CN115331406B - Vermicular brake drum molten iron quality early warning system and early warning method thereof - Google Patents

Vermicular brake drum molten iron quality early warning system and early warning method thereof Download PDF

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CN115331406B
CN115331406B CN202210856367.8A CN202210856367A CN115331406B CN 115331406 B CN115331406 B CN 115331406B CN 202210856367 A CN202210856367 A CN 202210856367A CN 115331406 B CN115331406 B CN 115331406B
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early warning
vermicular
brake drum
iron
molten iron
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CN115331406A (en
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杨湘杰
龙孟新
叶寒
顾嘉
李健雄
白宇轩
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Nanchang University
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    • GPHYSICS
    • G08SIGNALLING
    • G08BSIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
    • G08B21/00Alarms responsive to a single specified undesired or abnormal condition and not otherwise provided for
    • G08B21/18Status alarms
    • G08B21/24Reminder alarms, e.g. anti-loss alarms
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C33/00Making ferrous alloys
    • C22C33/08Making cast-iron alloys
    • GPHYSICS
    • G08SIGNALLING
    • G08BSIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
    • G08B5/00Visible signalling systems, e.g. personal calling systems, remote indication of seats occupied
    • G08B5/22Visible signalling systems, e.g. personal calling systems, remote indication of seats occupied using electric transmission; using electromagnetic transmission
    • G08B5/36Visible signalling systems, e.g. personal calling systems, remote indication of seats occupied using electric transmission; using electromagnetic transmission using visible light sources
    • G08B5/38Visible signalling systems, e.g. personal calling systems, remote indication of seats occupied using electric transmission; using electromagnetic transmission using visible light sources using flashing light

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  • Physics & Mathematics (AREA)
  • Chemical & Material Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Electromagnetism (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Business, Economics & Management (AREA)
  • Emergency Management (AREA)
  • Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
  • Investigating And Analyzing Materials By Characteristic Methods (AREA)
  • Investigating Or Analyzing Materials Using Thermal Means (AREA)

Abstract

The invention provides a vermicular iron brake drum molten iron quality early warning system and an early warning method thereof, wherein the system comprises a temperature acquisition module, a conversion module, an industrial control device, a digital I/O module and a display terminal/early warning device which are connected in sequence; the temperature acquisition module is used for acquiring signal data of a vermicular/ductile iron molten iron production line site and transmitting the acquired signal data to the industrial personal computer device through the conversion module; the industrial personal computer device is used for judging the received signal data and sending a judgment result to the display terminal/early warning device through the digital I/O module; the display terminal/early warning device is used for early warning. According to the invention, the sample solidification temperature curve of limited times of normal production of the vermicular brake drum is collected as the sample curve, and when the early warning system detects that the molten iron solidification curve deviates from a certain threshold value of the normal sample curve, early warning is carried out, so that the problem of product quality caused by casting molten iron is avoided, and the economic loss is reduced, and meanwhile, the product quality is effectively ensured.

Description

Vermicular brake drum molten iron quality early warning system and early warning method thereof
Technical Field
The invention relates to the technical field of quality management of vermicular brake drum molten iron, in particular to a vermicular brake drum molten iron quality early warning system and an early warning method thereof.
Background
The tensile strength and rigidity of the vermicular cast iron are respectively 75% and 45% higher than those of the common gray iron, and the fatigue strength is almost 2 times of that of the common gray iron, but the vermicular cast iron has good shock resistance, heat conductivity and castability, and is an ideal material for automobile parts such as brake drums and the like. The range of the residual amount of vermiculizer elements allowed by the production of vermicular iron is very narrow, and the change of the sulfur content of the raw materials easily causes insufficient vermiculization and even produces waste products. The existing vermicular cast iron melt state measuring instrument can effectively ensure the vermicular rate of products, but the price and the consumable material cost are expensive, and a secondary supplementing procedure is needed to be added, so that the production efficiency is affected. In addition, aiming at the production of products with different components, the existing instrument needs to correspondingly adjust the model, the field implementation period is increased, and under the condition that the current raw materials and technological parameters are stable, the vermicular brake drum molten iron quality management early warning system is invented, so that the development cost is not required, the production efficiency of enterprises is not influenced, and the product quality can be ensured.
Disclosure of Invention
The invention aims to provide a vermicular brake drum molten iron quality early warning system and a vermicular brake drum molten iron early warning method aiming at the problems. The method has the advantages that the solidification temperature curve of the samples, which is normally produced by the vermicular brake drum and is limited in times, is collected and used as the sample curve, and when the early warning system detects that the solidification curve of the molten iron deviates from a certain threshold value of the normal sample curve, early warning is carried out, so that the problem of product quality caused by casting the molten iron is avoided, and the product quality is effectively ensured while the economic loss is reduced.
In order to achieve the aim, the invention provides a vermicular brake drum molten iron quality early warning system which comprises a temperature acquisition module, a conversion module, an industrial control device, a digital I/O module and a display terminal/early warning device, wherein the temperature acquisition module, the conversion module, the industrial control device, the digital I/O module and the display terminal/early warning device are sequentially connected; the temperature acquisition module is used for acquiring signal data of a vermicular/ductile iron molten iron production line site and transmitting the acquired signal data to the industrial personal computer device through the conversion module; the industrial personal computer device is used for judging the received signal data and sending a judgment result to the display terminal/early warning device through the digital I/O module; the display terminal/early warning device is used for displaying the judging result of the industrial personal computer device.
Specifically, the signal data collected by the temperature collection module are thermal analysis solidification curves and temperature characteristic values on the curves, including liquidus temperature TL, eutectic start temperature TEN, eutectic minimum temperature TEU, eutectic maximum temperature TEU, eutectic rechueing temperature Δte and eutectic end temperature TS.
Specifically, the judging result of the industrial personal computer device on the received signal data is divided into the following two states, wherein the first state is as follows: the vermicular rate is more than or equal to 80 percent, and meets the production requirements of vermicular brake drum products; second state: the vermiculizer rate is lower than 80 percent, and does not meet the production requirements of vermicular iron brake drum products.
Specifically, the terminal/early warning device displays the judging result of the industrial personal computer device through the indicator lamp, and when the judging result is in the second state, the indicator lamp lights up a red light and warns that the product is unqualified.
An early warning method of a vermicular brake drum molten iron quality early warning system comprises the following steps:
s1, collecting a stable standard thermal analysis solidification curve of an existing vermicular brake drum production enterprise by using a special sample cup, and measuring the vermicular rate of a solidified sample of the sample cup;
s2, establishing a database for storing n stable and standard thermal analysis solidification curves and corresponding vermiculizer on an industrial personal computer device according to the standard thermal analysis solidification curves and the vermiculizer of the sample cup solidification samples collected in the step S1, and summarizing the vermiculizer within a certain characteristic parameter range to be used as basic data for judging production of vermicular iron brake drum products;
s3, collecting a solidification curve of the existing iron water sample cup to be tested;
step S4, inquiring whether the characteristic value of the thermal analysis solidification curve of the vermicular cast iron water to be detected is within the range of the characteristic value stored in the step S2 or not through an industrial personal computer device according to the solidification curve of the iron water sample cup to be detected obtained in the step S3, if not, executing the step S5, otherwise, executing the step S6;
s5, a red light of an indicator light of the display terminal/early warning device is turned on to remind workers of quality problems of vermicular iron brake drum molten iron;
and S6, ending.
Specifically, the creep rate in the step S2 is summarized in a certain characteristic parameter range, and the specific method is as follows:
firstly, finding out samples with the vermicular rate of more than or equal to 80% in a database, and then inducing the range of the eutectic minimum temperature TEU and the eutectic re-glow temperature delta Te corresponding to the samples.
The invention has the beneficial effects that:
according to the invention, the solidification temperature curve of the sample with limited times, which is normally produced by the vermicular brake drum, is collected as the sample curve, and when the early warning system detects that the solidification curve of the molten iron deviates from a certain threshold value of the normal sample curve, early warning is carried out, so that the problem of product quality caused by casting the molten iron is avoided, and the economic loss is reduced, and meanwhile, the product quality is effectively ensured.
Drawings
FIG. 1 is a schematic diagram of a composition structure of a vermicular brake drum molten iron quality early warning system of the present invention;
FIG. 2 is a flow chart of an early warning method of the vermicular brake drum molten iron quality early warning system of the present invention;
fig. 3 is a block diagram of a database in an embodiment of the invention.
Detailed Description
In order to make the technical solutions in the present specification better understood by those skilled in the art, the technical solutions in the embodiments of the present specification will be clearly and completely described below with reference to the drawings in the embodiments of the present specification, and it is obvious that the described embodiments are only some embodiments of the present application, but not all embodiments.
Examples: see fig. 1-3.
As shown in fig. 1, the system for early warning the quality of molten iron of the vermicular brake drum comprises a temperature acquisition module, a conversion module, an industrial control device, a digital I/O module and a display terminal/early warning device, wherein the temperature acquisition module, the conversion module, the industrial control device, the digital I/O module and the display terminal/early warning device are sequentially connected; the temperature acquisition module is used for acquiring signal data of a vermicular/ductile iron molten iron production line site and transmitting the acquired signal data to the industrial personal computer device through the conversion module; the industrial personal computer device is used for judging the received signal data and sending a judgment result to the display terminal/early warning device through the digital I/O module; the display terminal/early warning device is used for displaying the judging result of the industrial personal computer device.
Specifically, the signal data collected by the temperature collection module are thermal analysis solidification curves and temperature characteristic values on the curves, including liquidus temperature TL, eutectic start temperature TEN, eutectic minimum temperature TEU, eutectic maximum temperature TEU, eutectic rechueing temperature Δte and eutectic end temperature TS.
Specifically, the judging result of the industrial personal computer device on the received signal data is divided into the following two states, wherein the first state is as follows: the vermicular rate is more than or equal to 80 percent, and meets the production requirements of vermicular brake drum products; second state: the vermiculizer rate is lower than 80 percent, and does not meet the production requirements of vermicular iron brake drum products.
Specifically, the terminal/early warning device displays the judging result of the industrial personal computer device through the indicator lamp, and when the judging result is in the second state, the indicator lamp lights up a red light and warns that the product is unqualified.
As shown in FIG. 2, the early warning method of the vermicular cast iron brake drum molten iron quality early warning system comprises the following steps:
s1, collecting a stable standard thermal analysis solidification curve of an existing vermicular brake drum production enterprise by using a special sample cup, and measuring the vermicular rate of a solidified sample of the sample cup;
s2, establishing a database for storing n stable and standard thermal analysis solidification curves and corresponding vermiculizer on an industrial personal computer device according to the standard thermal analysis solidification curves and the vermiculizer of the sample cup solidification samples collected in the step S1, and summarizing the vermiculizer within a certain characteristic parameter range to be used as basic data for judging production of vermicular iron brake drum products;
s3, collecting a solidification curve of the existing iron water sample cup to be tested;
step S4, inquiring whether the characteristic value of the thermal analysis solidification curve of the vermicular cast iron water to be detected is within the range of the characteristic value stored in the step S2 or not through an industrial personal computer device according to the solidification curve of the iron water sample cup to be detected obtained in the step S3, if not, executing the step S5, otherwise, executing the step S6;
s5, a red light of an indicator light of the display terminal/early warning device is turned on to remind workers of quality problems of vermicular iron brake drum molten iron;
and S6, ending.
Specifically, the creep rate in the step S2 is summarized in a certain characteristic parameter range, and the specific method is as follows:
firstly, finding out samples with the vermicular rate of more than or equal to 80% in a database, and then inducing the range of the eutectic minimum temperature TEU and the eutectic re-glow temperature delta Te corresponding to the samples.
Referring to fig. 1-3, the present invention is further illustrated by a specific example.
Raw materials of the vermicular brake drum produced by certain enterprises comprise pig iron, scrap steel and recycled materials, and the requirements of the enterprises on specific components of the produced vermicular brake drum are shown in the following table 1. The scrap steel is taken as basic furnace charge, the carbon content and the silicon content are regulated by carburant and ferrosilicon, and are smelted in a 300Kg medium frequency induction furnace, and a vermiculizer R is adopted 2 A (the addition amount is shown in the following table 2) and inoculant YFY-8 (the addition amount is 0.6%), wherein a ladle bottom flushing method is adopted for vermiculizer and inoculation; the tapping temperature of molten iron is 1510-1550 ℃ and the casting temperature of the sample is 1380-1420 ℃.
TABLE 1 vermicular cast iron base iron composition and controlled final composition
C% Si% Mn% P% S% Cu% Cr% Mg% Re%
Base iron 3.7-3.8 1.4-1.6 <0.05 <0.03
Final ingredients 3.6-3.7 2.2-2.4 0.65-0.75 <0.05 <0.015 0.3-0.4 0.04-0.08 0.01-0.015 0.03-0.04
TABLE 2 vermiculizer addition
Sequence number 1 2 3 4 5 6 7 8 9 10
Addition amount (%) 0.08 0.09 0.10 0.11 0.12 0.13 0.15 0.18 0.22 0.29
And collecting a thermal analysis solidification curve of the vermicular cast iron which is just subjected to vermiculization and inoculation treatment by adopting a thermal analysis sample cup, casting a microstructure analysis sample, and measuring the vermiculization rate of the vermicular cast iron solidified sample. Then, the collected stable thermal analysis solidification curve, the corresponding characteristic values TEU, deltaTe and the vermicular rate are stored in a database (the database structure is shown as a figure 3), and the vermicular rate is more than or equal to 80% when the TEU is at 1130-1140 ℃ and the DeltaTe is at 8-18 ℃ and is taken as basic data for judging the production of the vermicular iron brake drum product; by adopting the vermicular iron brake drum molten iron quality management early warning method, whether the characteristic value TEU on the thermal analysis solidification curve of the vermicular iron molten iron to be tested is within the range of 1130-1140 ℃ and delta Te is within the range of 8-18 ℃ is inquired by a computer, and whether an alarm prompt is given or not is judged.
While the preferred embodiments of the present invention have been illustrated and described, the present invention is not limited to the embodiments, and various equivalent modifications and substitutions can be made by one skilled in the art without departing from the spirit of the present invention, and these are intended to be included in the scope of the present invention as defined in the appended claims.

Claims (5)

1. The early warning method of the vermicular brake drum molten iron quality early warning system is characterized in that the early warning system comprises a temperature acquisition module, a conversion module, an industrial control device, a digital I/O module and a display terminal/early warning device, wherein the temperature acquisition module, the conversion module, the industrial control device, the digital I/O module and the display terminal/early warning device are sequentially connected; the temperature acquisition module is used for acquiring signal data of a vermicular/ductile iron molten iron production line site and transmitting the acquired signal data to the industrial personal computer device through the conversion module; the industrial personal computer device is used for judging the received signal data and sending a judgment result to the display terminal/early warning device through the digital I/O module; the display terminal/early warning device is used for displaying the judging result of the industrial personal computer device;
the early warning method of the early warning system comprises the following steps:
s1, collecting a stable standard thermal analysis solidification curve of an existing vermicular brake drum production enterprise by using a special sample cup, and measuring the vermicular rate of a solidified sample of the sample cup;
s2, establishing a database for storing n stable and standard thermal analysis solidification curves and corresponding vermiculizer on an industrial personal computer device according to the standard thermal analysis solidification curves and the vermiculizer of the sample cup solidification samples collected in the step S1, and summarizing the vermiculizer within a certain characteristic parameter range to be used as basic data for judging production of vermicular iron brake drum products;
s3, collecting a solidification curve of the existing iron water sample cup to be tested;
step S4, inquiring whether the characteristic value of the thermal analysis solidification curve of the vermicular cast iron water to be detected is within the range of the characteristic value stored in the step S2 or not through an industrial personal computer device according to the solidification curve of the iron water sample cup to be detected obtained in the step S3, if not, executing the step S5, otherwise, executing the step S6;
s5, a red light of an indicator light of the display terminal/early warning device is turned on to remind workers of quality problems of vermicular iron brake drum molten iron;
and S6, ending.
2. The method for pre-warning the quality of the vermicular cast iron brake drum molten iron according to claim 1, wherein the signal data collected by the temperature collection module are the liquidus temperature TL, the eutectic start temperature TEN, the eutectic minimum temperature TEU, the eutectic maximum temperature TEU, the eutectic rechucking temperature Δte and the eutectic end temperature TS on the thermal analysis solidification curve and the respective temperature characteristic values on the curve.
3. The method for early warning of the quality of the vermicular brake drum molten iron according to claim 1, wherein the judging result of the industrial personal computer device on the received signal data is divided into the following two states, wherein the first state is: the vermicular rate is more than or equal to 80 percent, and meets the production requirements of vermicular brake drum products; second state: the vermiculizer rate is lower than 80 percent, and does not meet the production requirements of vermicular iron brake drum products.
4. The method for early warning the quality of the vermicular cast iron brake drum molten iron according to claim 1, wherein the display terminal/early warning device displays the judging result of the industrial personal computer device through the indicating lamp, and when the judging result is in the second state, the indicating lamp lights a red light and early warns that the vermicular cast iron brake drum product is unqualified.
5. The method for pre-warning the quality of the vermicular cast iron brake drum molten iron according to claim 1, wherein the vermicular rate induced in the certain characteristic parameter range in the step S2 is as follows:
firstly, finding out samples with the vermicular rate of more than or equal to 80% in a database, and then inducing the range of the eutectic minimum temperature TEU and the eutectic re-glow temperature delta Te corresponding to the samples.
CN202210856367.8A 2022-07-21 2022-07-21 Vermicular brake drum molten iron quality early warning system and early warning method thereof Active CN115331406B (en)

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