CN114951561B - Stream inoculation method of molten metal - Google Patents
Stream inoculation method of molten metal Download PDFInfo
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- CN114951561B CN114951561B CN202210714569.9A CN202210714569A CN114951561B CN 114951561 B CN114951561 B CN 114951561B CN 202210714569 A CN202210714569 A CN 202210714569A CN 114951561 B CN114951561 B CN 114951561B
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- liquid outlet
- inoculation
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- molten metal
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- 238000011081 inoculation Methods 0.000 title claims abstract description 71
- 238000000034 method Methods 0.000 title claims abstract description 66
- 239000002184 metal Substances 0.000 title claims abstract description 63
- 239000007788 liquid Substances 0.000 claims abstract description 66
- 238000003723 Smelting Methods 0.000 claims abstract description 58
- 239000002054 inoculum Substances 0.000 claims abstract description 29
- 230000003247 decreasing effect Effects 0.000 claims abstract description 8
- 238000010079 rubber tapping Methods 0.000 claims description 15
- 229910001338 liquidmetal Inorganic materials 0.000 claims description 4
- 238000012935 Averaging Methods 0.000 claims description 3
- 230000000977 initiatory effect Effects 0.000 claims 2
- 238000005266 casting Methods 0.000 abstract description 6
- 238000012417 linear regression Methods 0.000 abstract description 3
- 239000013589 supplement Substances 0.000 description 6
- 238000001514 detection method Methods 0.000 description 4
- 230000000295 complement effect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000003213 activating effect Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000007405 data analysis Methods 0.000 description 1
- 238000012886 linear function Methods 0.000 description 1
- 238000012163 sequencing technique Methods 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D1/00—Treatment of fused masses in the ladle or the supply runners before casting
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
Abstract
A stream inoculation method of molten metal belongs to the technical field of casting and is used for solving the problem of accurate control of stream inoculation, and comprises the steps of judging a liquid outlet starting state and detecting a liquid outlet flow rate, wherein the method for judging the liquid outlet starting state is a method for judging the weight of a smelting furnace in real time so as to realize the purpose of automatically judging the liquid outlet starting state of the molten metal; the method for detecting the liquid outlet flow rate is to perform linear regression fitting on a data set D consisting of a plurality of current weight values of a smelting furnace in a certain period of time to obtain the weight change rate of the metal liquid in the inoculation stage, and judge whether the adding amount of the inoculant needs to be increased or decreased according to the weight change rate of the metal liquid in the inoculation stage. By collecting, recording and processing the weight value of the smelting furnace within a certain period of time, the initial state and the flow velocity of the liquid outlet are accurately judged, so that the start of stream inoculation and the adjustment of inoculation dosage in the process can be accurately determined, and the accuracy of stream inoculation is improved.
Description
Technical Field
The invention relates to the technical field of casting, in particular to a method for smelting molten metal.
Background
The basic use condition of the existing tapping stream inoculation equipment in front of the smelting furnace is as follows: the inoculation parameters are manually input or the inoculation weight is issued by upper software, and the inoculation time is issued according to the estimated time of manual experience. After tapping starts, a worker clicks a start button manually to start inoculation, and the flow rate in the whole process is constant. In this case, there are problems in that: the whole smelting process has large manual intervention degree, and each judgment node is mostly sent out manually, such as key parameters of inoculation starting signals, process flow rate and the like. Due to human factors intervening on key nodes, the certainty and instability of the whole smelting process are caused, the repeatability of the smelting process is poor, and the same molten metal can be smelted to different results.
Disclosure of Invention
In view of the problems of unstable smelting process and poor consistency of smelting results caused by poor controllability of stream inoculation operation due to over high human intervention degree in the smelting process, it is necessary to provide a stream inoculation method of molten metal, and automation of the smelting process and accuracy of stream inoculation are realized.
A stream inoculation method of molten metal, comprising:
Judging the liquid outlet starting state, and adopting a method for judging the weight of the smelting furnace in real time to realize the purpose of automatically judging the liquid outlet starting state of the molten metal;
And detecting the flow rate of the liquid outlet, namely linearly fitting a data group D consisting of a plurality of current weight values of the smelting furnace in a certain period of time to obtain the weight change rate of the liquid metal in the inoculation stage, and judging whether the adding amount of the inoculant needs to be increased or decreased according to the weight change rate of the liquid metal in the inoculation stage.
Further, the stream inoculation method of the metal liquid further comprises a liquid outlet starting procedure, wherein the liquid outlet starting procedure can be started manually or can be an instruction from an upper computer; namely, after the molten metal is smelted and detected to be qualified, the smelting operation is carried out in a liquid outlet process; the liquid outlet procedure is used for pouring the molten metal qualified in smelting into a ladle so as to facilitate the casting of the casting.
Further, the method for judging the liquid outlet starting state comprises the following steps:
detecting and recording the weight value of the current smelting furnace at a certain frequency in every second, and forming a data set C;
Processing the data group C to obtain a data group A;
processing the data group A to obtain a data group B;
And judging whether to enter a liquid outlet starting state according to the condition of the data group B.
Still further, the data set C consists of 6-8 current smelting furnace weight values obtained in one second.
Further, the data set A is obtained by the method that,
Recording ten groups of data groups C in ten continuous seconds to avoid possible error judgment caused by unstable data and possible problems of loss, error and the like in the transmission process;
And removing the maximum value and the minimum value in each data group C, and then averaging the rest data in the data groups C to form one data in the data group A.
Further, the data set B is formed by the difference between the data of the next bit and the data of the previous bit in the data set a, that is, the data set B formed by the difference effectively limits the change rule of the data, enhances the stability of the data, that is, improves the accuracy and reliability of judging the liquid outlet starting state.
Still further, the data set A and the data set B follow a first-in first-out principle, and the data set C follows an automatic ordering principle.
Further, when the data set B meets the following conditions, judging that the smelting furnace enters a liquid outlet starting state: more than seventy percent of data in the data group B are more than zero, more than sixty percent of data which are more than zero in the data group B are continuously changed data, and the continuously changed data can form a change trend curve; i.e. when the weight value of the smelting furnace is in a steadily decreasing trend, the tapping start state is considered to be entered.
Further, in order to reduce the difficulty of real-time adjustment of the weight change rate of the molten metal in the inoculation stage, which changes in real time, on the adding of the inoculation dose, the weight change rate of the molten metal in the inoculation stage can be divided into a plurality of gears, and each gear corresponds to one inoculation dose, so that the adding of the inoculant is facilitated, the operation difficulty is simplified, and the realizability is improved.
The technical scheme of the invention has the beneficial effects that: by collecting, recording and processing the weight value of the smelting furnace within a certain period of time, the initial state and the flow velocity of the liquid outlet are accurately judged, so that the start of stream inoculation and the adjustment of inoculation dosage in the process can be accurately determined, and the accuracy of stream inoculation is improved.
Drawings
FIG. 1 is a schematic diagram of a stream inoculation process framework;
Fig. 2 is a schematic diagram of a data set processing.
Detailed Description
In order to more clearly illustrate the technical solution of the present invention, it is obvious that the following description is a few exemplary embodiments of the present invention, and other solutions can be obtained according to these embodiments without inventive effort for a person skilled in the art.
In order to avoid and reduce the influence of artificial factors on stream inoculation accuracy judgment, the stream inoculation method of the metal liquid is adopted.
A stream inoculation method of metal liquid comprises judging the beginning state of liquid outlet and detecting the flow velocity of liquid outlet,
The method for judging the liquid outlet starting state is a method for judging the weight of the smelting furnace in real time so as to realize the purpose of automatically judging the liquid outlet starting state of the molten metal;
The method for detecting the liquid outlet flow rate is to perform linear regression fitting on a data set D consisting of a plurality of current weight values of a smelting furnace in a certain period of time to obtain the weight change rate of the metal liquid in the inoculation stage, and judge whether the adding amount of the inoculant needs to be increased or decreased according to the weight change rate of the metal liquid in the inoculation stage.
The technical scheme of the invention is described in detail by taking the stream inoculation operation of molten metal as an example.
A stream inoculation method of metal liquid comprises judging the beginning state of liquid outlet and detecting the flow velocity of liquid outlet,
The method for judging the liquid outlet starting state is a method for judging the weight of the smelting furnace in real time so as to realize the purpose of automatically judging the liquid outlet starting state of the molten metal;
The method for detecting the liquid outlet flow rate is to perform linear regression fitting on a data set D consisting of a plurality of current weight values of a smelting furnace in a certain period of time to obtain the weight change rate of the metal liquid in the inoculation stage, and judge whether the adding amount of the inoculant needs to be increased or decreased according to the weight change rate of the metal liquid in the inoculation stage.
As a supplement of this embodiment, the stream inoculation method of the molten metal further includes a liquid outlet starting procedure, where the liquid outlet starting procedure may be started manually or may be an instruction from an upper computer; the purpose of starting the liquid outlet procedure is to switch the smelting operation of molten metal from the smelting procedure to the liquid outlet procedure, and the liquid outlet procedure is to pour the molten metal which is qualified in smelting and detection into a ladle so as to facilitate the casting of castings. Inoculating the molten metal in the process of pouring the molten metal (namely, pouring out the molten metal), namely, stream inoculation according to the invention, namely, adding an inoculant into the poured molten metal. Specifically, the manual start may be that a button or other device for starting the tapping process is provided on a console of the smelting furnace, so as to transmit a signal for starting the tapping process to an upper computer, thereby activating the tapping start state determination method and the tapping flow rate detection method; the instruction of the upper computer can be given by an intelligent smelting unit for controlling smelting in the upper computer, namely, after receiving the information of qualified molten metal detection, the intelligent smelting unit gives an instruction for starting a liquid outlet process to a control console of a smelting furnace, so that smelting operation enters the liquid outlet process.
As a supplement to this embodiment, the method for determining the weight of the smelting furnace in real time specifically includes:
Detecting and recording weight values of the smelting furnace at a frequency of 7 times per second within ten seconds after the smelting furnace enters the liquid outlet process to form 10 groups of data groups C7 containing 7 weight values;
Removing the maximum value and the minimum value in each data group C7, and averaging the remaining five weight values to form a data group A10 consisting of ten average values;
The difference of the last bit minus the last bit in data set a [10] forms data set B [9], e.g., B [1] = a [2] -a [1], B [2] = a [3] -a [2],.
And judging whether the molten metal enters a liquid outlet starting state according to the numerical value in the data group B [9 ].
In this embodiment, the liquid outlet state of the molten metal is not determined directly by using the data set C, but the data set C is processed into the data set a and the data set B, so as to reduce data interference and data distortion caused by erroneous data as much as possible, thereby causing a risk of erroneous determination of the liquid outlet state.
In addition to this, the method for determining whether the molten metal is in the liquid outlet start state is that seven or more values of the data set B9 are greater than zero, and six of the values are continuously changed, that is, the liquid outlet amount of the molten metal is continuously increased or kept stable. In another aspect, the data set B is the weight change rate of the smelting furnace every ten seconds, and by determining whether the weight change rate of the smelting furnace every ten seconds is in an overall increasing trend, whether the molten metal is continuously discharged can be determined, so that the continuity of the discharge is ensured. Description: discrete variables and continuous variables are two basic data types in data analysis and statistics, and the data sets in this patent application are continuous variables.
As another supplement of this embodiment, in order to continuously monitor the tapping state, that is, to keep the molten metal in the tapping state all the time, or to monitor the tapping end state of the molten metal, etc., the weight values of the smelting furnaces in the data set C are continuously updated over time, that is, the data set a and the data set B are also continuously updated over time, and the data set a and the data set B follow the first-in first-out principle, and the data set C follows the automatic sequencing principle. For example, when data is stored for the eleventh second, the value in A2 is stored in A1, the value in A3 is stored in A2, … … is stored in A8, the value in A10 is stored in A9, and the data for the eleventh second is stored in A10.
As a complement to this embodiment, in order to achieve stream inoculation at the time of tapping, accurate decisions are required as to when to add inoculant, how much inoculant is added, and so on. The time node of the liquid outlet start determined by the liquid outlet start state is the time point of adding inoculant, namely after a liquid outlet start signal is sent from a smelting furnace to an intelligent smelting unit, the intelligent smelting unit sends out an inoculant adding instruction; in the subsequent inoculation process, the specific adding of the inoculant is realized by the detection method of the liquid outlet flow rate, and the method specifically comprises the following steps:
1) After the inoculant addition command is received by the smelting furnace, detecting and recording the current weight value of the smelting furnace in two seconds, wherein the current weight value is detected and recorded 7 times per second to form a data group D14 containing 14 weight values, wherein the sequence of the values is stored according to time, for example, the earliest detected weight value is counted in D1, and the last detected weight value is counted in D14;
2) Linearly fitting the data set D14 to obtain the weight change rate of molten metal in inoculation stage;
3) And judging whether the adding amount of the inoculant needs to be increased or decreased according to the weight change rate of the metal liquid in the inoculation stage, so that real-time inoculation is realized, and the inoculation effect is improved.
As a complement to this embodiment, the data set D is identical to the data set a, also following the first-in first-out principle.
As another supplement of this embodiment, in the step of receiving the inoculant adding instruction in the smelting furnace, the inoculant adding instruction is issued when the outflow weight of the molten metal is 20% of the total weight of the molten metal. Description: linear fitting is a form of curve fitting. Let x and y be both observed quantities and y be a function of x: y=f (x; b), the curve fitting is to find the best estimate of the parameter b by x, y observations, and find the best theoretical curve y=f (x; b). When the function y=f (x; b) is an i linear function with respect to b, such curve fitting is referred to as a linear fitting.
As another supplement of the embodiment, in order to reduce the difficulty of stream inoculation, the adding amount of inoculant which needs to be adjusted in real time is changed into staged adjustment, so that the operability of the technical scheme is stronger and the implementation is easier; dividing the weight change rate of the molten metal in the inoculation stage into a plurality of gears. For example, the method of dividing the weight change rate of the molten metal in the inoculation stage may be to set one gear every ten points of change in the weight change rate of the molten metal in the inoculation stage; the total amount of inoculant required to be added according to the total weight of the molten metal can be used as a unit of the adding amount of the minimum weighed inoculant, and the weight change rate of the molten metal in the inoculation stage is divided into a plurality of gears; the weight change rate of the molten metal in the inoculation stage can be divided into a plurality of gears according to the calculated inoculation time; and a fixed amount of inoculant is added into each gear, so that the inoculant is conveniently weighed, and the problems of delay in inoculation time and the like possibly caused by weighing the inoculant in real time are avoided.
Further, in order to reduce the difficulty of real-time adjustment of the inoculation rate of the real-time change on the inoculation dosage, the inoculation rate can be divided into a plurality of gears according to the range of specific values, and each gear corresponds to one inoculation dosage, so that the inoculation dosage is convenient to add, the operation difficulty is simplified, and the realizability is improved.
As another supplement of this embodiment, when the time for stopping adding the inoculant is 80% of the total weight of the molten metal, that is, the rate of change after the node of 80% of the weight of the molten metal corresponding to the rate of change of the weight of the molten metal in the inoculation stage can be divided into one gear, that is, the last gear for adding the inoculant, and no inoculant is added in the last gear, so that a good inoculation effect is achieved.
The above embodiment is only a description of a typical application of the technical scheme of the present invention, and can be reasonably expanded on the basis of reasonable design and no need of creative labor.
Claims (4)
1. A stream inoculation method of molten metal, comprising:
1) Judging the liquid outlet starting state, and adopting a method for judging the weight of the smelting furnace in real time to realize the purpose of automatically judging the liquid outlet starting state of the molten metal; the method for judging the liquid outlet starting state comprises the following steps of,
Detecting and recording the weight value of the current smelting furnace at a certain frequency in each second, and forming a data set C, wherein the data set C consists of the weight values of the current smelting furnace obtained for 6-8 times in one second;
Processing the data set C to obtain a data set A, wherein the data set A is obtained by the method,
Recording ten sets of said data sets C for ten consecutive seconds;
removing the maximum value and the minimum value in each data group C, and then averaging the rest data in the data group C to form a data group A;
processing the data group A to obtain a data group B, wherein the data group B consists of the difference between the data of the next bit and the data of the previous bit in the data group A;
Judging whether to enter a tapping start state according to the condition of the data group B, wherein the condition of judging whether the smelting furnace enters the tapping start state is that more than seventy percent of data in the data group B are more than zero and more than sixty percent of data in the data group B are continuously changed data;
2) The method comprises the steps that liquid outlet is carried out, a smelting furnace enters a liquid outlet starting state to be a liquid outlet starting time node, the smelting furnace sends a liquid outlet starting signal to an intelligent smelting unit, and the intelligent smelting unit sends an inoculant adding instruction to the smelting furnace according to the liquid outlet starting signal so as to realize automatic inoculant adding;
3) And detecting the flow rate of the liquid outlet, namely linearly fitting a data group D consisting of a plurality of current weight values of the smelting furnace in a certain period of time to obtain the weight change rate of the liquid metal in the inoculation stage, and judging whether the adding amount of the inoculant needs to be increased or decreased according to the weight change rate of the liquid metal in the inoculation stage.
2. The stream inoculation method of molten metal of claim 1, further comprising initiating a tapping sequence, wherein the method of initiating the tapping sequence is either manual or automatic.
3. The stream inoculation method of molten metal according to claim 2, wherein the method for detecting the flow rate of the molten metal comprises the steps of:
After the smelting furnace receives an inoculant adding instruction, detecting and recording the current weight value of the smelting furnace by taking two seconds as a unit to form a data set D;
Performing linear fitting on the data set D to obtain the weight change rate of the molten metal in the inoculation stage;
And judging whether the adding amount of the inoculant needs to be increased or decreased according to the weight change rate of the metal liquid in the inoculation stage.
4. The stream inoculation method of molten metal according to claim 3, wherein the rate of change of molten metal weight in the inoculation stage is divided into a plurality of gear steps.
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| JPH09300064A (en) * | 1996-05-15 | 1997-11-25 | Hitachi Metals Ltd | Method for automatically pouring molten metal |
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| CN102470435A (en) * | 2009-07-06 | 2012-05-23 | 新东工业株式会社 | Apparatus and method for feeding inoculants into a flow of molten metal and automatic molten metal pouring machine |
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| CN107335788A (en) * | 2017-05-22 | 2017-11-10 | 宁夏共享模具有限公司 | A kind of electric furnace goes out the weighing technique of iron during tapping a blast furnace |
| CN214768770U (en) * | 2021-06-01 | 2021-11-19 | 永祺科技检测股份有限公司 | Pneumatic synchronous stream inoculation control device of vertical casting line constant temperature casting machine |
| CN113751700A (en) * | 2020-06-05 | 2021-12-07 | 宁国市志诚机械制造有限公司 | Automatic casting machine and control method |
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2022
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Patent Citations (8)
| Publication number | Priority date | Publication date | Assignee | Title |
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| JPH09300064A (en) * | 1996-05-15 | 1997-11-25 | Hitachi Metals Ltd | Method for automatically pouring molten metal |
| CN102470435A (en) * | 2009-07-06 | 2012-05-23 | 新东工业株式会社 | Apparatus and method for feeding inoculants into a flow of molten metal and automatic molten metal pouring machine |
| CN201880883U (en) * | 2010-12-16 | 2011-06-29 | 致恒(天津)实业有限公司 | Instantaneous and automatic stream inoculation device |
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