CN109570481A - A kind of pneumatic melt transport packet system and melt conveying method - Google Patents
A kind of pneumatic melt transport packet system and melt conveying method Download PDFInfo
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- CN109570481A CN109570481A CN201910061356.9A CN201910061356A CN109570481A CN 109570481 A CN109570481 A CN 109570481A CN 201910061356 A CN201910061356 A CN 201910061356A CN 109570481 A CN109570481 A CN 109570481A
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- melt
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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
- B22D41/00—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like
- B22D41/12—Travelling ladles or similar containers; Cars for ladles
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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
- B22D41/00—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like
- B22D41/005—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like with heating or cooling means
- B22D41/01—Heating means
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Casting Support Devices, Ladles, And Melt Control Thereby (AREA)
Abstract
The invention discloses a kind of pneumatic melt transport packet system and melt conveying methods, it include closed transport packet, temperature-controlling system, baric systerm, controller, closed transport packet is to store metal bath, and metal bath is transported to the holding furnace of foundry by calciner, and metal bath is conveyed into holding furnace；Temperature-controlling system includes temperature measuring equipment and heating device, and temperature measuring equipment is to the metal bath temperature in transport packet closed in real-time measurement conveying and transmission process, and temperature-controlling system is to heat the melt in enclosed conveying packet；Baric systerm allows compressed air into transport packet, and melt in transport packet is depressed into casting machine holding furnace, realizes that the conveying of interior metal bath is wrapped in transport；The temperature data that controller is acquired according to temperature measuring equipment, control heating device heats melt in enclosed conveying packet, and control pressure system realizes the conveying of melt.This invention ensures that transport packet transmission process accurately controls；Delivery safety is improved simultaneously.
Description
Technical field
The invention belongs to Casting Equipment technical fields, more particularly, to a kind of suitable metal bath, especially aluminium alloy
Pneumatic melt transport packet system and melt conveying method.
Background technique
Lightweight is one of fuel-engined vehicle energy-saving and emission-reduction, most important approach of new-energy automobile consumption reduction increasing journey, with aluminium alloy
Equal lightweighting materials replace traditional steel material, it has also become the inevitable choice that Automobile Design updates.On automobile
Aluminium alloy can be divided into cast aluminium alloy gold and wrought aluminium alloy, and cast aluminium alloy gold occupies leading, account for 80% or so of automobile aluminum amount,
Mainly for the manufacture of components such as engine, clutch housing, wheel, chassis members.With the development of foundry engieering, more zero
Component uses the casting method of advantage of lower cost, such as low pressure casting, counter-pressure casting, high-pressure casting, extrusion casint.
Aluminium ingot is melted in melting furnace or calciner first in casting process, the molten aluminum after fusing is by casting ladle by melting
Workshop is transported to foundry, then pours into the molten aluminum in casting ladle by flow-guiding mouth and carries out moulding by casting in cast insulation furnace.
However this traditional casting ladle is used to transport molten aluminum, it is conducted heat due to molten aluminum large area to pouring in backpack cover and environment in transportational process,
Temperature of aluminum liquid can decline rapidly, seriously affect molten aluminum density and quality, to be shipped when transporting to foundry, the aluminium of casting ladle endosexine
Liquid part can be solidified with the reduction of temperature, and be unfavorable for molten aluminum forms in a mold, largely effect on the molding matter of casting components
Amount.Simultaneously as molten aluminum is to backpack cover heat transfer is poured, when worker pours out molten aluminum, the high temperature for pouring backpack cover may cause to burn to worker.
Moreover, the problem that the method transhipment molten aluminum precision is low, largely effects on the production efficiency of casting.And existing Dumpage type casting ladle, often
Often topple over too fast or shake the problem of causing molten aluminum to leak, causes danger.
Summary of the invention
In order to overcome, traditional molten aluminum transhipment Dumpage type casting ladle transhipment molten aluminum is of poor quality, casting precision is low, safe operation is hidden
Suffer from the problems such as big, molten aluminum transfer efficiency is low, the present invention provides a kind of novel pneumatic ladling apparatus and pouring procedures, and the device is not
It is only capable of heating casting ladle in transport process, within the temperature range of so that molten aluminum is maintained and is met the requirements, and entirely be poured
Process is that totally enclosed type is pneumatically poured, and there is no the danger of molten aluminum leakage.
In order to achieve the above objectives, a kind of technical solution for pneumatic melt transport packet system that the present invention uses is: this is pneumatic
It includes closed transport packet, temperature-controlling system, baric systerm and controller that melt, which transports packet system,；
The baric systerm wraps gas into closed transport, and interior melt is wrapped in closed transport and is depressed into foundry
Holding furnace in, realize it is closed transport wrap in metal bath conveying；
The temperature data that the controller control pressure system is acquired according to temperature measuring mechanism, control heating mechanism transport closing
Melt is heated in defeated packet, and control pressure system realizes the conveying of melt.
Further, the closed transport packet includes backpack body, backpack cover is housed on backpack body, backpack cover fixing seal is in backpack body
On；Backpack body is equipped with air inlet；The backpack cover is equipped with molten metal outlet and the fire door for filling molten metal, sets on fire door
There is fire door；
The temperature-controlling system includes temperature measuring equipment and heating device, and temperature measuring equipment is mounted on the backpack cover, heating device
It is mounted on the backpack body；
The baric systerm include first pressure transmitter, second pressure transmitter, vent line, digital combination valve and
Described for controlling the intake valve of gas on-off, the vent line is connected to the air inlet, the first pressure pick-up
Device, intake valve and digital combination valve are successively set on vent line according to airintake direction, and the second pressure transmitter is set
It sets on the backpack cover；
The controller can receive temperature measuring equipment acquisition temperature signal and the first pressure transmitter and
The pressure signal of second pressure transmitter acquisition is commanded the heating device to wrap interior melt to closed transport and is heated, with
And command digital combination valve work.
Further, the digital combination valve is to be adjusted by the different solenoid valve block of one group of sectional area at combined type flow
Valve, namely by multiple valve groups formed by the valve of binary array.
Further, the backpack cover is equipped with liquid level detection device, wraps interior melt for the closed transport of real-time monitoring
Liquid level.
Further, the backpack cover, which is bolted, is sealed on backpack body, and the faying face of backpack cover and backpack body uses graphite
Packing compresses sealing.
Further, the closed transport packet further includes melt quantitative conveying device, the melt quantitative conveying device packet
Stalk and molten metal transfer pipeline are included, the stalk is fixedly mounted on the molten metal exit of backpack cover, the lower end of stalk
It is inserted into the lower part of the backpack body；One end of the molten metal transfer pipeline is fixedly connected with stalk, molten metal transfer pipeline
The other end is connected with casting machine holding furnace.
Further, the baric systerm further includes relief valve, which is arranged on the vent line, and position
Between the air inlet and digital combination valve.
Further, the temperature measuring equipment is thermocouple, and the heating device is high temperature resistance silk heater.
Further, the controller is PLC controller, and internal program uses closed loop pid algorithm.
Further, the pneumatic melt transport packet system further includes combined aural and visual alarm, when system occurs abnormal, acousto-optic
The capable of emitting alarm signal of alarm.
In order to achieve the above objectives, the melt conveying method carried out using pneumatic melt transport packet system that the present invention uses
Technical solution is: the melt conveying method successively includes the following steps:
The first step carries out temperature control: the temperature measuring equipment to the closed transport packet for having filled molten metal
The temperature of interior metal bath is wrapped in closed transport in real-time measurement conveying and casting process, and collected temperature signal is sent
To the controller, controller is commanded the heating device to wrap interior melt to closed transport and is heated；
Second step carries out pressure control to the closed transport packet: opening the intake valve, gas enters digital group
It closes in valve, the admission pressure of the first pressure transmitter monitoring gas, the second pressure transmitter monitors closed transport
Gas pressure in packet；Collected pressure signal is sent to controller by first pressure transmitter and second pressure transmitter,
Controller converts pressure value and gas flow by calculating, and digital combination valve receives binary valve that controller is sent
Opening value, according to the needs of gas flow, the solenoid valve for controlling corresponding valve opening value in digital combination valve is opened；
Third step, gas enter in backpack body after the air inlet, and with the increase of pressure in backpack body, gas will be sealed
Molten metal in enclosed transport packet is pressed out to molten metal outlet, complete by molten metal transfer pipeline until in casting machine holding furnace
At the conveying and casting of molten metal.
Further, the program inside the controller uses closed loop pid algorithm, and the output result of PID passes through linear ratio
It is limited between 0~511 after example relationship conversion, the pressure value of setting and the deviation of pressure signal export one after PID is calculated
A calculated result.
Further, the controller carries out dead zone function to digital combination valve, and dead zone function is according in digital combination valve
The size of each spool sectional area and the valve opening variable quantity of needs do ratio, i.e.,In formula, r is ratio, QYiFor
The opening value of single spool, i are the identification number of spool, and Δ Q is the increment of the valve opening value needed, the total aperture of the valve needed
A product is obtained multiplied by ratio, the valve that valve opening value is less than the product belongs to control failure.
The present invention compared with the existing technology the advantages of be:
1, by furnace insulation, molten aluminum dehydrogenation, gas pressure casting etc. functions realization, avoid tradition casting because with it is outer
Boundary's contact area is big, it is of long duration caused by the problem of molten aluminum is of poor quality, casting efficiency is low, operational hazards, casting has been effectively ensured
The quality of molten aluminum and the efficiency of production.
2, believed by precise acquisition field instrument and the relevant temperature of equipment, pressure, valve position state, equipment running status etc.
In number input controller, controller carries out output control after carrying out the calculating and data processing of related algorithm, realizes enclosed conveying
The quantitative pouring of the accurate control and molten aluminum of temperature of aluminum liquid in wrapping.
3, system through the invention realizes full-automatic, totally enclosed state in molten aluminum casting process, passes through controller
Heating device work is controlled to guarantee the temperature in molten aluminum transport process；Equipment operation transport casting flexibly, can be realized quickly
Safety to up-to-standard molten aluminum is filled in Casting Equipment furnace, effectively raise production efficiency and casting quality.
4, a kind of pneumatic melt of the invention transports packet system and melt conveying method, uses with digital group of independent development
It closes the industrial control system that valve is core and closed transport is guaranteed using sensitive pressure transmitter and software type PID controller
The accurate control of packet casting process；The control loop of the heater composition closure of thermocouple sensor and closed transport packet, is protected
Closed transport packet temperature control is demonstrate,proved at 720 DEG C~800 DEG C；Real-time alarm system can detection system failure in time, work as casting ladle
Temperature is too low, pressure superelevation or when other failures occur, and triggers combined aural and visual alarm, has the function that early warning.
Detailed description of the invention
Fig. 1 is the schematic diagram of pneumatic melt transport packet system of the invention.
Fig. 2 is the control system schematic diagram of pneumatic melt transport packet system of the invention.
Fig. 3 is the temperature control principle drawing of pneumatic melt transport packet system of the invention.
Fig. 4 is the closed transport pack arrangement schematic diagram of pneumatic melt transport packet system of the invention.
Specific embodiment
Below in conjunction with attached drawing, the present invention is described in further detail.
Packet system is transported referring to the pneumatic melt that Fig. 1, the present invention shown in Fig. 4 design comprising closed transport packet 11,
Temperature-controlling system, baric systerm and controller 13；
The closed transport packet 11 includes backpack body 17, backpack cover 19 is housed on backpack body 17,19 fixing seal of backpack cover is in backpack body
On 17；Backpack body 17 is equipped with air inlet 27；The backpack cover 19 is equipped with molten metal outlet 12 and the furnace for filling molten metal
Mouth 25, fire door 25 are equipped with fire door 24；Closed transport packet 11 is transported metal bath by calciner to store metal bath
It is conveyed into holding furnace at the holding furnace of foundry, and by metal bath；
The temperature-controlling system includes temperature measuring equipment and heating device, and temperature measuring equipment is mounted on the backpack cover 19, heating dress
It sets and is mounted on the backpack body 17；The temperature measuring equipment is in transport packet closed in real-time measurement conveying and transmission process
Metal bath temperature, the temperature measuring equipment is to heat the melt in enclosed conveying packet；
The baric systerm include first pressure transmitter 2, second pressure transmitter 8, vent line 5, by one group of section
The different valve group of product at digital combination valve 4 and intake valve 3 for controlling gas on-off, the vent line 5 with it is described
Air inlet 27 is connected to, and the first pressure transmitter 2, intake valve 3 and digital combination valve 4 are successively set on according to airintake direction
On vent line 5, the second pressure transmitter 8 is arranged on the backpack cover 19；The baric systerm allows compressed air into
Closed transport packet 11, and melt in 11 is wrapped into closed transport and is depressed into molten metal outlet 12, it realizes in closed transport packet 11
The conveying of metal bath；Digital combination valve 4 namely combination flow regulator.
The controller 13 can receive the temperature signal and the first pressure transmitter 2 of the temperature measuring equipment acquisition
The pressure signal acquired with second pressure transmitter 8 commands the heating device to add melt in closed transport packet 11
Heat, and digital combination valve 4 is commanded to work, realize the conveying of melt.
The first pressure transmitter 2 monitors the compressed air pressure from compressed air source, the second pressure pick-up
Device 8 monitors the gas pressure inside closed transport packet 11；Controller 13 controls the switch of each valve in digital combination valve 4, real
Now to the control of compression pressure and flow；
The backpack cover 19 is equipped with liquid level detection device 21, the liquid level for melt in the closed transport packet 11 of real-time monitoring
Highly.
The closed transport packet 11 further includes melt quantitative conveying device, which includes stalk
18 and molten metal transfer pipeline 20, the stalk 18 is fixedly mounted at the molten metal outlet 12 of backpack cover 19, stalk 18
The lower part of the backpack body 17 is inserted into lower end, provides to molten aluminum and extrudes channel；One end of the molten metal transfer pipeline 20 passes through method
Orchid is fixedly connected with stalk 18, and the other end of molten metal transfer pipeline 20 is connected with casting machine holding furnace, realizes molten aluminum conveying,
Molten aluminum transfer pipeline has thermal-insulating sealing function.
The baric systerm further includes relief valve, which is arranged on the vent line 5, and be located at it is described into
Between port 27 and digital combination valve 4.When closing pressure superelevation in casting ladle or other failures occur, compressed air can be by letting out
Pressure valve discharge, safety relief.
Pneumatic melt transport packet system further includes combined aural and visual alarm 15, and when device occurs abnormal, combined aural and visual alarm 15 can
Issue alarm signal.
The temperature measuring equipment is thermocouple 9, and the heating device is high temperature resistance silk heater 10.
The controller 13 is PLC controller, and internal program uses closed loop pid algorithm.
The melt conveying method carried out using pneumatic melt transport packet system, is successively included the following steps:
The first step, carry out temperature control to the closed transport packet 11 for having filled molten metal: the thermometric fills
The temperature of metal bath in closed transport packet 11 in real-time measurement conveying and casting process is set, and by collected temperature signal
It is sent to the controller 13, controller 13 commands the heating device to heat melt in closed transport packet 11；
Second step, to the closed 11 progress pressure control of transport packet: opening the intake valve 3, gas enters number
In word combination valve 4, the first pressure transmitter 2 monitors the admission pressure of gas, the monitoring of second pressure transmitter 8 closing
Gas pressure in formula transport packet 11；First pressure transmitter 2 and second pressure transmitter 8 send collected pressure signal
To controller 13, controller 13 converts pressure value and gas flow by calculating, and digital combination valve 4 receives controller 13 and sends out
The binary valve opening value sent controls corresponding valve opening value in digital combination valve 4 according to the needs of gas flow
Solenoid valve is opened；
Third step, gas enter in backpack body 17 after the air inlet 27, and gas wraps closed transport in 11
Molten metal is pressed out to molten metal outlet 12, completes the melt conveying of molten metal.
Program inside the controller 13 uses closed loop pid algorithm, and the output result of PID is changed by linear ratio relation
It is limited between 0~511 after calculation, the pressure value of setting and the deviation of pressure signal, a calculating knot is exported after PID is calculated
Fruit.
13 pairs of the controller digital combination valves 4 carry out dead zone function, and dead zone function is according to each valve in digital combination valve 4
The size of core section product and the valve opening variable quantity of needs do ratio, i.e.,In formula, r is ratio, QYiFor single valve
The opening value of core, i be spool identification number, Δ Q be needs valve opening value increment, the total aperture of the valve needed multiplied by than
Value obtains a product, and the valve that valve opening value is less than the product belongs to control failure.
In the present invention, the delivery method of pneumatic melt transport packet is as shown in Figure 1, Figure 2, Figure 3 shows, in Fig. 1, compressed air 1
Enter in backpack body 17 from air inlet 27, whether the pressure that first pressure transmitter 2 is used to monitor compressed air 1 meets the requirements；Into
Air valve 3 is used to control the on-off of compressed air 1, and compressed air 1 can enter digital combination valve 4 after opening intake valve 3, by operation
Digital combination valve 4 exports required compressed air require, and all compressed airs 1 are all flowed by compressed air line 5,
And enter in melt transport packet 11；Pressure inside melt transport packet 11 is detected by second pressure transmitter 8, according to setting
Needs, compressed air by melt transport packet 11 in molten aluminum 7 be pressed out to molten aluminum outlet 12, complete molten aluminum 7 melt conveying.When
When melt transport wraps pressure superelevation in 11 or other failures occur, compressed air 1 or molten aluminum 7 can pass through compressed air line 5
The relief valve 6 of upper setting is discharged, and achievees the purpose that safety relief.Thermocouple 9 is used to detect the temperature of molten aluminum 7, when temperature is too low
When, it can be heated by opening electric heating wire 10.
In Fig. 2, the temperature signal that thermocouple 9 measures, the pressure that first pressure transmitter 2 and second pressure transmitter 8 measure
Force signal, which is sent in controller 13, to be calculated, is analyzed, being compared；The technological parameter and equipment state of device can pass through
Human-computer interaction interface 14 is shown and is operated；When device occurs abnormal, the capable of emitting alarm signal of combined aural and visual alarm 15 is prompted
Operator.
In Fig. 2, the pressure control of closed transport packet 11 is the core of device control, passes through the program inside controller 13
It realizes, the function of digital combination valve 4 is the certain pressure for sending gas source and the compressed air of flow, not by one group of sectional area
Same valve realizes the control of general output by controlling the switch of each valve.By reception controller 13 when the operation of this valve
Valve opening is converted into binary system by the valve seat opening value of transmission, and then corresponding electromagnetism valve events are realized.Second pressure becomes
After sending the pressure signal that acquisition comes of device 8 to calculate by control algolithm, a valve opening value adjusted is exported.It is pressed in conversion
When force value, pressure value and gas flow are converted by calculating first, obtained gas flow is according to each in digital combination valve 4
This value is converted into controlling the switch of digital combination valve 4 by the flow value of valve by obtaining the aperture of a valve by bit comparison
State.
In the present invention, the pressure control algorithm of pressure signal to valve opening value specifically: digital combination valve 4 is by 13 valves
Door composition, number are set to Y1~Y13, the corresponding opening value of each valve in digital combination valve 4 are as follows:
| Title | Y1 | Y2 | Y3 | Y4 | Y5 | Y6 | Y7 | Y8 | Y9 | Y10 | Y11 | Y12 | Y13 |
| Opening value | 1 | 2 | 4 | 8 | 16 | 32 | 64 | 64 | 64 | 64 | 64 | 64 | 64 |
In the present invention, compressed air 1 is divided into 511 parts in equal size after entering digital combination valve 4, when the compression of different flow is empty
When gas 1 is needed by system, the corresponding valve open and close of 0~511 any value is can be achieved in openable corresponding valve, this combine.
After program inside controller 13 uses closed loop pid algorithm, the output result of PID to convert by linear ratio relation
It is limited between 0~511, the pressure value of setting and the deviation of pressure signal, a calculated result is exported after PID is calculated
(between 0~511), such as: when output result is 170 after the PID of controller 13 is calculated, it can be tied according to output in program
Fruit 170 carries out the conversion of valve opening, i.e. 170=64+64+32+8+2.At this point, controller 13 can the successively step-by-step from Y13 to Y1
Compare comparing calculation, it is known that needing open valve is Y13, Y12, Y6, Y4, Y2, corresponding binary system are as follows:
1100000101010, the control of 13 valves is written in binary digit operation result 1100000101010 by controller 13 at this time
Position, to make solenoid valve Y13, Y12, Y6, Y4, Y2 are opened, remaining solenoid valve is closed, it is thus achieved that pressure divergence and valve
The conversion of the conversion of aperture, i.e. pressure and flow.
In pressure control, it is real-time perfoming that all data, which acquire and compare calculating process, and the variation of gas consumption can
The each valve that can be will lead in digital combination valve 4 frequently switchs, and the valve of especially small flow, switching frequency can be very high, this
Sample will have very big damage to spool, therefore in the present invention, increase the dead zone function to digital combination valve 4.
The digital combination valves 4 of 13 pairs of controller carry out dead zone functions, dead zone function according to the size of each spool sectional area and
The valve opening variable quantity needed does ratio, i.e.,In formula, r is ratio, QYiFor the opening value of single spool, i is valve
The identification number of core, Δ Q are the increment of the valve opening value needed, and for the total aperture of the valve needed multiplied by ratio, valve opening value is small
Belong to control failure in the valve of the product.
Dead zone function, that is, reduced value r limitation.For example, being 0 r≤0.1 < by the dead time of r, when the valve of needs is opened
When angle value is more than 15, the corresponding opening value 1 < 1.5 of spool Y1 is limited by dead zone at this time, is controlled spool Y1 and is failed, no longer beats
It opens；Similarly, when the aperture of needs is more than 100, the corresponding valve opening value of spool Y1, Y2, Y3, Y4 is both less than 10, at this time
It fails to the control of Y1, Y2, Y3, Y4.
During by 7 melt conveying of molten aluminum, molten aluminum is gradually decreased in closed transport packet 11, to guarantee closed fortune
The pressure of defeated packet 11 is constant, and gas consumption gradually increases, and by the way that suitable dead zone is arranged, can control closed 11 pressure of transport packet
Power maintains acceptable pressure limit.It not only ensure that the stable operation of 11 control pressurer systems of closed transport packet in this way, but also
Improve the service life of digital combination valve 4.
In attached drawing 3, the detection of temperature in closed transport packet 11 is mainly completed in the 11 temperature control of closed transport packet, is passed through
Electric heating wire 10 heats, and is acquired using thermocouple 9, and temperature signal in 11 is wrapped in closed transport and is sent at temperature controller 16
Reason, while being compared on the basis of the temperature value being set, the on-off of high temperature resistance silk heater 10 is controlled by deviation
To adjust real time temperature, reach the requirement for meeting system temperature stable operation.
Deviation control temperature realizes P=aC ρ V Δ T by the following method, and in formula, P is the power of electric heating wire, and C is molten aluminum
Specific heat capacity, ρ be molten aluminum density, V be melt transport packet in molten aluminum volume, Δ T be molten aluminum set temperature and real time temperature
Difference, the above parameter is all made of the International System of Units；A is correction factor, and value range is (0.6~1.5) × 10-4。
For example, 11 temperature are wrapped in closed transport is set as 720 DEG C, when the collected temperature signal of thermocouple 9 is less than 720 DEG C
When, controller 13 provides instruction by comparing, and opens high temperature resistance silk heater 10 and is heated, and is added according to above-mentioned formula control
The temperature difference of thermal power, i.e. real time temperature and set temperature is bigger, and heating power is bigger, while heating power is also and the ratio of melt
Thermal capacitance, density and volume are proportional, wrap interior temperature with closed transport and gradually rise, the temperature difference reduces, and gradually drops at this time
Low heating power, etc. 7 temperature of molten aluminums reach set temperature when, controller issue stop resistance heater 10 work instruction,
Stop heating.But at this point, since the temperature of resistance heater 10 is still higher than temperature of aluminum liquid, thus still molten aluminum is heated,
Make temperature of aluminum liquid continue to rise, so that the molten aluminum after stopping heating is higher than set temperature, realize certain buffering.Both energy is reduced
Consumption, and improve insulating efficiency.
Wherein, in above-mentioned formula, 7 volume of molten aluminum in closed transport packet 11 can subtract melt conveying with initial volume
The product of melt conveying speed and time in the process obtains, and the level monitoring device 21 that can also be used in melt transport packet detects
Liquid level obtains.
Simultaneously as heating efficiency is declined after heating power increase, therefore, preferred embodiment is to add
Hot different phase, pair value be adaptively adjusted, generally increase 10 DEG C every, it is corresponding to increase 1.1~1.2 times.
Pneumatic melt transport packet specific structure of the invention is as shown in Fig. 4, and closed transport packet 11 includes backpack body 17, packet
Backpack cover 19 is housed, through high-strength bolt fixing seal on backpack body 17, the faying face of backpack cover 19 and backpack body 17 is used on body 17
Graphite packing 26 compresses sealing, guarantees to become enclosure space in backpack body 17；Backpack cover 19 is equipped with fire door 25, same fashionable dress on backpack cover 19
There are second pressure transmitter 8, thermocouple 9, liquid level detection device 21, the pressure in backpack body 17, temperature, liquid level is carried out real
When monitor, fire door 25 is furnished with fire door 24, and is equipped with mechanical locking device, and mechanical locking device includes fixed bracket 23 and lead screw rotation
Shaft 22 when fire door 24 is opened, can pass through fire door 25, it can be achieved that fire door 24 rotatably compresses sealing fixing seal and opening
Filling molten aluminum 7 is carried out, while according to the demand of casting technique, dehydrogenation can be carried out to molten aluminum 7 in furnace body by fire door 25, guarantee aluminium
Liquid quality；When fire door 24, which is closed, to be sealed, enclosed space is formed inside backpack body 17.
Molten aluminum quantitative conveyer includes stalk 18 and molten metal transfer pipeline 20.Wherein stalk 18 is fixed on backpack cover
On 19,17 bottom of backpack body is inserted into lower end, provides to molten aluminum 7 and extrudes channel；Molten metal transfer pipeline 20 is fixed on liter by flange
In liquid pipe 18, the other end is led into casting machine holding furnace, realizes molten aluminum conveying, and molten metal transfer pipeline 20 has thermal-insulating sealing function.
Pneumatic melt transport packet system further includes control cabinet 28, is equipped with PID controller 13, digital combination in control cabinet 28
Valve 4, vent line 5 and temperature controller 16.For transporting packet internal temperature, pressure signal by acquisition and controlling digital combination
Valve 4 acts.Human-computer interaction interface 14 is set on the shell of control cabinet 28, for display system parameter and realizes operation.
More specifically, A356 aluminum alloy melt is operated and is poured using pneumatic melt transport packet system of the invention,
The course of work are as follows:
Molten aluminum is injected this system and moved back to air injection machine by the first step, and molten metal outlet 12 connects in attached drawing 1
Low pressure casting machine holding furnace accesses compressed air in 1.
Second step accesses heating device power supply, and closed transport is set in temperature controller 16 and wraps 11 temperature as 720 DEG C, is pressed
Dynamic " automatic heating " button, controls heating power automatically according to formula P=aC ρ V Δ T.When the collected temperature signal of thermocouple 9
When less than 720 DEG C, temperature controller 16 provides instruction by comparing, and opens high temperature resistance silk heater 10 and is heated, i.e., warm in real time
Degree and set temperature temperature difference it is bigger, heating power is bigger, at the same heating power also with the specific heat capacity of melt, density and volume
It is proportional, as temperature gradually rises in casting ladle, the temperature difference reduce, gradually reduce heating power at this time, etc. 7 temperature of molten aluminums arrive
When up to set temperature, controller 13 issues the instruction for stopping high temperature resistance silk heater 10, stops heating.
Third step opens intake valve 3, the setup parameter in human-computer interaction interface 14.Once-cast amount is set as 600kg,
Pouring pressure is set as 80kPa, setting valve opening deadzone parameter r is set as 0.1, clicks " automatic casting " button.
Controller 13 is by the deviation of 8 signal of the pressure value 80kPa of setting and actual pressure, one meter of output after calculating
It calculates result (between 0~511), such as: it, can be according to output in program when output result is 170 after the calculating of controller 13
As a result the conversion of 170 progress valve openings, i.e. 170=64+64+32+8+2, i.e. Y2+Y4+Y6+Y7+Y8.At this point, controller 13
Bit comparison comparing calculation can be successively pressed from Y13 to Y1, it is known that need open valve for Y13, Y12, Y6, Y4, Y2, corresponding two
System are as follows: 1100000101010,13 valves are written in binary digit operation result 1100000101010 by controller 13 at this time
Control bit, to make the solenoid valve Y13, Y12, Y6 in digital combination valve 4, Y4, Y2 are opened, remaining solenoid valve is closed.
This operation recycles progress in casting, and each execution cycle of controller 13 is 500ms, the result of each period output
Operation result is converted to the switch motion of solenoid valve by corresponding different numerical value (between 0~511), controller 13 automatically.
4th step, in casting process, controller 13 pours fluence according to poring rate calculating in real time, when reaching pouring for setting
When fluence 600kg, intake valve 3 is automatically closed in controller 13, opens relief valve 6；When second pressure transmitter 8 detects current value
When being 0, the prompt of human-computer interaction interface 14 " completes casting ".
So far, the pneumatic melt transport packet system of the present embodiment completes once-cast work.
The above embodiments merely illustrate the technical concept and features of the present invention, and its object is to allow person skilled in the art
Scholar cans understand the content of the present invention and implement it accordingly, and it is not intended to limit the scope of the present invention.It is all according to the present invention
Equivalent change or modification made by Spirit Essence, should be covered by the protection scope of the present invention.
Claims (10)
1. a kind of pneumatic melt transports packet system, it is characterised in that: wrap (11), temperature-controlling system, air pressure system including closed transport
System and controller (13)；
Metal bath is transported to the guarantor of foundry to store metal bath by the closed transport packet (11) by calciner
At warm furnace, and metal bath is conveyed into holding furnace；
The temperature measuring equipment is to the metal bath temperature in transport packet (11) closed in real-time measurement transmission process, the control
Warm system is to heat the melt in closed transport packet (11)；
The baric systerm makes gas enter closed transport packet (11), and closed transport packet (11) interior melt is depressed into casting
In the holding furnace in workshop, the conveying of closed transport packet (11) interior metal bath is realized；
The temperature data that the controller control pressure system is acquired according to temperature measuring mechanism controls heating mechanism to enclosed conveying packet
Interior melt is heated, and control pressure system realizes the conveying of melt.
2. pneumatic melt according to claim 1 transports packet system, it is characterised in that: closed transport packet (11) packet
It includes backpack body (17), backpack cover (19) is housed on backpack body (17), backpack cover (19) fixing seal is on backpack body (17)；Backpack body (17) is equipped with
Air inlet (27)；The backpack cover (19) is equipped with molten metal outlet (12) and the fire door (25) for filling molten metal, fire door
(25) fire door (24) are equipped with；
The temperature-controlling system includes temperature measuring equipment and heating device, and temperature measuring equipment is mounted on the backpack cover (19), heating device
It is mounted on the backpack body (17)；
The baric systerm includes first pressure transmitter (2), second pressure transmitter (8), vent line (5), number combination
Valve (4) and intake valve (3) for controlling gas on-off, described, the vent line (5) and the air inlet (27) are even
Logical, the first pressure transmitter (2), intake valve (3) and digital combination valve (4) are successively set on ventilation according to airintake direction
On pipeline (5), the second pressure transmitter (8) is arranged on the backpack cover (19)；
The controller (13) can receive the temperature signal and the first pressure transmitter (2) of the temperature measuring equipment acquisition
With second pressure transmitter (8) acquisition pressure signal, command the heating device to closed transport wrap (11) interior melt into
Row heating, and digital combination valve (4) is commanded to work.
3. pneumatic melt according to claim 2 transports packet system, it is characterised in that: the backpack cover (19) is equipped with liquid level
Detection device (21), the liquid level for closed transport packet (11) the interior melt of real-time monitoring.
4. pneumatic melt according to claim 2 transports packet system, it is characterised in that: the closed transport packet (11) is also
Including melt quantitative conveying device, which includes stalk (18) and molten metal transfer pipeline (20), institute
It states stalk (18) to be fixedly mounted at the molten metal outlet (12) of backpack cover (19), the backpack body is inserted into the lower end of stalk (18)
(17) lower part；One end of the molten metal transfer pipeline (20) is fixedly connected with stalk (18), molten metal transfer pipeline
(20) the other end is connected with casting machine holding furnace.
5. pneumatic melt according to claim 2 transports packet system, it is characterised in that: the baric systerm further includes pressure release
Valve, the relief valve are arranged on the vent line (5), and are located between the air inlet (27) and digital combination valve (4).
6. pneumatic melt according to claim 2 transports packet system, it is characterised in that: the temperature measuring equipment is thermocouple
(9), the heating device is high temperature resistance silk heater (10).
7. pneumatic melt according to claim 2 transports packet system, it is characterised in that: the backpack cover (19) is solid by bolt
Surely it is sealed on backpack body (17), the faying face of backpack cover (19) and backpack body (17) compresses sealing using graphite packing (26).
8. the melt conveying method carried out using the transport packet system of pneumatic melt described in claim 1~7 any one, special
Sign is: successively including the following steps:
The first step carries out temperature control: the temperature measuring equipment to the closed transport packet (11) for having filled molten metal
The temperature of closed transport packet (11) interior metal bath in real-time measurement conveying and casting process, and by collected temperature signal
It is sent to the controller (13), controller (13) the commander heating device wraps (11) interior melt to closed transport and adds
Heat；
Second step carries out pressure control to the closed transport packet (11): opening the intake valve (3), gas enters number
In word combination valve (4), the admission pressure of first pressure transmitter (2) the monitoring gas, second pressure transmitter (8) prison
Control the gas pressure in closed transport packet (11)；First pressure transmitter (2) and second pressure transmitter (8) will be collected
Pressure signal is sent to controller (13), and controller (13) converts pressure value and gas flow by calculating, number combination
Valve (4) receives binary valve opening value that controller (13) are sent, according to the needs of gas flow, controller (13) control
The solenoid valve of corresponding valve opening value is opened in digital combination valve (4)；
Third step, gas are entered after the air inlet (27) in backpack body (17), with the increase of backpack body (17) interior pressure,
Molten metal in closed transport packet (11) is pressed out to molten metal outlet (12) by gas, straight by molten metal transfer pipeline (20)
To casting machine holding furnace, the conveying and casting of molten metal are completed.
9. melt conveying method according to claim 8, it is characterised in that: the internal program of the controller (13) uses
Closed loop pid algorithm, the output result of PID are limited between 0~511 after being converted by linear ratio relation, the pressure value of setting
And the deviation of pressure signal exports a calculated result after PID is calculated.
10. melt conveying method according to claim 8, it is characterised in that: the controller (13) is to digital combination valve
(4) dead zone function is carried out, dead zone function is opened according to the size of each spool sectional area and the valve of needs in digital combination valve (4)
Degree variable quantity does ratio, i.e.,In formula, r is ratio, QYiFor the opening value of single spool, i is the identification number of spool,
Δ Q is the increment of the valve opening value needed, and the total aperture of the valve needed obtains a product multiplied by ratio, and valve opening value is small
Belong to control failure in the valve of the product.
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