CN111940673A - Online batch weighing sand moisture detector for sand mixer - Google Patents
Online batch weighing sand moisture detector for sand mixer Download PDFInfo
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- CN111940673A CN111940673A CN202010825804.0A CN202010825804A CN111940673A CN 111940673 A CN111940673 A CN 111940673A CN 202010825804 A CN202010825804 A CN 202010825804A CN 111940673 A CN111940673 A CN 111940673A
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- sand
- moisture
- weighing hopper
- detection
- weighing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C5/00—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose
- B22C5/04—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose by grinding, blending, mixing, kneading, or stirring
- B22C5/0409—Blending, mixing, kneading or stirring; Methods therefor
- B22C5/0472—Parts; Accessories; Controlling; Feeding; Discharging; Proportioning
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01G—WEIGHING
- G01G19/00—Weighing apparatus or methods adapted for special purposes not provided for in the preceding groups
- G01G19/52—Weighing apparatus combined with other objects, e.g. furniture
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
- G01K7/00—Measuring temperature based on the use of electric or magnetic elements directly sensitive to heat ; Power supply therefor, e.g. using thermoelectric elements
- G01K7/16—Measuring temperature based on the use of electric or magnetic elements directly sensitive to heat ; Power supply therefor, e.g. using thermoelectric elements using resistive elements
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/02—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance
- G01N27/22—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating capacitance
- G01N27/221—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating capacitance by investigating the dielectric properties
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/02—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance
- G01N27/22—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating capacitance
- G01N27/223—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating capacitance for determining moisture content, e.g. humidity
Abstract
The invention discloses an online batch weighing sand moisture detection instrument of a sand mixer, wherein a weighing hopper positioned above the sand mixer is a metering instrument for weighing the weight of sand to be ground by an intermittent batch type sand mixer and is a container made of a metal steel plate material. The method comprises the following steps of (1) taking a sand weighing hopper as a cathode, taking an insulating probe in the sand weighing hopper as an anode, connecting the probe with a signal generator for generating current with specific frequency, and taking sand as a dielectric medium; the sand weighing hopper and the signal generator are respectively connected with the detection unit; when the sand moisture in the sand weighing hopper changes, the dielectric value changes along with the change of the sand moisture, the voltage detected by the detection unit changes, the online detection of the sand moisture is realized through the linear correlation between the voltage change and the sand moisture change, the measurement result is accurate, no additional facility or means is needed for installing instruments, the detection can be realized under the normal work of a sand treatment line, the sand moisture detection is easy to implement especially for the increase of the sand moisture in an old sand treatment line, and the blank of online detection of the sand adding moisture of the sand mixer for casting sand treatment is filled.
Description
Technical Field
The invention relates to the technical field of casting sand treatment, in particular to an online batch weighing sand moisture detection instrument of a sand mixer.
Background
Moisture, temperature, strength, air permeability and compaction control of the molding sand in a sand processing system are important technical indicators for controlling the quality of the molding sand, with moisture control being the most important indicator. The control of the water content of the molding sand is realized by knowing the water content of the molding sand in advance, judging the water adding amount during sand mixing and adding quantitative water.
The influence of the water control of the molding sand on the rejection rate of castings is very large, the bentonite in the molding sand with too low water content cannot be fully moistened, the strength of the sand mold is low, the fluidity is poor, the molding quality is influenced, and the defects of non-forming, uneven hardness and the like are caused; and the defects of casting air holes, sand inclusion, sand adhesion and the like can be caused by excessive moisture.
The prior method for measuring the sand moisture in China still depends on laboratory detection, the sand sample is obtained and detected on a molding sand moisture measuring instrument, 10 to 20 minutes is needed, and the online detection cannot be realized. The water content of the sand is dynamically changed, and the water content of the sand is changed along with the change of the sand iron ratio of the molding. The environmental temperature, the environmental humidity and the length of the sand return belt can cause the sand moisture change. Therefore, the results of laboratory tests are delayed, and the moisture of the sand in on-line sand mixing is dynamically changed, which makes no sense for controlling the moisture of the molding sand during sand mixing. Therefore, the current domestic sand treatment equipment can not realize the online moisture detection of the sand before sand mixing and realize the automatic control of the moisture of the molding sand. Most factories can only manually set a fixed water addition amount and adjust the water addition amount in real time according to laboratory detection or the feeling of grasping with hands by the experience of workers. The current advanced method is to add water for multiple times by on-line compaction rate detection, namely pre-adding water, coarse adding water and fine adding water or adding water twice, namely the coarse adding water and the fine adding water. Adding water or coarsely adding water in advance when the sand mixing starts, extracting a sand sample from the sand mixing machine on line after mixing for a period of time, and detecting the compaction rate by a compaction rate detector or a sand performance detector. And judging the water content according to the linear relation between the compaction rate and the water content when the performances of the sand, the new sand and the auxiliary materials in the molding sand are unchanged, and then judging the fine water addition amount. This operation has disadvantages in that the mixing cycle is already performed in half because of insufficient mixing of the water added halfway or finely added, and that a high partial water content of the molding sand and defects in the cast product may occur, or the mixing cycle is extended to sacrifice the ability of the mixer.
In a word, the sand treatment mixer lacks the control of online sand moisture detection on the quality of molding sand, and is one of bottlenecks that restrict the realization of intellectualization of sand treatment in a foundry.
Disclosure of Invention
The invention aims to provide a novel online batch weighing sand moisture detection instrument of a sand mixer aiming at the problem that the sand in a symmetrical hopper cannot be subjected to real-time moisture detection in the prior art, so that accurate sand moisture control is realized, the quality and the mixing capacity of the sand are ensured, the defects and the rejection rate of castings caused by inaccurate moisture control are reduced, the intelligentization of sand treatment is guaranteed, the casting cost is reduced, and the production efficiency is improved.
The technical scheme of the invention is detailed as follows:
an online batch weighing sand moisture detection instrument of a sand mixer takes a sand weighing hopper made of a metal steel plate as a cathode, an insulating probe is installed in the sand weighing hopper as an anode, the probe is connected with a signal generator and used for generating current with specific frequency, and sand between the probe and the weighing hopper is taken as a dielectric medium; the sand weighing hopper and the signal generator are respectively connected with the detection unit;
when the sand moisture in the sand weighing hopper changes, the dielectric value changes along with the change of the sand moisture, the voltage detected by the detection unit changes, and the online detection of the sand moisture is realized through the linear correlation between the voltage change and the sand moisture change.
The circuit consisting of the sand weighing hopper, the probe, the signal generator and the detection unit forms a capacitor, and the capacitance is constant under the condition that the area of a polar plate, the distance between electrodes and a dielectric medium are not changed according to the working principle of the capacitor. When the sand moisture changes, the dielectric medium value changes, and the voltage detected by the detection unit changes. The capacitance change is correlated with the sand moisture change. The change of the moisture corresponds to the change of the detection voltage value, and the linear relation between the moisture value and the voltage can be found out after the detection signal is processed by the detection unit. Due to the differences of the size and the shape of the sand weighing hopper, the sand temperature and the installation position of the probe, calibration needs to be carried out manually, so that the linear relation between the detected value of the sand moisture in the sand weighing hopper and the current output value on each site is determined. Therefore, the moisture value of the sand can be obtained by detecting the current value of the capacitor, and the moisture target value control of the mixed sand when being milled according to the process requirement is realized.
Preferably, in the online batch weighing sand moisture detection instrument for the sand mixer, temperature probes are further mounted on two sides of the sand weighing hopper and connected with the detection unit. The two temperature probes are preferably used for detecting the temperature of the sand.
Preferably, in the online batch weighing sand moisture detecting instrument for a sand mixer, the linear correlation range between the voltage change and the sand moisture change is as follows: the output current is 0-20 mA, which corresponds to-5% + 5% of sand moisture.
Preferably, in the online batch weighing sand moisture detecting instrument for the sand mixer, the frequency range of the current is 2.8 MHz.
Preferably, in the online batch weighing sand moisture detection instrument for the sand mixer, the sand comprises new sand, old sand and auxiliary materials. The addition amount of the new sand is usually very small, about 5% of the total addition amount, the water content is constant and can be ignored, and the addition amount of the old sand is large and the water content is changed greatly.
Compared with the prior art, the invention has the following beneficial effects:
the moisture measuring instrument of the invention finishes the online measurement of the moisture of the sand by means of the sand weighing hopper when the sand is weighed, the sand weighing hopper is simulated to be a capacitor as a detection point, the shell of the weighing hopper is used as the cathode of the capacitor, the probe is used as the anode of the capacitor, and the weighed sand and the ingredients are used as the dielectric medium of the capacitor. When the plate area, distance, voltage, current and frequency are determined, sand is the only changing condition as the dielectric, so the capacitance value is only related to the dielectric, i.e. the detected sand moisture is related to the output current.
The change frequency of quartz sand, coal powder, bentonite and water in the sand composition is not greatly changed from the physical composition, and other change amounts except moisture are not greatly changed from the composition amount, so that the high-frequency current and the content of the water are in corresponding regular reaction under a certain voltage, the moisture becomes a constant with the maximum change in a capacitance medium, the change of the moisture can be obtained through the change of a dielectric medium, and the online detection of the moisture is realized.
The moisture measuring instrument determines a stable control signal of which the output current is 0-20m through signal processing, and the corresponding moisture value is 0-5% of the sand moisture value in the conventional range of a foundry. And the detection of moisture is completed at the same time of sand weighing, and the high efficiency of the sand mixer can be completely realized. In addition, the online quantitative water adding of the sand mixer is completed simultaneously by matching with a control unit of the PLC. The error between the molding sand measurement and the laboratory water content measurement value is less than or equal to +/-0.2 percent, and the method is the detection means with the highest detection precision rate in China at present.
Compared with the prior moisture detection technologies such as a resistance method, an electromagnetic wave method and the like, the instrument has accurate detection results. The sand weighing hopper is used for detecting, no additional facility or means is needed for installing instruments, the installation and detection can be realized under the normal work of the sand processing line, and the sand moisture detection of the old sand processing line is very easy to implement. Of course, equipment of each plant is different, such as the size of the sand weighing hopper and the possibility of sand mixing change, but consistent detection results can still be found through the field calibration.
The invention fills the blank of online detection of sand moisture in the sand mixer equipment for casting sand treatment, and has great significance for the intelligent and digital development of casting sand treatment.
Drawings
FIG. 1 is a schematic diagram of the overall structure of an online batch weighing sand moisture detection instrument and a quantitative water adding system of a sand mixer;
FIG. 2 is a schematic view of the installation positions of a sand weighing hopper, a probe and a temperature probe of the online batch weighing sand moisture detection instrument of the sand mixer;
FIG. 3 is a main interface of a sand moisture controller of the PLC central control unit display;
FIG. 4 is an alarm interface of a PLC central control unit display;
FIG. 5 is a first sand mixer parameter setting interface of a PLC central control unit display;
FIG. 6 is a second sand mixer parameter setting interface (sand mixer temperature compensation setting interface) of the PLC central control unit display;
FIG. 7 is an analog interface of a PLC central control unit display;
fig. 8 is a manual water adding interface of a PLC central control unit display.
Reference numerals:
1-control unit, 2.1-signal generator, 2.22-rod probe, 2.3-temperature sensor, 3.1-water adding filter, 3.2-water adding flowmeter, 3.3-water adding stop valve.
Detailed Description
In order to more clearly illustrate the embodiments of the present invention or the corresponding technical solutions, the drawings that are needed in the embodiments or the prior art descriptions will be briefly described below.
Example 1
Referring to fig. 1, the online batch-weighed sand moisture detecting instrument for a sand mixer is a sample, and is matched with a quantitative water adding system, and the online batch-weighed sand moisture detecting instrument for a sand mixer can perform online measurement on the total moisture of sand to obtain a moisture value of the sand, and comprises a sand weighing hopper made of a metal steel plate material, an insulating probe (a rod type probe in fig. 1) arranged in the sand weighing hopper, and a signal generator connected with the probe, wherein the sand weighing hopper and the signal generator are respectively connected with a detecting unit. Referring to fig. 2, after sand (sand in fig. 2, auxiliary material) is filled, the sand is located between the probe and the weighing hopper, according to the capacitor structure and the working principle, the sand weighing hopper shell made of a metal steel plate is used as a cathode of a capacitor, the insulating probe is used as an anode of the capacitor, the weighed sand and ingredients are used as a dielectric medium of the capacitor, and a signal generator and a detection unit (contained in the control unit in fig. 1) form an analog circuit.
The change frequency of quartz sand, coal powder, bentonite and water in the sand composition of a foundry is not greatly changed from the physical composition, and the change amount except moisture is not greatly changed from the component amount.
According to the working principle and relation of the capacitor, when the area of a polar plate (a probe and a sand weighing hopper) is determined, the distance between an anode and a cathode is determined, and the voltage, the current and the frequency generated by a signal generator are determined, a capacitance value is related to a dielectric medium, namely, a moisture value in sand (the dielectric medium) is related to an output current. Thus, at a particular high frequency current, the capacitance value may be considered to be related only to the moisture in the sand.
Based on the method, when the sand moisture changes under a specific high frequency, the current change is monitored, the correlation is formed between the capacitance change and the sand moisture change, the detection signal is processed, the output current of 0-20 mA is defined to correspond to the sand moisture value of-5% to + 5%, and the linear relation between the capacitance value and the moisture is simulated.
Sand moisture value calculation function formula: c ═ R1X + R0.
Wherein C is the moisture percentage content of the sand, the error is less than or equal to +/-0.2% for a corrected measured value, and X is the moisture value measured by a detection unit. R1 is the slope value of the test cell moisture measurement and R0 is the displacement value of the test cell moisture measurement.
Because different instruments have different weighing hoppers in size and shape, different installation positions of the insulating probe rod and the like, when each instrument actually measures the moisture value C on site, manual calibration is needed, the linear relation between the output voltage of the detection unit and the moisture value is determined, and the manual calibration is carried out on R1 and R0.
The moisture content of the sand in the sand weighing hopper can be measured on line in real time through the instrument.
In the above instrument, two temperature probes can be arranged on two sides of the sand weighing hopper to detect the temperature of the sand in the sand weighing hopper, and the water adding amount of the sand mixer can be accurately controlled by matching the online temperature measurement value with the online measured water content.
Controlling the water target value of the when-milled sand, and calculating the water adding amount of the when-milled sand according to the weight of the sand as follows:
quantitative water addition value W ((Co-C) + Wy)
W is the when-milled sand weighing value, Co is the when-milled sand moisture target value, C is the measured current moisture value, and Wy is the evaporated water amount at the measured temperature (empirical value).
Embodiment 2 on-line batch weighing sand moisture detecting instrument of sand mixer cooperates with PLC central control unit to intelligently control water addition
The online batch weighing sand moisture detection instrument and the temperature probe of the sand mixer are respectively connected with a PLC central control unit, the PLC central control unit is also connected with a water adding system, and the water adding system comprises a water supply pipe, a filter, a metering instrument, a pneumatic angle valve and branch pipes which are used for detecting and distributing water pressure/air pressure in the sand mixer.
An online batch weighing sand moisture detection instrument of a sand mixer measures sand moisture in a sand weighing hopper, a traditional capacitance method is adopted to measure sand humidity, and an insulation probe is placed in the sand weighing hopper. The upper part of the probe is connected with a high-frequency signal to form a pole, and the lower part of the probe is welded with the weighing hopper to form a pole. When the sand falls into the weighing hopper, the humidity probe is buried in the sand to form a capacitor taking the sand as a dielectric medium. The sand moisture changes resulting in a change in capacitance. And calculating a humidity value through temperature and linearization treatment, multiplying the difference between the humidity value and the molding sand set value by the sand weight to be equal to the water adding amount, and controlling the water adding amount through the pulse number of the flowmeter. The temperature probe is buried on a belt of a charging opening of the sand mixer or on the wall of the weighing hopper, and the temperature measurement by a resistance method has important significance for the water content measurement and the calculation of the water adding evaporation capacity. The PLC central control unit comprehensively controls the function execution of each part, the receipt collection and the water adding control.
The PLC central control unit comprises a display and a control element, and the display is a 5.7-inch touch liquid crystal display.
The sander measurements and operating parameters were displayed on a 5.7 inch touch screen liquid crystal display for different sanders.
Controlling the sand mixer target, wherein the water content is 2.5-5.0%, and the control precision is +/-0.2%;
dynamic monitoring, and real-time display of technological parameters;
displaying and alarming system faults;
alarming when the moisture is over-wet;
alarming when the water adding time is out;
panel and pilot lamp.
The main interface of the PLC central control unit display is shown in fig. 3, which shows the main interface of the sand moisture controller.
Description of the Main interface
1. The weight of the batch of sand (the set weight of the sand mixer) and the set value of the humidity can be directly modified, namely the water content of the molding sand, and when the water content detected in a laboratory is higher than the set value, the set value is reduced; the phase reaction increases the set point. When the laboratory detection value is greater than or less than the set value of 0.2%, the humidity parameters A0 and A1 are adjusted. When the laboratory values are equal errors from the setpoint, their difference is added to AO when the laboratory values are greater than the setpoint, and conversely, their difference (which is a negative value) is added to AO. When the laboratory value and the set value are not equal in error, and when the sand humidity is changed from small to large, the A1 (more than 1 adjustment) is adjusted when the error between the laboratory value and the set value is large; instead, a1 should be adjusted to less than 1.
2. Real-time display of humidity and temperature.
3. And displaying the water adding amount/flow of the current batch. Water addition amount (sand weight) (set value-measured value (sand measured value) + temperature compensation value)/100 (liter).
4. Signal description of indicator lights:
moisture measurement signal: the sand mixer detects a humidity signal when sand is added to the weighing hopper.
Allow water addition signal: the sand mixer adds water signals after premixing.
Manual/automatic display: the light is on when the switch is in the automatic position.
Description of function keys:
setting parameters: and skipping to a parameter setting interface, wherein the login is effective after success.
Analog quantity: and jumping to a system analog quantity display interface.
The system state is as follows: jump to the system state interface.
And (3) alarm information: jump to the alarm message interface.
Manual water adding: and jumping to a manual water adding interface.
The alarm interface of the PLC central control unit display is shown in fig. 4.
Description of alarm interface:
the interface may be called up by pressing an alarm message button of the main interface. The alarm messages are contained in 5 types:
the sequence of the detection and the water adding signals is not correct, and the water adding signal generates an alarm when arriving first and stops adding water (the staff should add water manually).
Over-wetting means that it occurs when the amount of added water is greater than the maximum amount of added water.
The water adding overtime means that the water adding time exceeds the set time limit.
Description of function keys:
and returning: jump to the home interface.
A sand mixer parameter setting interface of the PLC central control unit display is shown in FIG. 5.
Description of the interface:
the parameters shown in the figure may be set. The method comprises the following steps:
humidity parameter a 0: the amount of humidity offset.
Humidity parameter a 1: and (5) humidity indexing.
Temperature parameter a 0: the amount of temperature offset.
Temperature parameter a 1: and (4) temperature division.
Humidity correction value a1 humidity value + a0 (humidity a0, a1)
Temperature correction value a1 × temperature value + a0 (temperature a0, a1)
The number of pulses per liter of water.
And (4) limiting the water adding time. Exceeding this time will generate a timeout alarm.
Sand mulling time (S): and second.
And a second sand mixer parameter setting interface of the PLC central control unit display, namely a sand mixer temperature compensation setting boundary surface is shown in FIG. 6.
Description of the interfaces
The temperature compensation refers to the amount of moisture evaporation of the molding sand during the transportation process, and the setting is determined by the field worker according to the actual situation.
Description of function keys:
determining: jump to the home interface.
The analog interface of the PLC central control unit display is shown in fig. 7.
Description of the interfaces
Displaying information: and the temperature sensor and the humidity sensor are used for displaying the corresponding voltage value in real time after the signals of the humidity sensor are processed by the operation unit.
The humidity display represents a (uncorrected) humidity value corresponding to 5-10. 0 to 10 in temperature range, and 0 to 100 DEG C
Description of function keys:
and returning: jump to the home interface.
The manual water adding interface of the PLC central control unit display is shown in figure 8.
Description of the interfaces
Flow rate (liter/sec): displaying the flow rate of water when adding water;
water supplement (l): the water can be supplemented according to the set water supplementing amount under the automatic state (under the condition of not automatically adding water);
manual water addition time (seconds): water can be added according to the set time in the manual state.
Manual water supplement: in an automatic state, pressing the manual water supplement to automatically add water according to the water supplement amount;
manual water adding: in the manual state, the manual water adding is pressed, and the water is automatically added according to the manual water adding time.
Through the control system, the water content and the temperature are detected on line, and the water adding amount is adjusted at any time.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.
Claims (5)
1. An online batch weighing sand moisture detection instrument of a sand mixer is characterized in that a sand weighing hopper made of a metal steel plate is used as a cathode, an insulating probe is installed in the sand weighing hopper and used as an anode, the probe is connected with a signal generator and used for generating current with specific frequency, and sand between the probe and the weighing hopper is used as a dielectric medium; the sand weighing hopper and the signal generator are respectively connected with the detection unit;
when the sand moisture in the sand weighing hopper changes, the dielectric value changes along with the change of the sand moisture, the voltage detected by the detection unit changes, and the online detection of the sand moisture is realized through the linear correlation between the voltage change and the sand moisture change.
2. The online batch weighing sand moisture detecting instrument of the sand mixer as claimed in claim 1, wherein temperature probes are further installed on two sides of the sand weighing hopper, and the temperature probes are connected with the detecting unit.
3. The online batch weighing sand moisture detection instrument of a sand mixer according to claim 1, wherein the linear correlation range of the voltage change and the sand moisture change is as follows: the output current is 0-20 mA, which corresponds to-5% + 5% of sand moisture.
4. The on-line batch weighed sand moisture detection instrument of a sand mixer according to claim 1, wherein the frequency range of the current is 2.8 MHz.
5. The online batch weighing sand moisture detecting instrument of a sand mixer according to claim 1, wherein the sand comprises new sand, old sand and auxiliary materials.
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| CN202010825804.0A CN111940673A (en) | 2020-08-17 | 2020-08-17 | Online batch weighing sand moisture detector for sand mixer |
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| CN113252740A (en) * | 2021-04-14 | 2021-08-13 | 葛洲坝集团试验检测有限公司 | Concrete mixing plant sand water content dynamic monitoring system and method |
| CN116238176A (en) * | 2023-05-11 | 2023-06-09 | 枣庄市永益新材料科技股份有限公司 | Artificial quartz stone plate raw material configuration control system |
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Application publication date: 20201117 |