CN111346531A - Double-loop double-station magnesium alloy low-pressure casting gas mixing process and device thereof - Google Patents
Double-loop double-station magnesium alloy low-pressure casting gas mixing process and device thereof Download PDFInfo
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- CN111346531A CN111346531A CN202010142433.6A CN202010142433A CN111346531A CN 111346531 A CN111346531 A CN 111346531A CN 202010142433 A CN202010142433 A CN 202010142433A CN 111346531 A CN111346531 A CN 111346531A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
- B01F23/70—Pre-treatment of the materials to be mixed
- B01F23/704—Drying materials, e.g. in order to mix them in solid state
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
- B01F23/10—Mixing gases with gases
- B01F23/19—Mixing systems, i.e. flow charts or diagrams; Arrangements, e.g. comprising controlling means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
- B01F23/70—Pre-treatment of the materials to be mixed
- B01F23/708—Filtering materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F33/00—Other mixers; Mixing plants; Combinations of mixers
- B01F33/80—Mixing plants; Combinations of mixers
- B01F33/81—Combinations of similar mixers, e.g. with rotary stirring devices in two or more receptacles
- B01F33/811—Combinations of similar mixers, e.g. with rotary stirring devices in two or more receptacles in two or more consecutive, i.e. successive, mixing receptacles or being consecutively arranged
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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
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17D—PIPE-LINE SYSTEMS; PIPE-LINES
- F17D1/00—Pipe-line systems
- F17D1/02—Pipe-line systems for gases or vapours
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17D—PIPE-LINE SYSTEMS; PIPE-LINES
- F17D3/00—Arrangements for supervising or controlling working operations
- F17D3/01—Arrangements for supervising or controlling working operations for controlling, signalling, or supervising the conveyance of a product
Abstract
The utility model provides a two return circuits duplex position magnesium alloy low pressure casting mixes gas technology and device, including a gas mixing tank, a gas mixing tank is connected with first air feed return circuit and second air feed return circuit respectively, first air feed return circuit is by the second return circuit relief pressure valve in proper order, first pressure switch, first speed control valve, first flow switch, first two-way solenoid valve, first check valve establishes ties through the pipeline and constitutes, first check valve communicates with the entry of a gas mixing tank, second air feed return circuit is by first return circuit relief pressure valve in proper order, second pressure switch, second speed control valve, second flow switch, second two-way solenoid valve and second check valve establish ties through the pipeline and constitute, the second check valve links with the entry of a gas mixing tank. It can solve the problems of overflow of magnesium alloy liquid, violent combustion and safety accident. And can realize double-station continuous production, and has high production efficiency and good product quality.
Description
Technical Field
The invention relates to the field of magnesium alloy casting, in particular to a double-loop double-station magnesium alloy low-pressure casting gas mixing process
Background
The low-pressure casting process of available magnesium alloy has the demerits of ① magnesium alloy being easy to corrode in most environment medium, such as dry air to produce magnesium oxide on the surface of magnesium and wet environment to convert magnesium oxide into magnesium hydroxide, and ② cast magnesium alloy has the features of great crystallization temperature interval, great volume shrinkage and linear shrinkage, less eutectic amount, specific heat capacity, latent solidification heat, density and liquid pressure head of magnesium alloy, so that it has low flowability, low mold filling capacity, high heat cracking and loosening tendency, etc. ③ magnesium alloy liquid will produce combustion in air with combustion rate up to 75%, and thus has complete safety measures for magnesium alloy melting, heat preservation and low pressure casting.
At present, the low-pressure casting of magnesium alloy is realized by adopting an aluminum alloy low-pressure casting process, and the main operation process is as follows: an operator firstly pours the molten aluminum alloy subjected to melting, degassing and refining into a heat preservation furnace by using a casting ladle, then places the sand box with the closed box on a sand box platform, and finishes horizontal movement and vertical lifting actions by a transmission mechanism of the heat preservation furnace to realize butt joint and sealing of a casting mold and a liquid lifting pipe orifice and wait for casting.
The compressed air machine provides an air source with certain pressure and flow, impurities and moisture in the compressed air are removed after the compressed air passes through the main path filter, the freeze dryer and the precision filter, then the compressed air is decompressed through the decompression valve, when the outlet pressure reaches certain pressure, the pressure gauge displays the pressure, under the control of the electromagnetic pilot valve, when the pouring condition is met, a button for controlling the two-position five-way electromagnetic valve is started or automatic time delay is carried out, under the control of the microcomputer liquid level pressurization system, the aluminum alloy liquid automatically carries out liquid lifting, filling, pressurization, pressure maintaining, pressure relief, time delay opening (cooling) and the like according to a set pressurization curve, and the automatic operation of the low-pressure casting process is realized.
However, in practice it has been found that the following problems exist as gases:
when the compressed air is not sufficiently dried, it contains a small amount of H2O molecules are mixed in the compressed air, and when the compressed air is applied to a crucible or a holding furnace containing magnesium alloy liquid, H molecules2The O molecules are instantaneously gasified, and the magnesium alloy liquid reacts with oxygen at the gas/liquid interface to generate violent oxidation, burn and slag. The temperature and pressure of the magnesium alloy liquid in the liquid lifting pipe are increased, when the gas is exhausted in time or the box is opened in advance, the magnesium alloy liquid at the pouring gate overflows and is violently combusted in the air, and when the pressure of the magnesium alloy liquid in the liquid lifting pipe is greater than the liquid level pressure of a crucible or a heat preservation furnace, the magnesium alloy liquid which is not solidified in a cavity and the magnesium liquid in the liquid lifting pipe can flow back under the action of the gas pressure. A large amount of gas generated by combustion can damage the liquid level of the crucible through the liquid lifting pipe, so that the liquid level of the crucible is ignited, and safety accidents can be caused in serious cases.
In summary, a set of safe and reliable process and a set of matched device with high production efficiency are urgently needed.
Disclosure of Invention
The invention aims to provide a double-loop double-station magnesium alloy low-pressure casting gas mixing process and a double-loop double-station magnesium alloy low-pressure casting gas mixing device, which can solve the problems of overflow, violent combustion and safety accidents of magnesium alloy liquid. And can realize double-station continuous production, and has high production efficiency and good product quality.
In order to achieve the purpose, the invention is realized by the following technical scheme: a double-loop double-station magnesium alloy low-pressure casting gas mixing process comprises the following steps:
s1: preparing a first air supply circuit capable of providing highly pure compressed air without any moisture;
s2: preparing a second gas supply loop, wherein the second gas supply loop can provide pure SF6 gas;
s3: detecting whether the air supply pressure and the air supply flow of the first air supply loop and the second air supply loop reach set values or not;
s4: after the air supply pressure and the air supply flow of the first air supply loop and the second air supply loop reach set values, the first mixing tank is inflated;
s5: detecting a first mixing tank, and when the internal parameter reaches a set value, namely the gas mixing pressure range is 5.5 to kgf/m2When the concentration range of SF6 is 0.15-0.35%, inflating the first mixing tank into the second mixing tank;
s6: after the first mixing tank supplies a certain amount of gas to the second mixing tank, the gas mixing pressure or the concentration range of SF6 in the first mixing tank is lower than a set value, at the moment, gas supply to the second mixing tank is suspended until the first gas supply loop and the second gas supply loop continue to supply gas so that the gas mixing parameters in the first mixing tank meet the set value in S5, and the first mixing tank supplies gas to the second mixing tank again;
s7: s5 and S6 are sequentially repeated, so that the first mixing tank continuously supplies gas to the second mixing tank, and qualified mixed gas is obtained when the mixed gas pressure in the second mixing tank is detected to be kept within the range of 4.0-5.0 kgf/m and the concentration of SF6 is detected to be kept between 0.20-0.30%, namely the gas supply condition for low-pressure casting of magnesium alloy is met;
s8: the second gas mixing tank supplies gas to the first holding furnace to realize the pouring process, and the gas supply pressure and flow are required to be adjusted at any time according to the existing process curve requirements of liquid lifting, filling, crystallization, pressurization, pressure maintaining, pressure relief and delayed opening during pouring; after the magnesium alloy liquid in the holding furnace is poured and pressure maintaining is finished, cooling the high-temperature mixed gas, and then discharging the high-temperature mixed gas after pressure reduction;
s9: after the heat preservation furnace in the S8 finishes the burning and injection, the second gas mixing tank supplies gas to the second heat preservation furnace to realize the pouring process, and during pouring, the gas supply pressure and flow are required to be adjusted at any time according to the existing process curve requirements of liquid lifting, filling, crystallization, pressurization, pressure maintaining, pressure relief and delayed opening; after the magnesium alloy liquid in the holding furnace is poured and pressure maintaining is finished, cooling the high-temperature mixed gas, and then discharging the high-temperature mixed gas after pressure reduction;
s10: and (5) after the heat preservation furnaces in the S9 finish the burning, the second gas mixing tank supplies gas to the first heat preservation furnace again to realize the pouring process, and the process is circulated so that the two heat preservation furnaces alternately and continuously produce.
The air supply pressures in S1 and S2 are kept uniform. When the air supply pressure of the first air supply loop and the second air supply loop is too low, the pressure needs to be adjusted to reach the required air supply pressure value. The use of double filtration and double stage drying allows the first air supply circuit to provide highly pure compressed air without any moisture. The second supply circuit is able to provide pure SF6 by filtering, depressurizing and removing oil mist.
The device for realizing the double-loop double-station magnesium alloy low-pressure casting gas mixing process comprises a first gas mixing tank, wherein the first gas mixing tank is respectively connected with a first gas supply loop and a second gas supply loop, the first gas supply loop is formed by serially connecting a second loop pressure reducing valve, a first pressure switch, a first speed control valve, a first flow switch, a first two-way electromagnetic valve and a first one-way valve through pipelines, the first one-way valve is communicated with the inlet of the first gas mixing tank, the second gas supply loop is formed by serially connecting a first loop pressure reducing valve, a second pressure switch, a second speed control valve, a second flow switch, a second two-way electromagnetic valve and a second one-way valve through pipelines, the second one-way valve is communicated with the inlet of the first gas mixing tank, a third pressure switch and a first SF6 infrared sensor assembly are arranged on the first gas mixing tank, the outlet of the first gas mixing tank is communicated with the inlet of the second gas mixing tank through a pipeline, a pilot-operated two-way electromagnetic valve is connected in series on a pipeline between the first gas mixing tank and the second gas mixing tank, a fourth pressure switch and a second SF6 infrared sensor assembly are installed on the second gas mixing tank, an outlet of the second gas mixing tank is respectively connected with two pouring stations to be communicated, the first pouring station is sequentially composed of a first three-way electromagnetic valve and a first heat preservation furnace, and the second pouring station is sequentially composed of a second three-way electromagnetic valve and a second heat preservation furnace; a liquid lifting pipe is arranged in the first heat preservation furnace and communicated with the casting mold, and a liquid lifting pipe is arranged in the second heat preservation furnace and communicated with the casting mold. The second loop pressure reducing valve is connected with an SF6 gas supply device, the SF6 gas supply device is formed by connecting an SF6 gas cylinder and a filter pressure reducing valve oil atomizer assembly in series, the filter pressure reducing valve oil atomizer assembly is positioned between the second loop pressure reducing valve and an SF6 gas cylinder, and the filter pressure reducing valve oil atomizer assembly is formed by connecting a filter, a pressure reducing valve and an oil atomizer in series. The first circuit pressure reducing valve is connected with a compressed air device, the compressed air device is formed by sequentially connecting an air storage tank, a main pipe filter, a first dryer, a first ultramicro mist separator and a second dryer in series, and the second dryer is communicated with the first circuit pressure reducing valve. And a pilot reducing valve is arranged between the first air supply loop and the second air supply loop and is respectively connected with the second loop reducing valve and the first loop reducing valve. A liquid level pressurization system is arranged between an outlet of the second gas mixing tank and the two casting stations, an outlet pipeline of the second gas mixing tank is communicated with the liquid level pressurization system, and outlets of the liquid level pressurization system are respectively connected with the two casting stations to be communicated.
The core working principle is as follows:
a. mainly composed of a PLC controller, an electrically controlled pneumatic proportional flow valve and high-precision SF6Magnesium alloy low-pressure casting compressed air + SF with real-time on-line continuous detection, closed-loop feedback servo control and concentration sensor, human-computer interface, various related pneumatic elements and the like6Gas mixing system with automatic gas control.
b. When compressing air circuit and SF6When the gas flow in the gas loop is set within the upper and lower limits of the two digital flow switches, SF in the control system is set on the human-computer interface touch screen according to production requirements6Concentration value, SF of the first mixing tank and the second mixing tank are respectively set6Concentration-time process curve.
c. In actual operation, SF6Set value and SF6The measured values detected by the concentration sensor are compared, and when the positive and negative deviation values exceed the precision requirement, the control system automatically sets SF6The proportional opening of the electric-controlled pneumatic proportional flow valve for gas can automatically control SF6Output of different flow rates of gas to SF6The gas components are adapted to the set values, and closed-loop feedback control is realized. Similarly, the control system can automatically set the proportional opening of the electric control pneumatic proportional flow valve for the compressed air and also can automatically control the output of different flows of the compressed air and the closed-loop feedback control of the output.
d. SF respectively displaying a first mixing tank and a second mixing tank on a human-computer interface touch screen6The concentration-time setting curve and the real-time curve and the picture of the control precision value thereof have SF at the same time6And the over-limit alarm and the overpressure alarm are convenient for real-time monitoring.
The invention has the positive effects that: the invention designs a contact point transmission corresponding to the pressure transmission and mutually safe, and a thermocouple can be arranged at the upper opening of the riser tube, and the monitoring can be carried out according to the value change of a thermometer, so that the SF after mixing can be overcome6The proportion is difficult to control accurately, the repeatability is poor, the difference of the flame retardant effect is large, and the magnesium alloy casting with stable quality is difficult to obtain continuously. The invention relates to a closed-loop feedback servo control 'compressed air + SF' in the process of magnesium alloy low-pressure casting6The gas mixing system' has novelty and creativity. In addition, the invention also has the following advantages:
1. the control mode of the mixed gas is SF6The gas concentration sensor is a detection element, closed-loop feedback servo control of the whole system is realized, and other process parameters are not required to be converted, so that SF in the gas mixing tank is subjected to6The control precision of the gas concentration is high.
2. SF for respectively displaying a first mixing tank and a second mixing tank on a human-computer interface touch screen6Concentration-time settingCurves and real-time curves and their frames of control accuracy values, with simultaneous SF6And the over-limit alarm and the overpressure alarm are convenient for real-time monitoring.
3. The whole control system of the invention adopts high-precision SF6Besides the concentration sensor, an intelligent pressure switch, a flow switch, a digital display pressure gauge and a human-computer interface are adopted, so that various parameters and SF of a first mixing tank and a second mixing tank can be displayed in real time6And (5) concentration curves are recorded and stored.
4. In the low-pressure casting production process of the magnesium alloy, the double-loop double-station low-pressure casting process of the magnesium alloy can be realized, and an alternate continuous production mode is created, so that the requirements of various small-batch markets are met.
Drawings
FIG. 1 is a schematic diagram of a dual-loop double-station magnesium alloy low-pressure casting gas mixing process according to the invention,
reference numerals: 1 filter pressure reducing valve atomizer assembly, 1a filter, 1b pressure reducing valve, 1c atomizer, 2 second circuit pressure reducing valve, 3 first pressure switch, 3a second pressure switch, 4 first speed control valve, 5 first flow switch, 6 first two-way solenoid valve, 7 first check valve, 8 main pipe filter, 9 first drier, 10 first ultramicro mist separator, 11 second drier, 12 pilot pressure reducing valve, 13 first circuit pressure reducing valve, 14 second speed control valve, 15 second two-way solenoid valve, 16 second check valve, 17 first gas mixing tank, 18 third pressure switch, 18a fourth pressure switch, 19 first SF6 infrared sensor component, 19a second SF6 infrared sensor component, 20 pilot two-way solenoid valve, 21 second gas mixing tank, 22 first three-way solenoid valve, 22a second three-way solenoid valve, 23 first cooler, 23a second cooler, 24a first pilot-operated electromagnetic valve, 24a second pilot-operated electromagnetic valve, 25 a second ultramicro fog separator, 26 a second flow switch, 27a first throttling valve, 27a second throttling valve, 28a first holding furnace, 28a second holding furnace, 29 a liquid level pressurization system, 30 human-computer interface, 31 casting mold and 32 liquid supply pipe.
Detailed Description
To achieve the objects, aspects and advantages of the inventionMore clearly, the technical solution of the present invention will be described below
And (4) a detailed description. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. Base of
In the embodiments of the present invention, all those obtained by a person of ordinary skill in the art without any inventive work
Other embodiments are within the scope of the invention. The technical description of the invention is as follows with reference to the attached drawings:
the invention relates to a double-loop double-station magnesium alloy low-pressure casting gas mixing process,
the method comprises the following steps:
s1: preparing a first air supply circuit capable of providing highly pure compressed air without any moisture;
s2: preparing a second gas supply loop, wherein the second gas supply loop can provide pure SF6 gas;
s1 and S2 may be prepared simultaneously, or S2 may be prepared first and S1 may be prepared second.
S3: detecting whether the air supply pressure and the air supply flow of the first air supply loop and the second air supply loop reach set values or not;
s4: the first mixing tank 17 is inflated after the air supply pressure and the air supply flow of the first air supply loop and the second air supply loop reach set values; the pressure and flow rate of the supplied gas need to be set according to the gas mixing process and the overall condition of the whole gas mixing device, for example, the volume of the first mixing tank 17 and the time for filling the first mixing tank 17 need to be considered.
S5: detecting the first mixing tank 17, when the internal parameter reaches the set value, the gas mixing pressure is in the range of 5.0-5.5 kgf/cm2When the concentration of SF6 is in the range of 0.15-0.35%, the first mixing tank 17 is inflated into the second mixing tank 21;
s6: after the first mixing tank 17 supplies a certain amount of gas to the second mixing tank 21, the gas mixing pressure or the concentration range of SF6 in the first mixing tank 17 is lower than the set value in S5, at this time, gas supply to the second mixing tank 21 is suspended until the first gas supply loop and the second gas supply loop continue supplying gas so that the gas mixing parameters in the first mixing tank 17 meet the set value in S5, and the first mixing tank 17 supplies gas to the second mixing tank 21 again;
s7: and sequentially repeating S5 and S6 to ensure that the first mixing tank 17 continuously supplies gas to the second mixing tank 21, and when the mixed gas pressure in the second mixing tank 21 is detected to be kept within the range of 4.0-5.0 kgf/cm2 and the concentration of SF6 is detected to be kept within the range of 0.20-0.30%, qualified mixed gas is obtained, namely the gas supply condition for low-pressure casting of the magnesium alloy is met.
Since the first mixing tank 17 continuously supplies gas to the second mixing tank 21, the mixed gas in the gas supply of the second mixing tank 21 can be ensured to be always kept in the pressure and concentration range in S7, and the second mixing tank 21 can be ensured to supply two holding furnaces to alternately and continuously work.
S8: the second gas mixing tank 21 firstly supplies gas to the first holding furnace to realize the pouring process, and the gas supply pressure and flow are required to be adjusted at any time according to the existing process curve requirements of liquid lifting, filling, crystallization, pressurization, pressure maintaining, pressure relief and delayed opening cooling during pouring; after the magnesium alloy liquid in the holding furnace is poured and pressure maintaining is finished, cooling the high-temperature mixed gas firstly, then reducing the pressure and discharging;
s9: after the heat preservation furnace in the step S8 finishes the burning, the second air mixing tank 21 supplies air to the second heat preservation furnace to realize the pouring process, and during pouring, the air supply pressure and flow rate need to be adjusted at any time according to the existing process curve requirements of liquid lifting, filling, crystallization, pressurization, pressure maintaining, pressure relief and delayed opening cooling; after the magnesium alloy liquid in the holding furnace is poured and pressure maintaining is finished, cooling the high-temperature mixed gas firstly, then reducing the pressure and discharging;
s10: after the heat preservation furnaces in the S9 finish the burning, the second gas mixing tank 21 supplies gas to the first heat preservation furnace again to realize the pouring process, and the process is circulated, so that the two heat preservation furnaces can alternately and continuously produce.
In order to accurately control the pressure of the mixed gas, the supply pressure in S1 and S2 is generally kept uniform.
When the air supply pressure of the first air supply loop and the second air supply loop is too low, the pressure needs to be adjusted to reach the required air supply pressure value.
In order to completely remove the water in the compressed air, a double filtering and double-stage drying method can be adopted, so that the first air supply loop can provide high-purity compressed air without any water.
To obtain more pure SF6The second air supply loop can provide pure SF by adopting the methods of filtering, decompressing and removing oil mist6. Purer compressed air and SF6Can effectively prevent magnesium from reacting with the external environment, ensure the low-pressure casting to be carried out smoothly and eliminate potential safety hazard.
The device for realizing the double-loop double-station magnesium alloy low-pressure casting gas mixing process comprises a first gas mixing tank 17 as shown in figure 1. The first gas mixing tank 17 is connected with the first gas supply circuit and the second gas supply circuit respectively. The first air supply loop is formed by sequentially connecting a second loop pressure reducing valve 2, a first pressure switch 3, a first speed control valve 4, a first flow switch 5, a first two-way electromagnetic valve 6 and a first one-way valve 7 in series through pipelines, the first one-way valve 7 is communicated with an inlet of a first air mixing tank 17, the second air supply loop is formed by sequentially connecting a first loop pressure reducing valve 13, a second pressure switch 3a, a second speed control valve 14, a second flow switch 26, a second two-way electromagnetic valve 15 and a second one-way valve 16 in series through pipelines, and the second one-way valve 16 is communicated with an inlet of the first air mixing tank 17. The first gas mixing tank 17 is provided with a third pressure switch 18 and a first SF6 infrared sensor assembly 19, and the third pressure switch 18 and the first SF6 infrared sensor assembly 19 are used for detecting the pressure in the first gas mixing tank 17 and the concentration of the mixed gas. The outlet of the first gas mixing tank 17 is communicated with the inlet of the second gas mixing tank 21 through a pipeline, a pilot type two-way electromagnetic valve 20 is connected in series on the pipeline between the first gas mixing tank 17 and the second gas mixing tank 21, and the pilot type two-way electromagnetic valve 20 controls whether the first gas mixing tank 17 can charge gas into the second gas mixing tank 21. The second gas mixing tank 21 is provided with a fourth pressure switch 18a and a second SF6 infrared sensor assembly 19a, and the fourth pressure switch 18a and the second SF6 infrared sensor assembly 19a are used for detecting the pressure in the first gas mixing tank 17 and the concentration of the mixed gas. The outlet of the second gas mixing tank 21 is respectively communicated with two casting stations, the first casting station is sequentially composed of a first three-way electromagnetic valve 22 and a first heat preservation furnace 28, and the second casting station is sequentially composed of a second three-way electromagnetic valve 22a and a second heat preservation furnace 28 a. When the first three-way electromagnetic valve 22 is electrified and conducted, the second gas mixing tank 21 can supply gas for the first holding furnace 28; when the second three-way electromagnetic valve 22a is powered on, the second gas mixing tank 21 can supply gas for the second holding furnace 28 a. A liquid lifting pipe 32 is arranged in the first holding furnace 28 and is communicated with the casting mold 31, and a liquid lifting pipe is arranged in the second holding furnace 28a and is communicated with the casting mold. The first pressure switch 3 and the second pressure switch 3a may both be existing mechanical pressure switches. The first speed control valve 4 and the second speed control valve 14 may be proportional flow valves. The first flow switch 5 and the second flow switch 26 may be digital flow switches. The first two-way solenoid valve 6 and the second two-way solenoid valve 15 may be direct-acting two-way solenoid valves. The third pressure switch 18 and the fourth pressure switch 18a may be digital display pressure switches. The first and second three- way solenoid valves 22 and 22a may be external pilot-operated three-way solenoid valves. The second-circuit pressure reducing valve 2 and the first-circuit pressure reducing valve 13 may both be pneumatically-controlled pilot-type pressure reducing valves. The ultramicro mist separator can be an existing ultramicro mist separator.
To ensure the use of SF during casting6Sufficiently pure, as shown in the upper left of FIG. 1, the second circuit pressure reducing valve 2 and SF6The air supply device is connected. SF6The gas supply device is composed of SF6The gas cylinder and the filter pressure reducing valve oil atomizer assembly 1 are connected in series. The filter pressure reducing valve oil atomizer assembly 1 is positioned between the second circuit pressure reducing valve 2 and SF6Between the gas cylinders, the filter pressure reducing valve atomizer assembly 1 is formed by connecting a filter 1a, a pressure reducing valve 1b and an atomizer 1c in series. SF6The gas in the gas cylinder is filtered by a filter 1a, then is reduced by a pressure reducing valve 1b, and finally is filtered by an oil atomizer 1c to obtain pure SF6Pure SF6And feeds the second circuit pressure reducing valve 2.
In order to obtain pure compressed air without moisture, as shown in the upper left part of fig. 1, the first circuit pressure reducing valve 13 is connected with a compressed air device, the compressed air device is formed by sequentially connecting an air storage tank, a main pipe filter 8, a first dryer 9, a first ultramicro mist separator 10 and a second dryer 11 in series, and the second dryer 11 is communicated with the first circuit pressure reducing valve 13. The compressed air is filtered twice by the main pipe filter 8 and the first ultramicro mist separator 10, and dried twice by the first drier 9 and the second drier 11, so that pure compressed air which meets the requirement of magnesium alloy low casting can be obtained. The first dryer 9 may be a freeze dryer. The second dryer 11 is a micro thermal adsorption dryer.
In order to ensure that the outlet pressures of the first gas supply loop and the second gas supply loop are consistent, as shown in the middle of fig. 1, a pilot pressure reducing valve 12 is installed between the first gas supply loop and the second gas supply loop, and the pilot pressure reducing valve 12 is respectively connected with the second loop pressure reducing valve 2 and the first loop pressure reducing valve 13.
In order to realize automatic accurate control, as shown in the lower right part of fig. 1, a liquid level pressurization system 29 is arranged between the outlet of the second gas mixing tank 21 and two pouring stations. The outlet of the second gas mixing tank 21 is communicated with a liquid level pressurization system 29, the outlets of the liquid level pressurization system 29 are respectively communicated with two casting stations, and the liquid level pressurization system 29 can be an electric control proportional valve. The liquid level pressurizing system 29 may also be an existing pneumatic control cabinet with a human-machine interface 30, which can remotely adjust the opening of various electromagnetic valves to realize the adjustment of pressure and flow, a controller in the pneumatic control cabinet can be used for setting programs, and the liquid level pressurizing system 29 can automatically adjust the opening of the pilot pressure reducing valve 12, the second loop pressure reducing valve 2, the first loop pressure reducing valve 13, the first speed control valve 4 and the second speed control valve 14 according to the preset programs and various parameters, so that the design process curve change of air supply pressure and flow in the pouring process is realized to realize accurate air supply.
In order to facilitate the recovery of the mixed gas discharged after casting, as shown in the lower part of the middle part of fig. 1, the exhaust gas treatment device is connected to the exhaust port of the first holding furnace 28, and the exhaust gas treatment device is composed of a first cooler 23, a first throttle valve 27 and a first pilot-operated solenoid valve 24 in this order. The exhaust gas treatment device is connected to the exhaust port of the second holding furnace 28a, and the exhaust gas treatment device is composed of a first cooler 23a, a second throttle valve 27a, and a second pilot-operated solenoid valve 24a in this order. The first pilot operated solenoid valve 24 and the second pilot operated solenoid valve 24a may be connected to a recovery device. The mixed gas after cooling and pressure reduction can be sent to a recovery device. The first cooler 23 and the first cooler 23a may be spiral coolers. The first throttle 27 and the second throttle 27a may be proportional flow valves.
The matching device for realizing the double-loop double-station magnesium alloy low-pressure casting gas mixing process specifically operates as follows:
step 1, on one hand, compressed air from a factory is filtered and then filled into an air storage tank, and then the compressed air is subjected to double filtration and double-stage drying sequentially through a main pipe filter 8, a first dryer 9, a first ultramicro mist separator 10 and a second dryer 11, so that high-purity compressed air without any moisture is obtained. On the other hand, SF from the plant6Filtering, decompressing and removing oil mist through a filter 1a, a decompression valve 1b and an oil mist device 1c to obtain pure SF6。
when the pressure of the first air supply loop or the second air supply loop is too low, the first pressure switch 3 and the second pressure switch 3a respectively send a signal to alarm, and the pressure and the opening degree of the pilot reducing valve 12 need to be adjusted to enable the first air supply loop or the second air supply loop to reach the required pressure value;
when the gas flow in the first gas supply loop or the second gas supply loop is controlled within the set upper and lower limits of the first flow switch 5 and the first two-way electromagnetic valve 6, the output of the compressed air flow can be automatically controlled by setting the proportional opening degree of the second speed control valve 14 of the first gas supply loop at the man-machine interface 30 by a user, and the proportional opening degree of the first speed control valve 4 of the second gas supply loop can be also automatically controlled by setting the proportional opening degree of the SF6Outputting the flow;
and 3, when the first gas mixing tank 17 starts to be inflated, the first two-way electromagnetic valve 6 and the second two-way electromagnetic valve 15 in the double circuit can be electrified and opened at the same time, and gas mixing can be started in the first gas mixing tank 17 according to different set flow rates according to different pipe diameters. The first SF6 infrared sensor assembly 19 is provided in the first air mixing tank 17 for on-line continuous detection and feedback control.
When the first SF6 infrared sensor assembly 19 detects SF in the first air mixing tank 176When the concentration is low, the proportional opening of the first speed control valve 4 is controlled to increase, so that SF is increased6The proportional opening degree of the second speed control valve 14 for compressed air can be decreased to relatively increase SF6The component (c).
And step 4, setting values of parameters in the first gas mixing tank 17 are as follows: the pressure is in the range of 5.0 to 5.5kgf/cm2，SF6When the concentration range is 0.15-0.35%, the pilot-operated two-way electromagnetic valve 20 is electrified and opened, the mixed gas in the first gas mixing tank 17 enters the second gas mixing tank 21, and the first gas mixing tank 17 starts to charge the second gas mixing tank 21.
When the first gas mixing tank 17 charges the second gas mixing tank 21, the pressure or SF in the first gas mixing tank 176Must be reduced, and the user can adjust the SF on the human-computer interface 30 respectively6The proportional opening of the first flow switch 5 and the proportional opening of the second flow switch 26 for compressed air in the circuit increase the flow rate of charging the first air mixer tank 17. When the pressure range and SF of the mixed gas are within6When the concentration reaches the set value of the first gas mixing tank 17, the solenoid valve pilot type two-way solenoid valve 20 can be electrified and opened again, and at the moment, the mixed gas in the first gas mixing tank 17 is filled into the second gas mixing tank 21 again.
This is repeated many times, and the mixed gas having a certain pressure and inert gas components in the first gas mixing tank 17 is continuously charged into the second gas mixing tank 21 under the action of the pressure, and the second SF6 infrared sensor assembly 19a and the fourth pressure switch 18a are arranged in the mixed tank, so that the feedback control of the continuous charging is realized.
And step 7, when the magnesium alloy liquid in the heat preservation furnace 28 is poured and pressure maintaining is finished, and the mixed gas is exhausted, firstly, the high-temperature mixed gas is cooled by the first cooler 23 and is exhausted through the first throttling valve 27 under the control of the first pilot-operated electromagnetic valve 24, and the exhausted mixed gas can be introduced into the recovery device for exhausting.
And step 10, sequentially carrying out the magnesium alloy low-pressure casting production process of the first holding furnace 28 and the second holding furnace 28a, realizing a double-loop double-station magnesium alloy low-pressure casting process, and creating an alternate continuous production mode, thereby meeting the requirements of various small-batch markets.
The above description is only for the specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can easily conceive of the changes or substitutions within the technical scope of the present invention, and all the changes or substitutions should be covered within the scope of the present invention. Therefore, all the equivalent structures or equivalent processes that are made by using the contents of the specification and the drawings of the present invention, or are directly or indirectly applied to other related technical fields, are included in the scope of the present invention.
Claims (10)
1. A double-loop double-station magnesium alloy low-pressure casting gas mixing process is characterized in that:
the method comprises the following steps:
s1: preparing a first air supply circuit capable of providing highly pure compressed air without any moisture;
s2: preparing a second gas supply loop, wherein the second gas supply loop can provide pure SF6 gas;
s3: detecting whether the air supply pressure and the air supply flow of the first air supply loop and the second air supply loop reach set values or not;
s4: the first mixing tank (17) is inflated after the air supply pressure and the air supply flow of the first air supply loop and the second air supply loop reach set values;
s5: detecting a first mixing tank (17), and when the internal parameters of the first mixing tank reach set values, namely the gas mixing pressure range is 5.0-5.5 kgf/cm2, and the concentration range of SF6 is 0.15-0.35%, inflating the first mixing tank (17) into a second gas mixing tank (21);
s6: after the first mixing tank (17) supplies a certain amount of gas to the second mixing tank (21), the gas mixing pressure or the concentration range of SF6 in the first mixing tank (17) is lower than a set value, at the moment, gas supply to the second mixing tank (21) is suspended until the first gas supply loop and the second gas supply loop continue to supply gas so that the gas mixing parameters in the first mixing tank (17) meet the set value in S5, and the first mixing tank (17) supplies gas to the second mixing tank (21) again;
s7: s5 and S6 are sequentially repeated, so that the first mixing tank (17) continuously supplies gas to the second mixing tank (21), and qualified mixed gas is obtained when the mixed gas pressure in the second mixing tank (21) is detected to be kept within the range of 4.0-5.0 kgf/cm2 and the concentration of SF6 is detected to be kept within the range of 0.20-0.30%, namely the gas supply condition for low-pressure casting of magnesium alloy is met;
s8: the second gas mixing tank (21) supplies gas to the first holding furnace to realize the pouring process, and the gas supply pressure and flow are required to be adjusted at any time according to the existing process curve requirements of liquid lifting, filling, crystallization, pressurization, pressure maintaining, pressure relief and delayed opening (cooling) during pouring; after the magnesium alloy liquid in the holding furnace is poured and pressure maintaining is finished, cooling the high-temperature mixed gas, and then discharging the high-temperature mixed gas after pressure reduction;
s9: after the heat preservation furnace in the S8 finishes the burning and injection, the second gas mixing tank (21) supplies gas to the second heat preservation furnace to realize the pouring process, and the gas supply pressure and flow are required to be adjusted at any time according to the existing process curve requirements of liquid lifting, filling, crystallization, pressurization, pressure maintaining, pressure relief and delayed opening (cooling) during pouring; after the magnesium alloy liquid in the holding furnace is poured and pressure maintaining is finished, cooling the high-temperature mixed gas, and then discharging the high-temperature mixed gas after pressure reduction;
s10: and (3) after the heat preservation furnaces in the S9 finish the burning, re-supplying gas to the first heat preservation furnace by the second gas mixing tank (21) to realize the pouring process, and circulating the steps so that the two heat preservation furnaces alternately and continuously produce.
2. The double-loop double-station magnesium alloy low-pressure casting gas mixing process according to claim 1, characterized in that: the air supply pressures in S1 and S2 are kept uniform.
3. The double-loop double-station magnesium alloy low-pressure casting gas mixing process according to claim 1, characterized in that: when the air supply pressure of the first air supply loop and the second air supply loop is too low, the pressure needs to be adjusted to reach the required air supply pressure value.
4. The double-loop double-station magnesium alloy low-pressure casting gas mixing process according to claim 1, characterized in that: the use of double filtration and double stage drying allows the first air supply circuit to provide highly pure compressed air without any moisture.
5. The double-loop double-station magnesium alloy low-pressure casting gas mixing process according to claim 1, characterized in that: the second air supply loop can provide pure SF by adopting the methods of filtering, decompressing and removing oil mist6。
6. The device for realizing the double-loop double-station magnesium alloy low-pressure casting gas mixing process of claim 1 is characterized in that: comprises a first gas mixing tank (17), the first gas mixing tank (17) is respectively connected with a first gas supply loop and a second gas supply loop, the first gas supply loop is formed by connecting a second loop pressure reducing valve (2), a first pressure switch (3), a first speed control valve (4), a first flow switch (5), a first two-way electromagnetic valve (6) and a first one-way valve (7) in series through pipelines, the first one-way valve (7) is communicated with the inlet of the first gas mixing tank (17), the second gas supply loop is formed by connecting a first loop pressure reducing valve (13), a second pressure switch (3a), a first speed control valve (14), a second flow switch (26), a second two-way electromagnetic valve (15) and a second one-way valve (16) in series through pipelines, the second one-way valve (16) is communicated with the inlet of the first gas mixing tank (17), a third pressure switch (18) and a first SF6 infrared sensor assembly (19) are arranged on the first gas mixing tank (17), an outlet of the first gas mixing tank (17) is communicated with an inlet of the second gas mixing tank (21) through a pipeline, a pilot-operated two-way electromagnetic valve (20) is connected in series on the pipeline between the first gas mixing tank (17) and the second gas mixing tank (21), a fourth pressure switch (18a) and a second SF6 infrared sensor assembly (19a) are installed on the second gas mixing tank (21), outlets of the second gas mixing tank (21) are respectively connected with two pouring stations to be communicated, the first pouring station is sequentially composed of a first three-way electromagnetic valve (22) and a first holding furnace (28), and the second pouring station is sequentially composed of a second three-way electromagnetic valve (22a) and a second holding furnace (28 a); a liquid lifting pipe is arranged in the first holding furnace (28) and communicated with the casting mold, and a liquid lifting pipe is arranged in the second holding furnace (28a) and communicated with the casting mold.
7. The device of claim 6 for the double-loop double-station magnesium alloy low-pressure casting gas mixing process, which is characterized in that: the second circuit pressure reducing valve (2) and SF6Gas supply means connection, SF6The gas supply device is composed of SF6The gas cylinder and the filter pressure reducing valve atomizer assembly (1) are connected in series, and the filter pressure reducing valve atomizer assembly (1) is positioned between the second loop pressure reducing valve (2) and SF6Between the gas cylinders, the filter pressure reducing valve atomizer assembly (1) is formed by connecting a filter (1a), a pressure reducing valve (1b) and an atomizer (1c) in series.
8. The device of claim 6 for the double-loop double-station magnesium alloy low-pressure casting gas mixing process, which is characterized in that: the first loop reducing valve (13) is connected with a compressed air device, the compressed air device is formed by sequentially connecting an air storage tank, a main pipe filter (8), a first dryer (9), a first ultramicro mist separator (10) and a second dryer (11) in series, and the second dryer (11) is communicated with the first loop reducing valve (13).
9. The device of claim 6 for the double-loop double-station magnesium alloy low-pressure casting gas mixing process, which is characterized in that: and a pilot reducing valve (12) is arranged between the first air supply loop and the second air supply loop, and the pilot reducing valve (12) is respectively connected with the second loop reducing valve (2) and the first loop reducing valve (13).
10. The device of claim 6 for the double-loop double-station magnesium alloy low-pressure casting gas mixing process, which is characterized in that: a liquid level pressurization system (29) is arranged between the outlet of the second gas mixing tank (21) and the two casting stations, the outlet pipeline of the second gas mixing tank (21) is communicated with the liquid level pressurization system (29), and the outlets of the liquid level pressurization system (29) are respectively connected with the two casting stations to be communicated.
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