CN117850503B - Detection control system for casting spheroidization temperature control - Google Patents
Detection control system for casting spheroidization temperature control Download PDFInfo
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- CN117850503B CN117850503B CN202410257592.9A CN202410257592A CN117850503B CN 117850503 B CN117850503 B CN 117850503B CN 202410257592 A CN202410257592 A CN 202410257592A CN 117850503 B CN117850503 B CN 117850503B
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- 238000001514 detection method Methods 0.000 title claims abstract description 229
- 238000005266 casting Methods 0.000 title claims abstract description 62
- 238000004458 analytical method Methods 0.000 claims abstract description 31
- 238000000034 method Methods 0.000 claims abstract description 19
- 230000008569 process Effects 0.000 claims abstract description 14
- 230000000694 effects Effects 0.000 claims description 72
- 238000007405 data analysis Methods 0.000 claims description 68
- 238000003723 Smelting Methods 0.000 claims description 61
- 238000005457 optimization Methods 0.000 claims description 41
- 238000007781 pre-processing Methods 0.000 claims description 28
- 239000000463 material Substances 0.000 claims description 25
- 238000011156 evaluation Methods 0.000 claims description 19
- 238000013441 quality evaluation Methods 0.000 claims description 13
- 239000011159 matrix material Substances 0.000 claims description 12
- 238000001303 quality assessment method Methods 0.000 claims description 12
- 238000001816 cooling Methods 0.000 claims description 11
- 238000010438 heat treatment Methods 0.000 claims description 9
- 238000013178 mathematical model Methods 0.000 claims description 9
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 8
- 229910002804 graphite Inorganic materials 0.000 claims description 8
- 239000010439 graphite Substances 0.000 claims description 8
- 239000003795 chemical substances by application Substances 0.000 claims description 6
- 238000012545 processing Methods 0.000 claims description 4
- 238000003756 stirring Methods 0.000 claims description 4
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 238000004321 preservation Methods 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 abstract description 9
- 238000012544 monitoring process Methods 0.000 abstract description 4
- 229910001018 Cast iron Inorganic materials 0.000 description 3
- 230000008859 change Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 230000005856 abnormality Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000013135 deep learning Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000010801 machine learning Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 238000007619 statistical method Methods 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C1/00—Refining of pig-iron; Cast iron
- C21C1/10—Making spheroidal graphite cast-iron
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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
- B22D46/00—Controlling, supervising, not restricted to casting covered by a single main group, e.g. for safety reasons
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
- G05D23/00—Control of temperature
- G05D23/19—Control of temperature characterised by the use of electric means
- G05D23/20—Control of temperature characterised by the use of electric means with sensing elements having variation of electric or magnetic properties with change of temperature
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Investigating Or Analyzing Materials Using Thermal Means (AREA)
Abstract
The invention discloses a detection control system for casting spheroidization temperature control, and particularly relates to the field of detection control. The invention collects data from a plurality of aspects and carries out comprehensive analysis, thereby realizing comprehensive monitoring and intelligent control on the casting spheroidization process, not only reducing the difficulty and error of manual operation, but also improving the automation level of the production process, saving a large amount of manpower resources for enterprises.
Description
Technical Field
The invention relates to the technical field of detection control, in particular to a detection control system for casting spheroidization temperature control.
Background
The spheroidizing process is mainly used for obtaining spheroidal graphite in the casting process, so that the mechanical property of cast iron is improved, and the appearance of spheroidizing technology is that the graphite in cast iron is specially treated and converted into spheroidal form from original flake or block, and the conversion not only retains the basic components, technological properties and various advantages of common cast iron, but also has quality change in the aspects of strength, plasticity and the like.
The existing detection control system for casting spheroidization temperature control mainly deploys a high-precision and quick-response temperature sensor network through an intelligent heat treatment monitoring system, the sensors are embedded into key positions of casting spheroidization, temperature changes of all areas are monitored in real time, a data acquisition module is responsible for receiving temperature data from the sensor network and converting the temperature data into a format which can be used for further analysis, an analysis module utilizes an advanced algorithm and a model to process the temperature data in real time so as to identify potential temperature fluctuation or abnormality, and an automatic control unit automatically adjusts output of heating and cooling equipment according to a data analysis result.
However, when the system is actually used, some disadvantages still exist, such as the existing system may only rely on a limited number of temperature sensors to collect data, so that data samples are insufficient, temperature distribution and change in the whole casting spheroidization process are difficult to comprehensively reflect, some systems may only use a basic statistical method or threshold judgment to process the temperature data, advanced algorithms and models are lack to deeply mine potential rules and trends in the data, data analysis may only stay on the surface, and technologies such as machine learning, deep learning and the like are not fully utilized to perform data-driven optimization.
Disclosure of Invention
In order to overcome the above-mentioned drawbacks of the prior art, an embodiment of the present invention provides a detection control system for controlling casting spheroidization temperature, which solves the problems set forth in the above-mentioned background art by adopting the following scheme.
In order to achieve the above purpose, the present invention provides the following technical solutions: a detection control system for casting spheroidization temperature control, comprising:
the detection area dividing module: the method comprises the steps of determining a target pouring spheroidizing process plant as a target detection area, dividing the target detection area into detection subareas according to a spheroidizing method of a single casting, and marking the detection subareas as 1 and 2 … … n in sequence;
spheroidizing data acquisition module: the system comprises a smelting data preprocessing module, a spheroidizing data preprocessing module and a pouring data preprocessing module, wherein the smelting data preprocessing module is used for acquiring smelting data, spheroidizing data and pouring data of each detection subarea;
spheroidizing data preprocessing module: the spheroidizing data processing module is used for preprocessing smelting data, spheroidizing data and pouring data transmitted by the spheroidizing data acquisition module and transmitting the processed data to the spheroidizing data analysis module;
Spheroidizing data analysis module: the system comprises a smelting data analysis unit, a spheroidizing data analysis unit and a pouring data analysis unit, wherein the smelting data analysis unit, the spheroidizing data analysis unit and the pouring data analysis unit are used for analyzing the data transmitted by the spheroidizing data preprocessing module and transmitting analysis results to the comprehensive analysis module;
the spheroidizing effect data acquisition module: the spheroidizing device is used for collecting spheroidizing effect data of each detection subarea and transmitting the collected data to a spheroidizing effect data analysis module;
And the spheroidizing effect data analysis module is used for: the spheroidizing effect data analysis module is used for establishing a spheroidizing effect data analysis model, importing the data transmitted by the spheroidizing effect data acquisition module into the spheroidizing effect data analysis model, calculating spheroidizing effect evaluation values of all detection subareas, and transmitting the spheroidizing effect evaluation values to the comprehensive analysis module;
and the comprehensive analysis module is used for: the comprehensive analysis module is used for establishing a comprehensive analysis model, importing the data transmitted by the spheroidizing data analysis module and the spheroidizing effect data analysis module into the comprehensive analysis model, calculating the comprehensive optimization index of each detection subarea, and transmitting the comprehensive optimization index to the control module;
And the control module is used for: and the comprehensive optimization index detection module is used for judging the comprehensive optimization index of the ith detection subarea according to the comprehensive optimization index target value and sending out a control signal according to a judgment result.
Preferably, the smelting data includes smelting time, initial material mass, final material mass, initial furnace temperature, smelting temperature, and material liquidus temperature, respectively labeled、/>、/>、/>、/>/>Spheroidization data including melting temperature, spheroidization temperature, stirrer rotation speed, spheroidization temperature fluctuation value and holding time are respectively marked as/>、/>、/>、/>The casting data includes casting time, mold volume, mold pre-heat temperature, mold cool temperature, and casting volume, respectively labeled/>、/>、/>、/>/>Where i=1, 2 … … n, i denotes the i-th detection sub-region.
Preferably, the spheroidizing data preprocessing module calculates the heating rate of the ith detection subarea through the initial furnace temperature of the ith detection subarea, the smelting temperature of the ith detection subarea and the smelting time of the ith detection subarea, and the specific mathematical formula is as follows: the smelting rate of the ith detection subarea is calculated by the initial material mass of the ith detection subarea and the final material mass of the ith detection subarea, and a specific mathematical formula is as follows: calculating the material superheat degree of the ith detection subarea according to the smelting temperature of the ith detection subarea and the material liquidus temperature of the ith detection subarea, wherein a specific mathematical formula is as follows: /(I) Calculating the adding amount of the spheroidizing agent of the ith detection subarea according to the smelting temperature of the ith detection subarea and the spheroidizing temperature of the ith detection subarea, wherein the specific mathematical formula is as follows: /(I)Wherein/>The proportional constant is represented, the temperature fluctuation rate of the ith detection subarea is calculated through the spheroidizing temperature fluctuation value of the ith detection subarea and the heat preservation time of the ith detection subarea, and a specific mathematical formula is as follows: /(I)Calculating the pouring speed of the ith detection subarea according to the pouring time of the ith detection subarea and the die volume of the ith detection subarea, wherein a specific mathematical formula is as follows: /(I)The cooling rate of the ith detection subarea is calculated through the pouring time of the ith detection subarea, the mould preheating temperature of the ith detection subarea and the mould cooling temperature of the ith detection subarea, and the specific mathematical formula is as follows: /(I)Calculating the shrinkage rate of the casting of the ith detection subarea according to the mould volume of the ith detection subarea and the casting volume of the ith detection subarea, wherein a specific mathematical formula is as follows: /(I)。
Preferably, the smelting data analysis unit is configured to establish a smelting data analysis model, and the specific mathematical model is:，/> Smelting quality assessment value representing the i-th detection sub-region,/> Indicating the heating rate of the ith detection sub-region,/>Representing the smelting rate of the ith detection sub-zone,/>Indicating the material superheat of the ith detection sub-region,/>Other influencing factors representing the smelting quality assessment value.
Preferably, the spheroidizing data analysis unit is configured to establish a spheroidizing data analysis model, and the specific mathematical model is:，/> Spheroidization quality evaluation value representing the i-th detection subarea,/> Indicating the spheroidizing agent addition amount of the ith detection subarea,/>Representing the maximum value of the temperature fluctuation rate,/>Representing the stirring speed of the ith detection sub-region,/>Other influencing factors representing the spheroidization quality assessment value.
Preferably, the pouring data analysis unit is configured to build a pouring data analysis model, and the specific mathematical model is:，/> casting quality evaluation value representing the i-th detection subarea,/> Representing the casting speed of the ith detection subarea,/>Representing the cooling rate of the ith detection sub-region,/>Representing the shrinkage of the casting in the ith detection zone,/>Other influencing factors representing casting quality evaluation values.
Preferably, the spheroidization effect data comprises spheroidization rate, graphite sphere size, matrix hardness and spheroidization element content, which are respectively marked as、/>、/>/>Where i=1, 2 … … n, i denotes the i-th detection sub-region.
Preferably, the spheroidizing effect data analysis model specifically represents:，/> Evaluation value of spheroidization effect indicating the i-th detection subregion,/> Representing the spheroidization rate of the ith detection subarea,/>Graphite nodule size representing the ith detection sub-region,/>Matrix hardness representing the i-th detection sub-region,/>Representing the spheroidization element content of the ith detection subarea,/>Represents the maximum value of matrix hardness,/>Representing the minimum value of matrix hardness,/>Other influencing factors representing the evaluation value of the spheroidization effect.
Preferably, the comprehensive analysis model is specifically expressed as:，/> Comprehensive optimization index representing the ith detection subregion,/> Evaluation value of spheroidization effect indicating the i-th detection subregion,/>Smelting quality assessment value representing the i-th detection sub-region,/>Spheroidization quality evaluation value representing the i-th detection subarea,/>Evaluation value of spheroidization effect indicating the i-th detection subregion,/>Other influencing factors representing the integrated optimization index.
Preferably, the integrated optimization index target value is marked asWhen/>When the comprehensive optimization index of the ith detection subarea is larger than the target value of the comprehensive optimization index, the casting spheroidization temperature control effect of the ith detection subarea is good, the data acquisition and analysis of spheroidization and spheroidization effect are kept, and when/>And when the comprehensive optimization index of the ith detection subarea is smaller than the target value of the comprehensive optimization index, the fact that the casting spheroidization temperature control effect of the ith detection subarea is poor is indicated, and then a detection report is generated and an early warning signal is sent out according to the spheroidization treatment and spheroidization effect data of the ith detection subarea.
The invention has the technical effects and advantages that:
According to the invention, a detection area dividing module is used for dividing a target pouring spheroidizing process plant into detection subareas and numbering the detection subareas, a spheroidizing data acquisition module is used for acquiring smelting data, spheroidizing data and pouring data of the detection subareas, a spheroidizing data preprocessing module is used for preprocessing data transmitted by the spheroidizing data acquisition module, a spheroidizing data analysis module is used for analyzing the data transmitted by the spheroidizing data preprocessing module, a spheroidizing effect data acquisition module is used for acquiring spheroidizing effect data of the detection subareas, a spheroidizing effect evaluation value of the detection subareas is calculated by a spheroidizing effect data analysis module, a comprehensive optimization index of the detection subareas is calculated by a comprehensive analysis module, a control module is used for judging the comprehensive optimization index of the ith detection subarea, and a control signal is sent according to a judgment result;
The invention can monitor the temperature in the casting spheroidization process in real time, thereby ensuring the stability and consistency of the spheroidization quality, not only avoiding the quality problem caused by overhigh or overlow temperature, but also improving the production efficiency, reducing the production cost, collecting and comprehensively analyzing the data from multiple aspects, realizing the comprehensive monitoring and intelligent control of the casting spheroidization process, reducing the difficulty and error of manual operation, improving the automation level of the production process, saving a large amount of human resources for enterprises, and realizing the accurate control of the casting spheroidization process, thereby improving the production efficiency and the product quality. This not only enhances the market competitiveness of the enterprise, but also provides a better quality product experience for the consumer.
Drawings
Fig. 1 is a schematic diagram of the overall structure of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The detection control system for casting spheroidization temperature control shown in reference to fig. 1 comprises a detection area dividing module, a spheroidization data acquisition module, a spheroidization data preprocessing module, a spheroidization data analysis module, a spheroidization effect data acquisition module, a spheroidization effect data analysis module, a comprehensive analysis module and a control module.
The detection region dividing module is used for determining a target casting spheroidizing processing plant as a target detection region, dividing the target detection region into detection subregions according to a spheroidizing dividing method of a single casting, and marking the detection subregions as 1 and 2 … … n in sequence.
The spheroidizing data acquisition module is used for acquiring smelting data, spheroidizing data and pouring data of each detection subarea and transmitting the acquired data to the spheroidizing data preprocessing module.
The smelting data includes smelting time, initial material mass, final material mass, initial furnace temperature, smelting temperature and material liquidus temperature, respectively marked as、/>、/>、/>、/>/>Spheroidization data including melting temperature, spheroidization temperature, stirrer rotation speed, spheroidization temperature fluctuation value and holding time are respectively marked as/>、/>、/>、/>AndThe casting data includes casting time, mold volume, mold pre-heat temperature, mold cool temperature, and casting volume, respectively labeled/>、/>、/>、/>/>Where i=1, 2 … … n, i denotes the i-th detection sub-region.
The spheroidizing data preprocessing module is used for preprocessing smelting data, spheroidizing data and pouring data transmitted by the spheroidizing data acquisition module and transmitting the processed data to the spheroidizing data analysis module.
The spheroidizing data preprocessing module calculates the heating rate of the ith detection subarea through the initial furnace temperature of the ith detection subarea, the smelting temperature of the ith detection subarea and the smelting time of the ith detection subarea, and the specific mathematical formula is as follows: the smelting rate of the ith detection subarea is calculated by the initial material mass of the ith detection subarea and the final material mass of the ith detection subarea, and a specific mathematical formula is as follows: /(I) Calculating the material superheat degree of the ith detection subarea according to the smelting temperature of the ith detection subarea and the material liquidus temperature of the ith detection subarea, wherein a specific mathematical formula is as follows: /(I)Calculating the adding amount of the spheroidizing agent of the ith detection subarea according to the smelting temperature of the ith detection subarea and the spheroidizing temperature of the ith detection subarea, wherein the specific mathematical formula is as follows: Wherein/> The proportional constant is represented, the temperature fluctuation rate of the ith detection subarea is calculated through the spheroidizing temperature fluctuation value of the ith detection subarea and the heat preservation time of the ith detection subarea, and a specific mathematical formula is as follows: Calculating the pouring speed of the ith detection subarea according to the pouring time of the ith detection subarea and the die volume of the ith detection subarea, wherein a specific mathematical formula is as follows: /(I) The cooling rate of the ith detection subarea is calculated through the pouring time of the ith detection subarea, the mould preheating temperature of the ith detection subarea and the mould cooling temperature of the ith detection subarea, and the specific mathematical formula is as follows: /(I)Calculating the shrinkage rate of the casting of the ith detection subarea according to the mould volume of the ith detection subarea and the casting volume of the ith detection subarea, wherein a specific mathematical formula is as follows:。
The smelting data processed by the spheroidizing data preprocessing module comprises a heating rate, a smelting rate and a material superheat degree, and are respectively marked as 、/>/>Spheroidization data including spheroidizer addition, temperature fluctuation rate, and stirring speed are respectively marked as/>、/>/>Casting data including casting speed, cooling rate, and casting shrinkage, respectively labeled/>、/>/>Where i=1, 2 … … n, i denotes the i-th detection sub-region.
The spheroidizing data analysis module comprises a smelting data analysis unit, a spheroidizing data analysis unit and a pouring data analysis unit, and is used for analyzing the data transmitted by the spheroidizing data preprocessing module and transmitting the analysis result to the comprehensive analysis module.
The smelting data analysis unit is used for establishing a smelting data analysis model, and the specific mathematical model is as follows:，/> Smelting quality assessment value representing the i-th detection sub-region,/> Indicating the heating rate of the ith detection sub-region,/>Representing the smelting rate of the ith detection sub-zone,/>Indicating the material superheat of the ith detection sub-region,/>Other influencing factors representing the smelting quality assessment value.
The spheroidization data analysis unit is used for establishing a spheroidization data analysis model, and the specific mathematical model is as follows:，/> Spheroidization quality evaluation value representing the i-th detection subarea,/> Indicating the spheroidizing agent addition amount of the ith detection subarea,/>Representing the maximum value of the temperature fluctuation rate,/>Representing the stirring speed of the ith detection sub-region,/>Other influencing factors representing the spheroidization quality assessment value.
The pouring data analysis unit is used for establishing a pouring data analysis model, and the concrete mathematical model is as follows:，/> casting quality evaluation value representing the i-th detection subarea,/> Representing the casting speed of the ith detection subarea,/>Representing the cooling rate of the ith detection sub-region,/>Representing the shrinkage of the casting in the ith detection zone,/>Other influencing factors representing casting quality evaluation values.
The spheroidizing effect data acquisition module is used for acquiring spheroidizing effect data of each detection subarea and transmitting the acquired data to the spheroidizing effect data analysis module.
The spheroidization effect data comprise spheroidization rate, graphite sphere size, matrix hardness and spheroidization element content, which are respectively marked as、/>、/>/>Where i=1, 2 … … n, i denotes the i-th detection sub-region.
The spheroidizing effect data analysis module is used for establishing a spheroidizing effect data analysis model, importing the data transmitted by the spheroidizing effect data acquisition module into the spheroidizing effect data analysis model, calculating spheroidizing effect evaluation values of all detection subareas, and transmitting the spheroidizing effect evaluation values to the comprehensive analysis module.
The spheroidizing effect data analysis model specifically comprises the following steps:， Evaluation value of spheroidization effect indicating the i-th detection subregion,/> Representing the spheroidization rate of the ith detection subarea,/>Graphite nodule size representing the ith detection sub-region,/>Matrix hardness representing the i-th detection sub-region,/>Representing the spheroidization element content of the ith detection subarea,/>Represents the maximum value of matrix hardness,/>Representing the minimum value of matrix hardness,/>Other influencing factors representing the evaluation value of the spheroidization effect.
The comprehensive analysis module is used for establishing a comprehensive analysis model, importing the data transmitted by the spheroidizing data analysis module and the spheroidizing effect data analysis module into the comprehensive analysis model, calculating the comprehensive optimization index of each detection subarea, and transmitting the comprehensive optimization index to the control module.
The comprehensive analysis model is specifically expressed as:，/> Comprehensive optimization index representing the ith detection subregion,/> Evaluation value of spheroidization effect indicating the i-th detection subregion,/>Smelting quality assessment value representing the i-th detection sub-region,/>Spheroidization quality evaluation value representing the i-th detection subarea,/>Evaluation value of spheroidization effect indicating the i-th detection subregion,/>Other influencing factors representing the integrated optimization index.
The control module is used for judging the comprehensive optimization index of the ith detection subarea according to the comprehensive optimization index target value and sending out a control signal according to a judgment result.
The comprehensive optimization index target value is marked asWhen/>When the comprehensive optimization index of the ith detection subarea is larger than the target value of the comprehensive optimization index, the casting spheroidization temperature control effect of the ith detection subarea is good, the data acquisition and analysis of spheroidization and spheroidization effect are kept, and when/>And when the comprehensive optimization index of the ith detection subarea is smaller than the target value of the comprehensive optimization index, the fact that the casting spheroidization temperature control effect of the ith detection subarea is poor is indicated, and then a detection report is generated and an early warning signal is sent out according to the spheroidization treatment and spheroidization effect data of the ith detection subarea.
According to the invention, a target pouring spheroidizing processing plant is divided into detection subareas and numbered by a detection area dividing module, smelting data, spheroidizing data and pouring data of the detection subareas are collected by a spheroidizing data collecting module, data transmitted by the spheroidizing data collecting module are preprocessed by a spheroidizing data preprocessing module, data transmitted by the spheroidizing data preprocessing module are analyzed by a spheroidizing data analyzing module, spheroidizing effect data of the detection subareas are collected by a spheroidizing effect data collecting module, spheroidizing effect evaluation values of the detection subareas are calculated by a spheroidizing effect data analyzing module, comprehensive optimization indexes of the detection subareas are calculated by a comprehensive analyzing module, the comprehensive optimization indexes of the ith detection subarea are judged by a control module, and a control signal is sent according to a judgment result.
The invention can monitor the temperature in the casting spheroidization process in real time, thereby ensuring the stability and consistency of the spheroidization quality, not only avoiding the quality problem caused by overhigh or overlow temperature, but also improving the production efficiency, reducing the production cost, collecting and comprehensively analyzing the data from multiple aspects, realizing the comprehensive monitoring and intelligent control of the casting spheroidization process, reducing the difficulty and error of manual operation, improving the automation level of the production process, saving a large amount of human resources for enterprises, and realizing the accurate control of the casting spheroidization process, thereby improving the production efficiency and the product quality. This not only enhances the market competitiveness of the enterprise, but also provides a better quality product experience for the consumer.
Secondly: in the drawings of the disclosed embodiments, only the structures related to the embodiments of the present disclosure are referred to, and other structures can refer to the common design, so that the same embodiment and different embodiments of the present disclosure can be combined with each other under the condition of no conflict;
Finally: the foregoing description of the preferred embodiments of the invention is not intended to limit the invention to the precise form disclosed, and any such modifications, equivalents, and alternatives falling within the spirit and principles of the invention are intended to be included within the scope of the invention.
Claims (4)
1. The utility model provides a pour detection control system of spheroidization accuse temperature which characterized in that includes:
the detection area dividing module: the method comprises the steps of determining a target pouring spheroidizing process plant as a target detection area, dividing the target detection area into detection subareas according to a spheroidizing method of a single casting, and marking the detection subareas as 1 and 2 … … n in sequence;
spheroidizing data acquisition module: the system comprises a smelting data preprocessing module, a spheroidizing data preprocessing module and a pouring data preprocessing module, wherein the smelting data preprocessing module is used for acquiring smelting data, spheroidizing data and pouring data of each detection subarea;
The smelting data includes smelting time, initial material mass, final material mass, initial furnace temperature, smelting temperature and material liquidus temperature, respectively marked as 、/>、/>、/>、/>/>Spheroidization data including melting temperature, spheroidization temperature, stirrer rotation speed, spheroidization temperature fluctuation value and holding time are respectively marked as/>、/>、/>、/>AndThe casting data includes casting time, mold volume, mold pre-heat temperature, mold cool temperature, and casting volume, respectively labeled/>、/>、/>、/>/>Where i=1, 2 … … n, i represents the i-th detection sub-region;
spheroidizing data preprocessing module: the spheroidizing data processing module is used for preprocessing smelting data, spheroidizing data and pouring data transmitted by the spheroidizing data acquisition module and transmitting the processed data to the spheroidizing data analysis module;
Spheroidizing data analysis module: the system comprises a smelting data analysis unit, a spheroidizing data analysis unit and a pouring data analysis unit, wherein the smelting data analysis unit, the spheroidizing data analysis unit and the pouring data analysis unit are used for analyzing the data transmitted by the spheroidizing data preprocessing module and transmitting analysis results to the comprehensive analysis module;
the smelting data analysis unit is used for establishing a smelting data analysis model, and the specific mathematical model is as follows: ，/> Smelting quality assessment value representing the i-th detection sub-region,/> Indicating the heating rate of the ith detection sub-region,/>Representing the smelting rate of the ith detection sub-zone,/>Indicating the material superheat of the ith detection sub-region,/>Other influencing factors representing the smelting quality assessment value;
the spheroidization data analysis unit is used for establishing a spheroidization data analysis model, and the specific mathematical model is as follows: ，/> Spheroidization quality evaluation value representing the i-th detection subarea,/> Indicating the spheroidizing agent addition amount of the ith detection subarea,/>Representing the maximum value of the temperature fluctuation rate,/>Representing the stirring speed of the ith detection sub-region,/>Other influencing factors representing the spheroidization quality assessment value;
the pouring data analysis unit is used for establishing a pouring data analysis model, and the concrete mathematical model is as follows: ，/> representing the casting quality evaluation value of the i-th detection sub-area, Representing the casting speed of the ith detection subarea,/>Representing the cooling rate of the ith detection sub-region,/>Representing the shrinkage of the casting in the ith detection zone,/>Other influencing factors representing casting quality evaluation values;
the spheroidizing effect data acquisition module: the spheroidizing device is used for collecting spheroidizing effect data of each detection subarea and transmitting the collected data to a spheroidizing effect data analysis module;
And the spheroidizing effect data analysis module is used for: the spheroidizing effect data analysis module is used for establishing a spheroidizing effect data analysis model, importing the data transmitted by the spheroidizing effect data acquisition module into the spheroidizing effect data analysis model, calculating spheroidizing effect evaluation values of all detection subareas, and transmitting the spheroidizing effect evaluation values to the comprehensive analysis module;
The spheroidizing effect data analysis model specifically comprises the following steps: ，/> Evaluation value of spheroidization effect indicating the i-th detection subregion,/> Representing the spheroidization rate of the ith detection subarea,/>Graphite nodule size representing the ith detection sub-region,/>Matrix hardness representing the i-th detection sub-region,/>Representing the spheroidization element content of the ith detection subarea,/>Represents the maximum value of matrix hardness,/>Representing the minimum value of matrix hardness,/>Other influencing factors representing the spheroidization effect evaluation value;
and the comprehensive analysis module is used for: the comprehensive analysis module is used for establishing a comprehensive analysis model, importing the data transmitted by the spheroidizing data analysis module and the spheroidizing effect data analysis module into the comprehensive analysis model, calculating the comprehensive optimization index of each detection subarea, and transmitting the comprehensive optimization index to the control module;
the comprehensive analysis model is specifically expressed as: ，/> Comprehensive optimization index representing the ith detection subregion,/> Evaluation value of spheroidization effect indicating the i-th detection subregion,/>Smelting quality assessment value representing the i-th detection sub-region,/>Spheroidization quality evaluation value representing the i-th detection subarea,/>Casting quality evaluation value representing the i-th detection subarea,/>Other influencing factors representing the integrated optimization index;
And the control module is used for: and the comprehensive optimization index detection module is used for judging the comprehensive optimization index of the ith detection subarea according to the comprehensive optimization index target value and sending out a control signal according to a judgment result.
2. The detection control system for casting spheroidization temperature control according to claim 1, wherein: the spheroidizing data preprocessing module calculates the heating rate of the ith detection subarea through the initial furnace temperature of the ith detection subarea, the smelting temperature of the ith detection subarea and the smelting time of the ith detection subarea, and the specific mathematical formula is as follows: the smelting rate of the ith detection subarea is calculated by the initial material mass of the ith detection subarea and the final material mass of the ith detection subarea, and a specific mathematical formula is as follows: /(I) Calculating the material superheat degree of the ith detection subarea according to the smelting temperature of the ith detection subarea and the material liquidus temperature of the ith detection subarea, wherein a specific mathematical formula is as follows: /(I)Calculating the adding amount of the spheroidizing agent of the ith detection subarea according to the smelting temperature of the ith detection subarea and the spheroidizing temperature of the ith detection subarea, wherein the specific mathematical formula is as follows: Wherein/> The proportional constant is represented, the temperature fluctuation rate of the ith detection subarea is calculated through the spheroidizing temperature fluctuation value of the ith detection subarea and the heat preservation time of the ith detection subarea, and a specific mathematical formula is as follows: Calculating the pouring speed of the ith detection subarea according to the pouring time of the ith detection subarea and the die volume of the ith detection subarea, wherein a specific mathematical formula is as follows: /(I) The cooling rate of the ith detection subarea is calculated through the pouring time of the ith detection subarea, the mould preheating temperature of the ith detection subarea and the mould cooling temperature of the ith detection subarea, and the specific mathematical formula is as follows: /(I)Calculating the shrinkage rate of the casting of the ith detection subarea according to the mould volume of the ith detection subarea and the casting volume of the ith detection subarea, wherein a specific mathematical formula is as follows: /(I)。
3. The detection control system for casting spheroidization temperature control according to claim 1, wherein: the spheroidization effect data comprise spheroidization rate, graphite sphere size, matrix hardness and spheroidization element content, which are respectively marked as、/>、/>/>Where i=1, 2 … … n, i denotes the i-th detection sub-region.
4. The detection control system for casting spheroidization temperature control according to claim 1, wherein: the comprehensive optimization index target value is marked as，/>Comprehensive optimization index representing the ith detection sub-region, when/>When the comprehensive optimization index of the ith detection subarea is larger than the target value of the comprehensive optimization index, the casting spheroidization temperature control effect of the ith detection subarea is good, the data acquisition and analysis of spheroidization and spheroidization effect are kept, and when/>And when the comprehensive optimization index of the ith detection subarea is smaller than the target value of the comprehensive optimization index, the fact that the casting spheroidization temperature control effect of the ith detection subarea is poor is indicated, and then a detection report is generated and an early warning signal is sent out according to the spheroidization treatment and spheroidization effect data of the ith detection subarea.
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