Method and device for casting pipe
Technical Field
The invention relates to the technical field of pipe continuous casting, in particular to a method and a device for pipe casting.
Background
In the production and processing process of the pipe, the continuous casting of the pipe blank is the first step of the pipe production, and the quality of the cast and formed pipe blank directly influences the quality of the finally processed pipe, so that the continuous casting process of the pipe blank is the most important step in the production and processing process of the pipe, the production efficiency and the process quality are improved, and the method has considerable economic value for the whole production process of the pipe. The existing pipe casting device has larger defects in the aspects of production efficiency, process quality and even production flow control, and compared with the existing devices, the following problems which need to be solved urgently are summarized:
1. in the process of solidifying and forming molten metal into a tube blank, the conventional tube casting device often causes a core rod to be damaged in a small range at a solid-liquid phase change boundary point due to the solid-liquid phase change volume change and the high-temperature working condition influence, directly causes the quality of the produced tube blank to be unsatisfactory, and cannot find the damage of the core rod in time in the conventional device and method.
2. The existing pipe casting device has a low utilization rate of the core rod, and in the process of researching the actual production of pipes, most devices are directly stopped to replace the core rod or a casting cavity for ensuring the production quality after the core rod is damaged, however, the replaced core rod is often only a damaged area of a few millimeters, the utilization rate of the core rod is extremely low, and the frequent stop and replacement seriously affect the production efficiency and easily cause production safety accidents.
3. The existing pipe casting device can not monitor the quality of a produced pipe blank in real time, particularly the quality of an inner hole of the pipe blank greatly influences the subsequent process and the quality of the manufactured pipe in the production process of the pipe blank, but the existing device can not monitor the quality of the inner hole of the pipe blank in real time.
Therefore, there is a need for a method and apparatus for casting pipe to solve the above problems.
Disclosure of Invention
Aiming at the problems, the invention aims to provide a method and a device for casting a pipe, which adopt a stress sensor and a vibration sensor to monitor the axial stress and the radial runout amplitude of a core rod in real time, can find whether the core rod is damaged or not in time according to data fluctuation, and control the solidifying point of a pipe blank to move out of a damaged area of the core rod in time, can effectively improve the utilization rate of the core rod, reduce the safety problem caused by the shutdown for replacing the core rod, and realize the monitoring of the inner hole quality of the pipe blank.
The technical scheme adopted by the invention is as follows:
the invention provides a pipe casting device, which comprises a casting device, a condensing device, an electromagnetic crystallization device, a casting outer cavity, a core rod, a roller, a pipe blank, a stress sensor and a vibration sensor, wherein the condensing device is arranged on one side of the casting device; the condensing device and the electromagnetic crystallization device are used for controlling the molten metal crystallization and solidification, the stress sensor and the vibration sensor are used for monitoring the vibration condition of the core rod, and the output state of the condensing device and the position of the electromagnetic crystallization device are adjusted based on information monitored by the stress sensor and the vibration sensor.
Further, the pouring device comprises a liquid inlet box, a casting pipe and a heat preservation cavity, the casting pipe is arranged below the liquid inlet box, the heat preservation cavity is arranged below the casting pipe, and the metal liquid enters the heat preservation cavity through the casting pipe to preserve heat.
Furthermore, condensing equipment includes condensation chamber, basin, force (forcing) pump, water inlet, delivery port, and the condensation chamber upper end is provided with the water inlet, and the condensation chamber lower extreme is provided with the delivery port, and the delivery port below is provided with the basin, and the basin front end is provided with the force (forcing) pump.
Furthermore, the electromagnetic crystallization device comprises an electromagnetic crystallizer, the mechanism for adjusting the position of the electromagnetic crystallization device comprises a feed screw and a screw motor which are connected to the electromagnetic crystallization device, four feed screws are uniformly arranged outside the electromagnetic crystallizer, and the screw motor is arranged below the electromagnetic crystallizer.
Furthermore, the stress sensor and the vibration sensor are high-temperature-resistant sensors, and the outer layers of the stress sensor and the vibration sensor are both wrapped by high-temperature-resistant materials.
Furthermore, the casting outer cavity has preset heat-conducting property, so that the condensate water can bring the heat of the metal liquid to form a tube blank.
Furthermore, the condensation chamber has predetermined heat conductivility, and the comdenstion water of being convenient for takes the heat of metal liquid to make its shaping become the pipe.
The invention also discloses a method for casting the pipe, which comprises the following steps:
s1, device initialization:
the method comprises the following steps that molten metal is contained in a liquid inlet box of a pouring device, the molten metal enters a heat preservation cavity through a pouring pipe for heat preservation and then flows into a condensing device for cooling, the initial position of an electromagnetic crystallization device is located on one side close to a water inlet of the condensing device, the load pressure of a pressure pump reaches a set initial value to control the flow Q of condensed water in the condensing device, the crystallization and solidification of the molten metal are controlled through the combined action of the condensing device and the electromagnetic crystallization device, a pipe blank is formed under the action of a casting outer cavity and a core rod, and the pipe blank is pulled out through the pulling of a roller, so that the continuous casting of the pipe blank is realized;
s2: monitoring damage of the core rod:
under the combined action of a condensing device, an electromagnetic crystallization device and a roller pulling speed V, the solid-liquid phase line and the liquid-liquid phase line of the tube blank appear in the action range of an electromagnetic crystallizer, the axial stress and the radial vibration of the core rod are monitored in real time through a stress sensor and a vibration sensor, when the core rod is damaged, the axial stress magnitude monitored by the stress sensor can generate unstable fluctuation or sudden change, and the radial vibration amplitude magnitude monitored by the vibration sensor can also generate unstable fluctuation;
s3: monitoring the position of the freezing point:
when a pipe blank is formed, the volume of a liquid phase and a solid phase at a solidifying point is changed, when the solidifying point is farther away from a fixed end D of a core rod, the radial runout amplitude F of the core rod is larger, the distance D and the amplitude F are measured for multiple times to determine the functional relation D = F (F), and the position of the solidifying point D is obtained according to the amplitude F obtained by a vibration sensor and the functional relation D = F (F);
s4: moving the position of a solidification point:
when the core rod is damaged at the solidification point of the tube blank, the screw motor controls the electromagnetic crystallizer to move towards one side of the water outlet of the condensing device until the data monitored by the stress sensor and the vibration sensor are stable, and obtains the distance l between the middle point of the electromagnetic crystallizer and the fixed end of the core rod, namely the solidification point is separated from the damage range of the core rod at the moment, and the solidification point is finely adjusted to be positioned in the action range of the electromagnetic crystallizer;
and repeating the steps until the continuous casting is completed or the core rod is completely damaged.
Further, the freezing point position fine adjustment specifically comprises the following steps:
the action width of the electromagnetic crystallizer is x, when the position d of the solidification point is less than or equal to l-x/2, namely the solidification point is on the left side of the electromagnetic crystallizer, the flow Q of the condensed water in the condensing device is reduced, and the pulling speed V of the roller is increased, when the position d of the solidification point is greater than or equal to l + x/2, namely the solidification point is on the right side of the electromagnetic crystallizer, the flow Q of the condensed water in the condensing device is increased, and the pulling speed V of the roller is reduced;
when the solidifying point is adjusted, the adjustment and control are not limited to be carried out through the flow rate Q of the condensed water and the pulling speed V of the roller, and the adjustment and control can be carried out cooperatively through controlling the size of the electrified current i of the electromagnetic crystallizer.
Furthermore, after the screw motor controls the electromagnetic crystallizer to move for a distance y once, the electromagnetic crystallizer stays for t time, monitoring time is given to the stress sensor and the vibration sensor, and whether the freezing point is located at the damaged position or not is judged according to the monitoring numerical value so as to determine whether the electromagnetic crystallizer continues to move or not.
Compared with the prior art, the invention has the following beneficial effects:
1. according to the device, the axial stress and the radial runout amplitude of the mandrel are monitored in real time through the stress sensor and the vibration sensor, whether the mandrel is damaged or not can be found in time according to data fluctuation, the solidifying point of the tube blank is controlled to move out of the damaged area of the mandrel in time, the utilization rate of the mandrel can be effectively improved, the shutdown frequency is reduced, the safety problem caused by replacement of the mandrel is reduced, and considerable economic benefits are brought;
2. the method is simple and clear, has better compatibility with the existing pipe casting device, can realize the judgment of whether the core rod is damaged or not and the determination of the position of the solidifying point of the pipe blank and the like through the simple stress sensor and the vibration sensor, can be realized by utilizing the method for most pipe casting devices, and does not need to carry out excessive structural change.
3. The quality monitoring device can monitor the quality of the inner hole of the tube blank, can judge the stress and vibration states of the mandrel in the production process through the real-time data monitored by the stress sensor and the vibration sensor, and directly influences the quality of the inner hole of the tube blank due to the state of the mandrel in the production process because the inner hole of the tube blank is solidified and formed under the action of the mandrel, so that the quality of the inner hole of the tube blank can be monitored by acquiring the real-time data of the mandrel through the analysis sensor.
Drawings
FIG. 1 is a schematic view of the overall structure of the apparatus of the present invention;
FIG. 2 is a front view of the apparatus of the present invention;
FIG. 3 is a partial cross-sectional view of the device of the present invention;
FIG. 4 is a schematic diagram of the construction of the condensing unit of FIG. 1;
FIG. 5 is a schematic structural view of the mandrel of FIG. 1;
FIG. 6 is a schematic flow chart of the operation of the method of the present invention.
Wherein, the reference numbers: 1-a casting device; 101-a liquid inlet tank; 102-a casting tube; 103-heat preservation cavity; 2-a condensing unit; 201-a condensation chamber; 202-a water tank; 203-a pressure pump; 204-water inlet; 205-water outlet; 3-an electromagnetic crystallization device; 301-an electromagnetic crystallizer; 302-optical bar; 303-a screw motor; 4-casting an outer cavity; 5-a core rod; 6-rolling; 7-tube blank; 8-a stress sensor; 9-vibration sensor.
Detailed Description
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the embodiments or the description of the prior art are briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
It should be noted that in the description of the present invention, the terms "upper", "lower", "top", "bottom", "one side", "the other side", "left", "right", and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of describing the present invention and simplifying the description, but do not mean that a device or an element must have a specific orientation, be configured and operated in a specific orientation.
Referring to the accompanying drawings 1 to 5, a concrete structure of an embodiment of a pipe casting device provided by the invention is shown, and the pipe casting device comprises a pouring device 1, a condensing device 2, an electromagnetic crystallization device 3, a casting outer cavity 4, a core rod 5, a roller 6, a pipe blank 7, a stress sensor 8 and a vibration sensor 9, wherein the condensing device is arranged on one side of the pouring device, the electromagnetic crystallization device is arranged outside the condensing device, the casting outer cavity is arranged inside the condensing device, the core rod is arranged inside the casting outer cavity, a core rod fixing end is arranged inside the pouring device, the stress sensor and the vibration sensor are uniformly arranged on the outer wall of the core rod fixing end, the pipe blank is formed between the casting outer cavity and the core rod, and the roller is arranged on one side of the pipe blank;
the pouring device comprises a liquid inlet tank 101, a casting pipe 102 and a heat preservation cavity 103, wherein the casting pipe is arranged below the liquid inlet tank, and the heat preservation cavity is arranged below the casting pipe;
the condensing device comprises a condensing cavity 201, a water tank 202, a pressure pump 203, a water inlet 204 and a water outlet 205, wherein the upper end of the condensing cavity is provided with the water inlet, the lower end of the condensing cavity is provided with the water outlet, the water tank is arranged below the water outlet, and the front end of the water tank is provided with the pressure pump;
the electromagnetic crystallization device comprises an electromagnetic crystallizer 301, feed bars 302 and a screw motor 303, wherein four feed bars are uniformly arranged outside the electromagnetic crystallizer, and the screw motor is arranged below the electromagnetic crystallizer.
The outer layers of the stress sensor and the vibration sensor are wrapped by high-temperature resistant materials and are high-temperature resistant sensors.
The casting outer cavity and the condensation cavity both have higher heat-conducting property, so that the condensate water can bring the heat of the molten metal to form a tube blank.
Referring to fig. 6, a method of pipe casting is shown, comprising the steps of:
s1, device initialization:
the liquid metal is contained in a liquid inlet box of a pouring device, the liquid metal enters a heat preservation cavity through a pouring pipe for heat preservation and then flows into a condensing device for cooling, the initial position of an electromagnetic crystallization device is positioned at one side close to a water inlet of the condensing device, the load pressure of a pressure pump reaches a set initial value so as to control the flow rate Q of condensed water in the condensing device, the liquid metal is controlled to crystallize and solidify under the combined action of the condensing device and the electromagnetic crystallization device, a pipe blank is formed under the action of a casting outer cavity and a core rod, and the pipe blank is pulled out through the pulling of a roller, so that the continuous casting of the pipe blank is realized;
s2: monitoring damage of the core rod:
under the combined action of a condensing device, an electromagnetic crystallization device and a roller pulling speed V, a solid-liquid phase line of a pipe blank appears in the action range of an electromagnetic crystallizer, a core rod is easy to damage in a small range at a solidifying point due to the difference of a metal solid phase and a metal liquid phase as shown in a point D, the axial stress and the radial vibration of the core rod are monitored in real time through a stress sensor and a vibration sensor, when the core rod is damaged, the axial stress monitored by the stress sensor can generate unstable fluctuation or mutation, and the amplitude of the radial vibration monitored by the vibration sensor can also generate unstable fluctuation;
s3: monitoring the position of the freezing point:
when the tube blank is solidified and formed, due to volume transformation between a metal liquid phase and a metal solid phase, the core rod can jump in the radial direction, when the solidifying point is farther away from the fixed end of the core rod, the radial jumping amplitude F of the core rod is larger, the distance D between the solidifying point and the fixed end of the core rod is provided with a function D = F (F), and the relational expression can be obtained through actual adjustment and verification, so that the position of the solidifying point D can be obtained according to the amplitude of the vibration sensor;
s4: moving the position of a solidification point:
when the core rod is damaged at the solidification point of the tube blank, the screw motor controls the electromagnetic crystallizer to move towards one side of the water outlet of the condensing device until the data monitored by the stress sensor and the vibration sensor are stable, and obtains the distance l between the middle point of the electromagnetic crystallizer and the fixed end of the core rod, namely the solidification point is separated from the damage range of the core rod at the moment, and the solidification point is finely adjusted to be positioned in the action range of the electromagnetic crystallizer in order to ensure the casting quality and efficiency of the tube blank;
s5: freezing point position fine adjustment:
the action width of the electromagnetic crystallizer is x, when the position d of the solidification point is less than or equal to l-x/2, namely the solidification point is on the left side of the electromagnetic crystallizer, the flow Q of the condensed water in the condensing device can be reduced, and the pulling speed V of the roller is increased, when the position d of the solidification point is greater than or equal to l + x/2, namely the solidification point is on the right side of the electromagnetic crystallizer, the flow Q of the condensed water in the condensing device can be increased, and the pulling speed V of the roller is reduced;
and judging the stress and vibration states of the mandrel in the production process according to the real-time data monitored by the stress sensor and the vibration sensor, and recording the forming quality of the inner hole of the tube blank according to the stress and vibration states of the mandrel.
And repeating the steps until the continuous casting is finished or the core rod is completely damaged.
And after the screw motor controls the electromagnetic crystallizer to move for a distance y once, the electromagnetic crystallizer stays for t time, the stress sensor and the vibration sensor are given monitoring time, and whether the freezing point is positioned at the damaged part or not is judged according to the monitoring value so as to determine whether the electromagnetic crystallizer continuously moves or not.
When the solidifying point is adjusted, the adjustment and control are not limited to be carried out through the flow rate Q of the condensed water and the pulling speed V of the roller, and the adjustment and control can be carried out cooperatively through controlling the size of the electrified current i of the electromagnetic crystallizer.
The invention relates to a method and a device for casting a pipe, which are different from the devices in the prior art in that: the axial stress and the radial jumping amplitude of the mandrel are monitored in real time through the stress sensor and the vibration sensor, whether the mandrel is damaged or not can be found in time, the lead screw motor controls the movement of the electromagnetic crystallizer and is matched with the condensing device, the solidifying point of the tube blank can be controlled to move out of the damaged area of the mandrel in time, the utilization rate of the mandrel can be effectively improved while the casting quality of the tube blank is ensured, the shutdown times are reduced, the safety problem caused by replacement of the mandrel is reduced, and considerable economic benefit is brought; (ii) a
The invention relates to a method and a device for casting a pipe, which are different from the devices in the prior art in that: compared with the traditional pipe casting device which is only added with a stress sensor, a vibration sensor and an electromagnetic crystallization device, the method can realize the judgment of whether the core rod is damaged or not and the determination of the position of the solidifying point of the pipe blank and the like through the simple stress sensor and the simple vibration sensor, can be realized by utilizing the method of the invention for most pipe casting devices, and does not need to carry out excessive structural change.
The above-described embodiments are merely illustrative of the preferred embodiments of the present invention, and do not limit the scope of the present invention, and various modifications and improvements made to the technical solutions of the present invention by those skilled in the art without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.