement and control of the cast ingot are carried out to prevent overburning: before the ingot is prepared to enter the furnace and be heated at the feeding and discharging device, the measuring device measures and records the length of the ingot; when the length value of the heated ingot is measured to be just the value that one or more side temperature control thermocouples and/or side temperature thermocouple are/is positioned at the end critical position of the ingot, the thermocouples at the position are controlled to be in a non-working state.
Further, the energy input control is carried out for double-prevention over-burning:
heat Q of electric energy generation1＝I·U·t，
Heat Q absorbed by ingot2＝c·m·△T，
Then k.Q1＝k·I·U·t＝Q2＝c·m·△T，
K is the ratio of the heat absorbed by the cast ingot to the heat generated by electric energy, namely the effective absorption rate, I is the current flowing through the induction heating coil, U is the voltage at two ends of the induction heating coil, T is the heating time, c is the specific heat capacity of the aluminum alloy cast ingot, m is the mass of the aluminum alloy cast ingot, and Delta T is the temperature rise value of the aluminum alloy cast ingot;
when a given cast ingot is heated, the energy monitor controls the total heat input into the cast ingot by monitoring the current I, the voltage U and the heating time t, and when the energy monitor detects that the total heat input into the cast ingot exceeds the total heat required by heating, the energy monitor triggers the audible and visual alarm device to give an alarm.
Further, triple over-burning prevention is carried out through comparison control of the thermocouple: the measured values of the symmetrical side temperature control thermocouples are compared with the measured values of the side temperature control thermocouples, and when deviation is found, the sound-light alarm device is triggered to give an alarm.
Has the advantages that:
according to the invention, by adopting the multiple over-burning prevention method, the phenomenon of over-burning of the cast ingot caused by failure of a single over-burning prevention means under an accident condition in the prior art is avoided. The multiple measures of ingot length measurement and heating control, energy input control, temperature measurement monitoring thermocouple comparison control and the like in the invention are mutually independent, and simultaneously, the measures are not mutually influenced, thereby finally achieving the effects of multiple guarantee and preventing the excessive burning of the ingot.
Drawings
FIG. 1 is a schematic structural view of a preferred embodiment of an electromagnetic induction heating over-burning prevention device for aluminum alloy ingots according to the present invention;
notation in the figure: 1. 3, 5, 7, 9-side temperature control thermocouple; 2. 4, 6, 8, 10-side temperature thermocouple; 11-end temperature measurement monitoring thermocouple; 12-an electromagnetic induction heating furnace; 13-an induction heating coil; 14-an energy monitor; 15-a feeding and discharging device; 16-measuring means.
Detailed Description
The invention is further described with reference to the following figures and specific examples.
Example 1
The method is characterized in that an aluminum alloy ingot electromagnetic induction heating anti-overburning device is used for preventing overburning in the aluminum alloy ingot electromagnetic induction heating process;
the aluminum alloy ingot casting electromagnetic induction heating anti-overburning device is shown in figure 1 and comprises:
the electromagnetic induction heating furnace 12 is provided with a steel structure for supporting the electromagnetic induction heating furnace, a water cooling system and a control system, and the electromagnetic induction heating furnace 12 is provided with an induction heating coil 13;
an energy monitor 14 connected in series with the induction heating coil 13; for monitoring the power input to the induction heating coil;
the temperature control assembly comprises a side temperature control thermocouple 1, a side temperature control thermocouple 3, a side temperature control thermocouple 5, a side temperature control thermocouple 7 and a side temperature control thermocouple 9; a side temperature thermocouple 2, a side temperature thermocouple 4, a side temperature thermocouple 6, a side temperature thermocouple 8 and a side temperature thermocouple 10; an end temperature measuring and monitoring thermocouple 11 and an acousto-optic alarm device;
the side temperature control thermocouple and the side temperature thermocouple are symmetrically arranged on two different side surfaces of the electromagnetic induction heating furnace 12 in pairs, such as: the side temperature control thermocouple 1 and the side temperature thermocouple 2 are symmetrically arranged, the side temperature control thermocouple 3 and the side temperature thermocouple 4 are symmetrically arranged, and the like; the side temperature control thermocouple and the side temperature thermocouple are designed to be telescopic, when the ingot is fed into and discharged from the hearth, the thermocouple retracts to avoid interference with the movement of the ingot, when the ingot is normally heated, the thermocouple extends out and is in contact with the surface of the ingot, the temperature control thermocouple controls the heating of the ingot, and the temperature measurement monitoring thermocouple monitors the temperature of the ingot in real time;
the end temperature measurement monitoring thermocouple 11 is arranged at the central position of the opening end of the hearth of the electromagnetic induction heating furnace 12, the center of the end of the ingot is monitored in real time in the normal heating process, the end temperature measurement monitoring thermocouple 11 is designed to be movable, and when the ingot enters and exits the hearth, the thermocouple moves out of the measuring position to avoid interference with the movement of the ingot.
The acousto-optic alarm device is respectively connected with the side temperature control thermocouples 1, 3, 5, 7 and 9, the side temperature measurement thermocouples 2, 4, 6, 8 and 10, the end temperature measurement monitoring thermocouple 11 and the energy monitor 14;
the feeding and discharging device 15 is arranged at an opening of the electromagnetic induction heating furnace 12, and a measuring device 16 for measuring the length of the cast ingot is arranged on one side of the feeding and discharging device 15; before the ingot is heated by the electromagnetic induction heating furnace 12 in preparation of the feeding and discharging device 15, the measuring device 16 measures and records the length of the ingot; the measuring device 16 is connected with all the side temperature control thermocouples 1, 3, 5, 7 and 9 and all the side temperature measurement monitoring thermocouples 2, 4, 6, 8 and 10, and the side temperature control thermocouples 1, 3, 5, 7 and 9 and the side temperature measurement thermocouples 2, 4, 6, 8 and 10 are started or stopped through the measuring device 16.
The anti-overburning operation in the electromagnetic induction heating process of the aluminum alloy cast ingot comprises the following steps:
the ingot is standby at the feeding and discharging device 15 → the measuring device 16 measures and records the length of the ingot → the end temperature monitoring thermocouple 11 is moved out → the ingot is fed into the furnace → the side temperature thermocouples 1, 3, 5, 7 and 9 and the side temperature control thermocouples 2, 4, 6, 8 and 10 are extended out, the end temperature monitoring thermocouple 11 is moved into contact with the surface of the ingot to carry out real-time temperature measurement and temperature control → the induction heating coil 13 heats the ingot → the energy monitor 14 carries out real-time monitoring on the electric energy in the heating process → the heating of the ingot is completed → the induction heating coil 13 stops heating → the temperature thermocouples 1, 3, 5, 7 and 9 and the temperature control thermocouples 2, 4, 6, 8 and 10 are retracted, the end temperature monitoring thermocouple 11 is moved out → the ingot is moved out of the furnace through the feeding and discharging device 15 →. When the temperature detected by any thermocouple is abnormal or the energy monitor detects that the total heat input is abnormal, the sound-light alarm device is immediately triggered to give an alarm and record the abnormal condition in the control system, the equipment is automatically powered off, and the fault is manually removed.
The steps of preventing the overburning in the ingot casting heating process are as follows:
firstly, preventing overburning:
measuring and controlling the length of the cast ingot: before the ingot is ready to enter the furnace and be heated at the feeding and discharging device 15, the measuring device 16 measures and records the length of the ingot; when the length of the heated ingot is measured to be just the value that one or more side thermocouples (9 and 10 in the figure 1) are positioned at the end critical position of the ingot, the thermocouples at the position (9 and 10 in the figure 1) are controlled to be in a non-working state, and the phenomenon that the thermocouples at the position cause the over-burning of the ingot due to poor contact is avoided.
Double-prevention of overburning:
energy input control: according to the law of conservation of energy, the heat generated by the electric energy is converted into the heat of the ingot casting and the heat Q generated by the electric energy except that a part of the heat is absorbed by the cooling system and the ambient environment of the furnace1I.u.t, heat Q absorbed by the ingot2K · Q, where k is the effective absorption rate, which is the ratio of the amount of heat absorbed by the ingot to the amount of heat generated by the electric energy1＝k·I·U·t＝Q2Where I is a current flowing through the induction heating coil 13, U is a voltage across the induction heating coil 13, T is a heating time, c is a specific heat capacity of the aluminum alloy ingot, m is a mass of the aluminum alloy ingot, and Δ T is a temperature rise value of the aluminum alloy ingot. When a given ingot is heated, the specific heat capacity c, the mass m, the temperature rise value delta T and the absorption rate k of the ingot are known values, the energy monitor 14 can control the total heat input into the ingot by monitoring the current I, the voltage U and the heating time T, when the energy monitor 14 detects that the total heat input into the ingot exceeds the total heat required by heating, the actual temperature rise of the ingot is beyond a set value, and at the moment, the energy monitor 14 triggers the sound-light alarm device to give an alarm and records abnormal conditions in the control system.
Triple prevention of overburning:
temperature measurement monitoring thermocouple contrast control: the side temperature thermocouple and the side temperature control thermocouple are designed on two different sides of the cast ingot in pairs, so that the design has the advantages that when the surface quality of a certain position of the cast ingot is poor or foreign matters are adhered, the thermocouple at the position may be in poor contact with the surface of the cast ingot at the moment, but the side temperature thermocouple and the temperature control thermocouple are on two different sides, the two thermocouples are different in measuring position at the moment, the situation that the two thermocouples are in poor contact is avoided, the system compares the measured values of the two thermocouples, if the deviation is found, the situation that one of the thermocouples is abnormal is indicated, the audible and visual alarm device is immediately triggered to give an alarm, and the abnormal situation is recorded in the control system. Going back again, even if in an extreme case, a pair of thermocouples (such as 5 and 6 in fig. 1) are abnormal at the same time, the scheme can be monitored by the nearby thermocouples: when the 5 and 6 thermocouples are abnormal at the same time, the temperature of the cast ingot at the position is abnormal, aluminum is a good thermal conductor, the cast ingots at the positions measured by the 5 and 6 and the positions measured by the nearby 7 and 8, 3 and 4 are subjected to heat conduction, so that the actual temperatures of the cast ingots at the positions 7 and 8, 3 and 4 are deviated, and the heating abnormality can be monitored from the four thermocouples 7, 8, 3 and 4, so that the audible and visual alarm device is triggered to give an alarm, and the abnormal condition is recorded in the control system. In addition, the end temperature measuring and monitoring thermocouple 11 at the central position of the end part monitors the temperature of the core part of the cast ingot in real time, and under extreme conditions, such as 1 and 2 thermocouples are abnormal at the same time, the end temperature measuring and monitoring thermocouple 11 can also detect the temperature, so that an audible and visual alarm device is triggered to give an alarm and the abnormal condition is recorded in a control system.
According to the multiple over-burning prevention technology, the probability of the over-burning of the cast ingot can be reduced to be infinitesimal, the phenomenon that the over-burned cast ingot flows into the next procedure due to abnormal heating is fundamentally avoided, and the heating quality of the cast ingot is ensured.
Although the present invention has been described with respect to the preferred embodiments, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (8)
1. The method for preventing overburning in the electromagnetic induction heating process of the aluminum alloy ingot is characterized by comprising the following steps: the aluminum alloy ingot electromagnetic induction heating anti-overburning device is used for preventing overburning in the aluminum alloy ingot electromagnetic induction heating process;
the aluminum alloy ingot casting electromagnetic induction heating anti-overburning device comprises:
an electromagnetic induction heating furnace equipped with an induction heating coil;
the energy monitor is connected with the induction heating coil in series;
the temperature control assembly comprises a plurality of side temperature control thermocouples, a plurality of side temperature measuring thermocouples, an end temperature measuring monitoring thermocouple and an audible and visual alarm device; the side temperature control thermocouple and the side temperature thermocouple are symmetrically arranged on two different side surfaces of the electromagnetic induction heating furnace in pairs; the end temperature measuring and monitoring thermocouple is arranged at the central position of the opening end of the hearth of the electromagnetic induction heating furnace; the acousto-optic alarm device is respectively connected with the side temperature control thermocouple, the side temperature thermocouple, the end temperature monitoring thermocouple and the energy monitor;
the feeding and discharging device is arranged at an opening of the electromagnetic induction heating furnace, and a measuring device for measuring the length of the cast ingot is arranged on one side of the feeding and discharging device; the measuring device is connected with all the side temperature control thermocouples and all the side temperature measurement monitoring thermocouples, and the side temperature control thermocouples and the side temperature measurement thermocouples are started or stopped through the measuring device;
the specific over-burning prevention operation comprises the following steps: the ingot is standby at a feeding and discharging device → the measuring device measures and records the length of the ingot → the end temperature measurement monitoring thermocouple is moved out → the ingot is fed into the furnace → the side temperature measurement thermocouple and the side temperature control thermocouple are extended out, the end temperature measurement monitoring thermocouple is moved into contact with the surface of the ingot to carry out real-time temperature measurement and temperature control → the induction heating coil heats the ingot → the energy monitor carries out real-time monitoring on the electric energy in the heating process → the ingot is heated completely → the induction heating coil stops heating → the temperature measurement thermocouple and the temperature control thermocouple are retracted, the end temperature measurement monitoring thermocouple is moved out → the ingot is moved out;
in the heating process of the cast ingot, when the temperature detected by any one thermocouple is abnormal or the energy monitor detects that the total heat input is abnormal, the sound-light alarm device is immediately triggered to give an alarm.
2. The method for preventing overburning of the aluminum alloy ingot in the electromagnetic induction heating process according to claim 1, wherein: the side temperature control thermocouple and the side temperature thermocouple are telescopic thermocouples.
3. The method for preventing overburning of the aluminum alloy ingot in the electromagnetic induction heating process according to claim 1, wherein: the end temperature measuring and monitoring thermocouple is a movable thermocouple.
4. The method for preventing overburning of the aluminum alloy ingot in the electromagnetic induction heating process according to claim 1, wherein: the electromagnetic induction heating furnace also comprises a steel structure for supporting the electromagnetic induction heating furnace, a control system and a water cooling system.
5. The method for preventing overburning of the aluminum alloy ingot in the electromagnetic induction heating process according to claim 4, wherein: the energy monitor is respectively connected with the control system and the sound-light alarm device.
6. The method for preventing overburning of the aluminum alloy ingot in the electromagnetic induction heating process according to claim 1, wherein: the method comprises the following steps of performing primary overburning prevention on the length measurement and control of the cast ingot: before the ingot is prepared to enter the furnace and be heated at the feeding and discharging device, the measuring device measures and records the length of the ingot; when the length value of the heated ingot is measured to be just the value that one or more side temperature control thermocouples and/or side temperature thermocouple are/is positioned at the end critical position of the ingot, the thermocouples at the position are controlled to be in a non-working state.
7. The method for preventing overburning of the aluminum alloy ingot in the electromagnetic induction heating process according to claim 1, wherein: the energy input control is carried out for double prevention of overburning:
heat Q of electric energy generation1＝I·U·t，
Heat Q absorbed by ingot2＝c·m·△T，
Then k.Q1＝k·I·U·t＝Q2＝c·m·△T，
K is the ratio of the heat absorbed by the cast ingot to the heat generated by electric energy, namely the effective absorption rate, I is the current flowing through the induction heating coil, U is the voltage at two ends of the induction heating coil, T is the heating time, c is the specific heat capacity of the aluminum alloy cast ingot, m is the mass of the aluminum alloy cast ingot, and Delta T is the temperature rise value of the aluminum alloy cast ingot;
when a given cast ingot is heated, the energy monitor controls the total heat input into the cast ingot by monitoring the current I, the voltage U and the heating time t, and when the energy monitor detects that the total heat input into the cast ingot exceeds the total heat required by heating, the energy monitor triggers the audible and visual alarm device to give an alarm.
8. The method for preventing overburning of the aluminum alloy ingot in the electromagnetic induction heating process according to claim 1, wherein: triple anti-overburning was performed by comparative control of thermocouples: the measured values of the symmetrical side temperature control thermocouples are compared with the measured values of the side temperature control thermocouples, and when deviation is found, the sound-light alarm device is triggered to give an alarm.
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