CN116329496A - Spheroidization recession system and operation process thereof - Google Patents

Spheroidization recession system and operation process thereof Download PDF

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Publication number
CN116329496A
CN116329496A CN202310330789.6A CN202310330789A CN116329496A CN 116329496 A CN116329496 A CN 116329496A CN 202310330789 A CN202310330789 A CN 202310330789A CN 116329496 A CN116329496 A CN 116329496A
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China
Prior art keywords
casting
time
inoculation
molten metal
spheroidization
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CN202310330789.6A
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Chinese (zh)
Inventor
常涛
刘亚宾
杨秀琴
高颖
于建君
邱建斌
杨伟强
胡志斌
白晋成
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Ningxia Vocational And Technical College Ningxia Open University
National Intelligent Foundry Industry Innovation Center
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Ningxia Vocational And Technical College Ningxia Open University
National Intelligent Foundry Industry Innovation Center
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Priority to CN202310330789.6A priority Critical patent/CN116329496A/en
Publication of CN116329496A publication Critical patent/CN116329496A/en
Pending legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D1/00—Treatment of fused masses in the ladle or the supply runners before casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D2/00—Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D41/00—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like
    • B22D41/12—Travelling ladles or similar containers; Cars for ladles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D46/00—Controlling, supervising, not restricted to casting covered by a single main group, e.g. for safety reasons
    • 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
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

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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

The utility model provides a spheroidization decay system and operation process thereof, belongs to electrical technology field for solve the unable timely control of spheroidization decay time in the molten metal casting in-process and cause the unqualified problem of foundry goods metallography that spheroidization decay overtime caused, including control unit, inoculation unit, logistics device and casting equipment, control unit inoculation unit logistics device with communication connection between the casting equipment is used for control unit inoculation unit logistics device with transfer information between the casting equipment. By arranging the independent inoculation unit, the inoculation and smelting of the molten metal are carried out in steps, so that the interaction influence among various working procedures is avoided, the casting time is effectively controlled by timing spheroidization recession allowable time, and the quality disqualification of castings caused by continuous casting after spheroidization timeout is avoided.

Description

Spheroidization recession system and operation process thereof
Technical Field
The invention relates to the technical field of electricity, in particular to a molten metal smelting control system.
Background
In the production process, graphite forms in castings, particularly when large-section ductile iron castings are cast, are frequently deformed, and the change of the graphite forms is called spheroidization degradation in the industry, so that the graphite forms are a common waste condition of ductile iron materials. In the production of ferritic spheroidal graphite cast iron, it is generally required that the spheroidization rate reaches more than 90%.
The field characterization of spheroidization recession is that if the residence time is long after spheroidization inoculation is finished and the casting is finished, spheroidization elements (magnesium, rare earth elements) in the spheroidizing agent are insufficient due to gradual consumption of elements such as oxygen, sulfur and the like, graphite can be promoted to infinitely grow in the process of crystallizing the graphite into a spheroidization shape, even the graphite is formed into a bloom shape or a worm shape, so that the graphite grade cannot meet the technical requirement, spheroidization recession is generated, and castings are scrapped. The common confusion phenomenon is that the spheroidization is good after the spheroidization is finished, and the spheroidization is not good after casting; or the molten iron in the same ladle, the cast which is poured firstly has good spheroidization, and the cast which is poured later has poor spheroidization condition.
The reason for the spheroidization deterioration is that the magnesium and rare earth amounts decay with the extension of the iron bath rest time. Magnesium and rare earth have higher affinity with oxygen than sulfur, so MgS and Ce2S3 inclusions floating on the surface of molten iron react with oxygen in air as follows:
2MgS+O 2 ＝2MgO+2S；2Ce 2 S 3 +O 2 ＝2Ce 2 O 3 +6S
at this time, the generated sulfur enters into the molten iron again to react with magnesium and rare earth:
Mg+S＝MgS；2Ce+3S＝Ce 2 S 3
thus, along with the extension of the stopping time of the molten iron, sulfur continuously reacts with magnesium and rare earth to continuously generate MgS and Ce 2 S 3 They are oxidized by oxygen in the air continuously and circularly. As a result, the magnesium and rare earth in the molten iron are consumed, and sulfur again enters the molten iron from the dross, so that a 'sulfur recovery phenomenon' occurs.
Common measures to reduce spheroidization deterioration are as follows:
I. shortening the stopping time of the molten iron: from the finishing of spheroidizing inoculation treatment to the casting completion, the process should be finished within 15 minutes;
II. Reducing the sulfur content of the raw iron liquid: the high sulfur content in the raw iron liquid requires more spheroidizing elements to be consumed, and in addition, the high sulfur content in the raw iron liquid increases the sulfide content in slag, so that the 'sulfur recovery phenomenon' is promoted to be aggravated, and spheroidizing decay is accelerated;
III, reinforcing covering and slag skimming: after spheroidizing, adding slag collecting agent for covering, and taking slag off for multiple times, so that the 'sulfur return phenomenon' can be reduced;
IV, properly increasing the dosage of the nodulizer: according to the sulfur content in the molten iron, the amount of the nodulizer is correspondingly increased, but the method is uneconomical.
Among the above measures, shortening the stopping time of the molten iron is an economically viable method. However, the casting of the former package and the inoculation of the latter package are required to be crossed and even synchronously performed under the requirement of on-site production beats, and abnormal delay phenomena caused by equipment problems are inevitably generated. How to get the casting operator or the automatic casting control system to know the spheroidization decay time in real time through a high-cost scheme, and to intervene or perform corresponding treatment (such as stopping casting, returning the residual molten iron to the furnace, etc.) in time, so as to avoid a series of subsequent production and quality problems, which becomes a key link.
Disclosure of Invention
In view of the above problem that the actual spheroidization degradation time cannot be obtained in time, which causes excessive spheroidization of the casting molten metal to cause spheroidization degradation of metallographic graphite morphology of the casting, it is necessary to provide a spheroidization degradation system and a spheroidization degradation control method.
The utility model provides a spheroidization decay system, includes control unit, inoculation unit, logistics device and casting equipment, control unit inoculation unit logistics device with communication connection between the casting equipment is used for control unit inoculation unit logistics device with transfer information between the casting equipment, namely inoculation unit logistics device with be equipped with information acquisition unit and information receiving unit on the casting equipment for with on-the-spot information transmission extremely control unit also is used for receiving the instruction from control unit, inoculation unit logistics device with casting equipment is according to come from control unit's instruction carries out corresponding operation or action, in order to realize spheroidization decay system's automatic operation.
As an optimization of the technical scheme, the inoculation unit, the logistics device and the casting equipment are respectively provided with an inoculation reset button, a logistics reset button and a casting reset button, and when an instruction sent by the control unit cannot be correctly executed, the control unit is used for manually confirming related instructions so that the inoculation unit, the logistics device and the casting equipment execute related operations or actions, and meanwhile, the current alarm state is eliminated.
Further, the spheroidizing degradation system also comprises a molten metal containing device, such as a ladle, for receiving molten metal to be inoculated from the smelting furnace, receiving molten metal to be cast from the inoculating unit and pouring the molten metal contained in the molten metal containing device into a casting mould to form a casting.
An operational process of a spheroidization degradation system, comprising,
1) The first logistics device receives qualified molten metal to be inoculated from smelting equipment, and transfers the molten metal to be inoculated to an inoculation unit, and the molten metal to be inoculated is inoculated in the inoculation unit;
2) The second stream device receives qualified molten metal to be cast and transfers the molten metal to be cast to a casting middle area; transferring the molten metal containing equipment after casting or molten metal containing equipment with overtime spheroidizing decline from the casting middle zone to the first logistics device; after the inoculation of the metal liquid is qualified, starting the timing of the allowable time of spheroidization recession;
3) The casting intermediate zone transmits the metal liquid to be cast to casting equipment, the casting equipment adopts the metal liquid to be cast to carry out casting operation, and pays attention to the spheroidizing recession allowable time in real time so as to ensure that the casting time is within the spheroidizing recession allowable time range and avoid unqualified castings caused by continuous casting after overtime spheroidizing recession;
4) The molten metal containing equipment after casting is transported to smelting equipment by the first logistics device and is used for receiving the molten metal to be inoculated;
5) Transferring the molten metal containing equipment with overtime spheroidizing recession from the second stream device to the inoculation unit for secondary inoculation, so that the molten metal can reach the performance of the molten metal to be cast;
6) And (5) the steps are circulated to realize continuous qualified casting operation.
The spheroidizing recession control method covers two modes of a casting proceeding state and an inoculation proceeding state, and casting operators can only pay attention to the spheroidizing recession countdown of the molten metal in the casting proceeding state, so that the operation of the operators is simpler and more convenient, and the possible errors caused by various conditions are avoided, such as the problem that the molten metal spheroidizing recession timeout in the casting proceeding state is not timely contraindicated, and the metallographic phase of the casting is unqualified.
As a supplement to the technical scheme, the spheroidizing decay allowable time is from the inoculation completion, and the spheroidizing decay allowable time is the sum of the waiting time of the inoculated molten metal in the inoculation unit and the casting time after entering the casting middle zone.
The technical scheme of the invention has the beneficial effects that: by arranging the independent inoculation unit, the inoculation and smelting of the molten metal are carried out in steps, so that the interaction influence among various working procedures is avoided, the casting time is effectively controlled by timing spheroidization recession allowable time, and the quality disqualification of castings caused by continuous casting after spheroidization timeout is avoided.
Drawings
FIG. 1 is a schematic diagram of an embodiment of a spheroidization degradation system;
FIG. 2 is a schematic diagram of an inoculation completion process.
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.
According to the technical scheme, the problem that two molten metal containing devices (ladles) and one casting device are required to perform casting operation, and the molten metal spheroidizing decay time in the two molten metal containing devices (ladles) needs to be monitored simultaneously is solved, and the spheroidizing decay system is provided.
The spheroidization recession system comprises a control unit, an inoculation unit, a logistics device and casting equipment, wherein the control unit, the inoculation unit, the logistics device and the casting equipment are in communication connection and used for transmitting information among the control unit, the inoculation unit, the logistics device and the casting equipment.
Specifically, fig. 1 shows an embodiment of the present technical solution.
The utility model provides a spheroidization decay system, includes the control unit that contains the PLC controller, by the inoculation unit that one inoculates the equipment and constitute, by the logistics device that two transfer cars are constituteed, by the smelting district and the casting equipment that two smelting stoves are constituteed, specifically, inoculation unit is spheroidization inoculation station, casting equipment sets up in the casting district, specifically the casting machine still be equipped with the casting intermediate zone between spheroidization inoculation station and the casting district, namely the pouring ladle in fig. 1 refutes the district, the pouring ladle refutes the district can be automatic with the casting machine dock of casting district, realizes the automatic transmission of pouring ladle (metal liquid holding device) between casting machine and pouring ladle refutes the district.
The running process of the spheroidization recession system comprises the following steps:
s11, smelting molten metal by a first smelting furnace and/or a second smelting furnace according to smelting instructions sent by the control unit;
s12, after molten metal is smelted to be qualified, transferring the molten metal to be inoculated to a spheroidizing inoculation station by a first transfer vehicle, and inoculating the molten metal to be inoculated in the spheroidizing inoculation station;
s13, after the inoculation of the metal liquid is qualified, transferring the metal liquid to be cast to a ladle connection area by a second transfer trolley, namely transferring a ladle filled with the metal liquid to be cast to the ladle connection area; in the step, monitoring the spheroidizing recession allowable time of the molten metal to be cast;
s14, the ladle connection area transmits a ladle filled with the molten metal to be cast to a casting machine of a casting area;
and S15, the casting machine casts corresponding castings according to the casting instruction sent by the control unit, specifically, the casting machine needs to finish casting tasks within the allowable time of spheroidization recession, otherwise, unqualified castings are generated.
As a supplement of this embodiment, the spheroidizing recession allowable time is divided into two sections, the first time section is waiting time, the waiting time is time before the qualified molten metal to be cast is transported to the ladle docking area by the second transfer vehicle, and the second time section is casting time, and the casting time is time when the molten metal to be cast enters the ladle docking area and performs casting operation. In order to facilitate operators to know and know the spheroidizing recession allowable time in time, an LED display screen and an alarm indicator are arranged in the casting area, the LED display screen is used for displaying the spheroidizing recession allowable time, and the alarm indicator sends out a casting stopping alarm warning sound when the time displayed by the LED display screen is zero.
In order to monitor the allowable time of spheroidizing recession of two ladles at the same time and display the allowable time of remaining spheroidizing recession of the ladles of the current casting operation in a casting area, a 'waiting position No. 1' and a 'waiting position No. 2' are set in a PLC (programmable logic controller) of the control unit, wherein the waiting position No. 1 and the waiting position No. 2 are used for storing and displaying the waiting time of a ladle No. 1 and a ladle No. two, namely the waiting time No. 1 and the waiting time No. 2 respectively, the waiting time No. 1 and the waiting time No. 2 are the waiting time of the allowable time of spheroidizing recession of the metal liquid to be cast in the spheroidizing inoculation station, and the longer the waiting time is, the shorter the remaining casting time is, namely the casting is, the less the casting can be cast.
As a supplement to this embodiment, the treatment process of the molten metal to be cast after inoculation is completed is as follows:
1) After the inoculation of the metal liquid is finished, the spheroidizing inoculation station sends an inoculation completion instruction;
2) When the control unit detects the rising edge of the inoculation completion instruction, the control unit stores the time of completing the inoculation of the molten metal so as to facilitate the subsequent statistical analysis and quality tracing of the molten metal performance;
3) Judging whether the waiting time No. 1 and the waiting time No. 2 are zero, if the waiting time No. 1 is zero and the waiting time No. 2 is not zero, transferring the first ladle corresponding to the waiting time No. 1 to the ladle docking area by the transfer trolley No. two, giving the waiting time No. 1 to the waiting time No. 1 again, and restarting time metering; if the waiting time No. 2 is zero and the waiting time No. 1 is not zero, transferring the second ladle corresponding to the waiting position No. 2 from the second transfer trolley to the ladle docking area, endowing the waiting time No. 2 to the waiting position No. 2 again, and restarting time measurement; if the waiting time No. 1 and the waiting time No. 2 are both zero, transferring the first ladle corresponding to the waiting time No. 1 from the second transfer vehicle to the ladle docking area, endowing the waiting time No. 1 with the waiting time No. 1 again, and restarting time measurement;
4) And circularly judging whether the waiting time No. 1 and the waiting time No. 2 are zero, and monitoring the allowable time for alternately transferring, casting and spheroidizing recession of the first ladle and the second ladle.
As a supplement to this embodiment, in order to avoid a situation that the casting time is insufficient to cast a complete casting due to the excessively long waiting time, the waiting time No. 1 and the waiting time No. 2 need to be measured in real time, and the specific process flow is as follows:
1) If the waiting time No. 1 or the waiting time No. 2 is larger than the sum of the mean value of the connection time and the maximum time for casting the single box, assigning a zero value to the waiting position No. 1 or the waiting position No. 2;
2) The control unit sends out a connection prohibition instruction, the casting ladle connection area stops transferring the casting ladle to the casting machine in the casting area, the casting is prevented from being incomplete, and the spheroidization recession allowable time is finished.
The processing flow for judging the waiting time is set, so that the situation that a complete casting cannot be cast before the spheroidizing recession allowable time is finished is avoided, the quality problem of cast castings is avoided, the waste of molten metal is avoided, and the production quality cost is reduced.
Judging according to the connection sequence of the first ladle and the second ladle in the ladle connection zone and the waiting time 1 and the waiting time 2, namely preferentially transmitting the ladle with longer waiting time to a casting machine, and avoiding overtime of spheroidizing decay of the molten metal; specifically, if the waiting time No. 1 is greater than or equal to the waiting time No. 2, transferring the first ladle to a casting machine; and if the waiting time No. 2 is greater than or equal to the waiting time No. 1, transferring the second ladle to the casting machine. Meanwhile, when the first ladle or the second ladle is transmitted to the casting machine, the control unit displays the remaining allowable spheroidizing decay time of the molten metal to be cast, which can be used for casting, on an LED display screen of the casting area according to the recorded time when the molten metal of the corresponding ladle is inoculated and the allowable spheroidizing decay time.
Additionally, when a plurality of castings are continuously cast by a ladle of molten metal, the relationship between the maximum casting time of the next casting to be cast and the remaining allowable spheroidization degradation time needs to be determined, specifically:
1) If the remaining spheroidization degradation allowable time is greater than zero, continuously judging whether the remaining spheroidization degradation allowable time is less than or equal to the maximum casting time of the next casting to be cast, otherwise, giving a warning and stopping casting;
2) If the remaining spheroidization recession allowable time is less than or equal to the maximum casting time of the next casting to be cast, sending out a warning and stopping casting; otherwise, casting is continued.
And (3) circulating the two steps until the casting operation is finished or the allowable time of the spheroidization decline is in a cut-off alarm, and finishing the casting task of the ladle molten metal at the present time.
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 (9)

1. The spheroidization recession system is characterized by comprising a control unit, an inoculation unit, a logistics device and casting equipment, wherein the control unit, the inoculation unit, the logistics device and the casting equipment are in communication connection and used for transmitting information among the control unit, the inoculation unit, the logistics device and the casting equipment.
2. The spheroidizing degradation system of claim 1, wherein an inoculation reset button, a logistics reset button and a casting reset button are respectively arranged on the inoculation unit, the logistics device and the casting equipment, and when the command sent by the control unit cannot be correctly executed, the control unit is used for manually confirming the related command so as to enable the inoculation unit, the logistics device and the casting equipment to execute related operation or action and eliminate the current alarm state.
3. The spheroidization-regression system of claim 1 further comprising a molten metal containment device.
4. An operational process of a spheroidization degradation system, comprising:
the first logistics device receives qualified molten metal to be inoculated from smelting equipment, and transfers the molten metal to be inoculated to an inoculation unit, and the molten metal to be inoculated is inoculated in the inoculation unit;
the second stream device receives qualified molten metal to be cast and transfers the molten metal to be cast to a casting middle area; transferring the molten metal containing equipment after casting or molten metal containing equipment with overtime spheroidizing decline from the casting middle zone to the first logistics device;
the casting middle zone transmits the molten metal to be cast to casting equipment, and the casting equipment adopts the molten metal to be cast for casting operation and pays attention to the spheroidization recession allowable time in real time;
the molten metal containing equipment after casting is transported to smelting equipment by the first logistics device and is used for receiving the molten metal to be inoculated;
transferring the molten metal containing equipment with overtime spheroidizing recession from the second stream device to the inoculation unit for secondary inoculation, so that the molten metal can reach the performance of the molten metal to be cast;
and (5) the steps are circulated to realize continuous qualified casting operation.
5. The process of claim 4 wherein said spheroidization-degradation allowable time is the sum of the waiting time of the inoculated molten metal in said inoculation unit and the casting time after entering said casting intermediate zone.
6. The operation process of the spheroidizing degradation system according to claim 5, further comprising a treatment process of the molten metal to be cast after inoculation is completed, specifically comprising:
after the inoculation of the metal liquid is finished, the spheroidizing inoculation station sends an inoculation completion instruction;
when the control unit detects the rising edge of the inoculation completion instruction, the control unit stores the time of completing inoculation of the metal liquid;
judging whether the waiting time No. 1 and the waiting time No. 2 are zero, if the waiting time No. 1 is zero and the waiting time No. 2 is not zero, transferring a first ladle corresponding to the waiting position No. 1 to a ladle connection area by a second transfer vehicle, endowing the waiting time No. 1 with the waiting position No. 1 again, and restarting time measurement; if the waiting time No. 2 is zero and the waiting time No. 1 is not zero, transferring a second ladle corresponding to the waiting position No. 2 to the ladle docking area by a second transfer vehicle, endowing the waiting time No. 2 to the waiting position No. 2 again, and restarting time measurement; if the waiting time No. 1 and the waiting time No. 2 are both zero, transferring the first ladle corresponding to the waiting time No. 1 from the second transfer vehicle to the ladle docking area, endowing the waiting time No. 1 with the waiting time No. 1 again, and restarting time measurement;
and circularly judging whether the waiting time No. 1 and the waiting time No. 2 are zero, and monitoring the allowable time for alternately transferring, casting and spheroidizing recession of the first ladle and the second ladle.
7. The process of claim 6, further comprising a latency process, specifically:
if the waiting time No. 1 or the waiting time No. 2 is larger than the sum of the mean value of the connection time and the maximum time for casting the single box, assigning a zero value to the waiting position No. 1 or the waiting position No. 2;
the control unit sends out a connection prohibition instruction, the casting ladle connection area stops transferring the casting ladle to the casting machine in the casting area, the casting is prevented from being incomplete, and the spheroidization recession allowable time is finished.
8. The process of claim 7, further comprising a process flow of a docking sequence, specifically:
if the waiting time No. 1 is greater than or equal to the waiting time No. 2, transmitting the first ladle to a casting machine; and if the waiting time No. 2 is greater than or equal to the waiting time No. 1, transferring the second ladle to the casting machine.
9. The process of claim 8, further comprising a process of determining a relationship between a maximum casting time of a next casting to be cast and a remaining allowable spheroidization degradation time, in particular:
if the remaining spheroidization degradation allowable time is greater than zero, continuously judging whether the remaining spheroidization degradation allowable time is less than or equal to the maximum casting time of the next casting to be cast, otherwise, giving a warning and stopping casting;
if the remaining spheroidization recession allowable time is less than or equal to the maximum casting time of the next casting to be cast, sending out a warning and stopping casting; otherwise, casting is continued.
CN202310330789.6A 2023-03-31 2023-03-31 Spheroidization recession system and operation process thereof Pending CN116329496A (en)

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Application Number Priority Date Filing Date Title
CN202310330789.6A CN116329496A (en) 2023-03-31 2023-03-31 Spheroidization recession system and operation process thereof

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Application Number Priority Date Filing Date Title
CN202310330789.6A CN116329496A (en) 2023-03-31 2023-03-31 Spheroidization recession system and operation process thereof

Publications (1)

Publication Number Publication Date
CN116329496A true CN116329496A (en) 2023-06-27

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