CN118091076A - Low sulfur survey monitoring system in nickel base superalloy - Google Patents
Low sulfur survey monitoring system in nickel base superalloy Download PDFInfo
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- 229910052717 sulfur Inorganic materials 0.000 title claims abstract description 207
- 239000011593 sulfur Substances 0.000 title claims abstract description 207
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 title claims abstract description 160
- 238000012544 monitoring process Methods 0.000 title claims abstract description 95
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 title claims abstract description 54
- 229910000601 superalloy Inorganic materials 0.000 title claims abstract description 28
- 229910052759 nickel Inorganic materials 0.000 title claims abstract description 27
- 238000003723 Smelting Methods 0.000 claims abstract description 125
- 238000000034 method Methods 0.000 claims abstract description 59
- 230000008569 process Effects 0.000 claims abstract description 56
- 238000004458 analytical method Methods 0.000 claims abstract description 44
- 238000011156 evaluation Methods 0.000 claims abstract description 22
- 239000000523 sample Substances 0.000 claims description 208
- 238000007405 data analysis Methods 0.000 claims description 84
- 230000004907 flux Effects 0.000 claims description 45
- 238000012545 processing Methods 0.000 claims description 45
- 238000005259 measurement Methods 0.000 claims description 42
- 238000005554 pickling Methods 0.000 claims description 41
- 238000013178 mathematical model Methods 0.000 claims description 27
- 229910045601 alloy Inorganic materials 0.000 claims description 26
- 239000000956 alloy Substances 0.000 claims description 26
- 239000012496 blank sample Substances 0.000 claims description 21
- 230000008859 change Effects 0.000 claims description 15
- 230000032683 aging Effects 0.000 claims description 9
- 239000002253 acid Substances 0.000 claims description 6
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 6
- 229910052760 oxygen Inorganic materials 0.000 claims description 6
- 239000001301 oxygen Substances 0.000 claims description 6
- 238000005406 washing Methods 0.000 claims description 6
- 238000002474 experimental method Methods 0.000 claims description 5
- 238000012795 verification Methods 0.000 claims description 5
- 238000001816 cooling Methods 0.000 claims description 3
- 230000007613 environmental effect Effects 0.000 claims description 3
- 125000000446 sulfanediyl group Chemical group *S* 0.000 claims description 3
- 230000002159 abnormal effect Effects 0.000 abstract description 11
- 230000000694 effects Effects 0.000 abstract description 2
- 239000003795 chemical substances by application Substances 0.000 description 4
- 230000007547 defect Effects 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 238000003908 quality control method Methods 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 229910052715 tantalum Inorganic materials 0.000 description 1
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 1
- 239000011573 trace mineral Substances 0.000 description 1
- 235000013619 trace mineral Nutrition 0.000 description 1
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Abstract
The invention discloses a low sulfur determination monitoring system in nickel-based superalloy, which particularly relates to the technical field of low sulfur monitoring. The invention provides comprehensive and accurate data support and analysis for the low-sulfur smelting process, effectively evaluates the comprehensive efficiency of the low-sulfur smelting, and in addition, the sulfur analyzer performance evaluation and early warning system can monitor the performance and sample treatment effect of the sulfur analyzer in real time, early warn abnormal conditions in time and improve the quality and efficiency of the smelting process.
Description
Technical Field
The invention relates to the technical field of low-sulfur monitoring, in particular to a system for measuring and monitoring low sulfur in nickel-based superalloy.
Background
The nickel-base superalloy is a special alloy, is composed of nickel, chromium, molybdenum, tantalum, iron, aluminum and other elements, has extremely high heat resistance, oxidation resistance and corrosion resistance, and sulfur content is an important quality control index in the production process of the nickel-base superalloy, and the existence of sulfur element can negatively influence the performance of the alloy, such as reducing the corrosion resistance and oxidation resistance of the alloy and affecting the high-temperature strength and stability of the alloy, so that the sulfur content in the nickel-base superalloy is extremely important to the accurate determination.
The existing nickel-based superalloy medium-low sulfur determination monitoring system realizes accurate determination and monitoring of sulfur content in alloy through a series of steps, firstly, the system collects alloy samples and performs pretreatment to ensure sample uniformity and analysis accuracy, then, an analysis instrument is used for determining the sulfur content of the samples, related data is recorded and stored in real time, in a data analysis link, the system performs statistical processing and quality control judgment on the collected data to ensure that the sulfur content meets the standard, finally, the system generates an exhaustive report, displays analysis results in a chart form, and provides decision support for production management personnel.
However, when the method is actually used, some defects still exist, such as that the existing low-sulfur determination monitoring system in the nickel-based superalloy only focuses on the determination of sulfur content, but omits the analysis of other trace elements or impurities which can affect the alloy performance, so that the result of data analysis is not comprehensive and accurate enough, the existing algorithm can not fully extract and utilize useful information in the data processing and analysis stage, so that the analysis result has deviation, and in addition, the algorithm can not fully consider the change characteristics of the alloy sulfur content under different batches and different process conditions, so that the fluctuation of the sulfur content can not be accurately predicted and controlled, and the existing system lacks an intelligent data processing and early warning mechanism.
Disclosure of Invention
In order to overcome the above-mentioned drawbacks of the prior art, an embodiment of the present invention provides a system for measuring and monitoring low sulfur in a nickel-based superalloy, 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 nickel-based superalloy medium low sulfur determination monitoring system comprising:
Monitoring a sample dividing module: the method is used for dividing the nickel-based superalloy to be monitored into monitoring samples according to the mode of dividing the monitoring samples, and sequentially marking the nickel-based superalloy as 1 and 2 … … n;
The smelting process data acquisition module: the system comprises a flux data acquisition module, a smelting process data analysis module, a blank value data acquisition module and a smelting condition data acquisition module, wherein the flux data acquisition module is used for acquiring flux data, blank value data and smelting condition data of each monitoring sample;
a smelting process data analysis module: the smelting process data acquisition module is used for acquiring smelting process data, and the smelting process data acquisition module is used for acquiring smelting process data of each monitored sample;
Sample processing data acquisition module: the system comprises a sample processing data analysis module, a sample processing data acquisition module, a sample processing data analysis module and a sample processing data analysis module, wherein the sample processing module is used for acquiring pickling processing data, sulfur content measurement data and equipment performance data of each monitoring sample;
Sample processing data analysis module: the system comprises an acid washing data analysis unit, a sulfur content measurement data analysis unit and a device performance data analysis unit, wherein each analysis unit is used for establishing a corresponding mathematical model, importing data transmitted by a sample processing data acquisition module into the corresponding analysis unit, calculating the acid washing efficiency coefficient, the sulfur content measurement environment calibration coefficient and the sulfur analyzer accuracy of each monitoring sample, and transmitting the data to a comprehensive low-sulfur analysis module;
And (3) a comprehensive low-sulfur analysis module: the system is used for establishing a comprehensive low-sulfur analysis model, importing data transmitted by a smelting process data analysis module and a sample processing data analysis module into the comprehensive low-sulfur analysis model, calculating a comprehensive low-sulfur evaluation value of each monitoring sample, and transmitting the comprehensive low-sulfur evaluation value to an early warning module;
And the early warning module is used for: and the comprehensive low-sulfur evaluation value judgment module is used for judging the comprehensive low-sulfur evaluation value of each monitoring sample according to the comprehensive low-sulfur early warning value and sending an early warning signal according to a judgment result.
Preferably, the flux data comprises the sulfur content of the flux, the flux usage amount, the mixing proportion of the flux and the nickel-based alloy, the temperature when the flux is added, and the sulfur content change of the nickel-based alloy after the addition of the flux, which are respectively marked as、、/>、/>And/>The blank value data comprises blank sample sulfur content, blank sample processing temperature, blank sample storage environment humidity and blank value measuring instrument reading, which are respectively marked as/>、/>、/>And/>The smelting condition data comprise smelting temperature, smelting time, oxygen content in the smelting process and time required for the nickel-base alloy to be cooled to room temperature after smelting, which are respectively marked as/>、/>、/>And/>。
Preferably, the flux data analysis unit is configured to establish a flux data analysis model, and the specific mathematical model is:，/> Represents the fluxing sulfur control coefficient of the ith monitored sample,/> Represents the flux sulfur content of the ith monitored sample,/>Indicating the flux usage of the ith monitored sample,Indicating the mixing ratio of the flux and the nickel-based alloy of the ith monitoring sample,/>Represents the temperature at which flux of the ith monitored sample was added,/>Indicating the change in sulfur content of the nickel-base alloy after flux addition for the ith monitored sample.
Preferably, the blank value data analysis unit is configured to establish a blank value data analysis model, and the specific mathematical model is:，/> represents blank thio value of ith monitored sample,/> Represents the blank sulfur content of the ith monitored sample,/>Blank sample processing temperature representing the ith monitored sample,/>Blank sample storage ambient humidity representing the ith monitored sample,/>Blank value measuring instrument reading representing the ith monitored sample,/>Represents the maximum value of sulfur content of blank sample of each monitoring sample,/>The minimum sulfur content of the blank sample for each monitored sample is shown.
Preferably, the smelting condition data analysis unit is used for establishing a smelting condition data analysis model, and the specific mathematical model is as follows:，/> representing the smelting ageing coefficient of the ith monitoring sample,/> Representing the smelting temperature of the jth smelting time zone of the ith monitored sample,/>Represents the smelting time of the ith monitoring sample,/>Represents the oxygen content in the smelting process of the jth smelting time zone of the ith monitoring sample,The time required for cooling the nickel-base alloy to room temperature after smelting of the ith monitoring sample is represented, j represents the jth smelting time zone, the smelting time of each monitoring sample is divided into each smelting time zone by means of equal time division, and j=1 and 2 … … m.
Preferably, the smelting process data analysis module calculates a low-sulfur smelting comprehensive efficiency value of the ith monitored sample through a fluxing sulfur control coefficient of the ith monitored sample, a blank sulfur base value of the ith monitored sample and a smelting aging coefficient of the ith monitored sample, and the specific mathematical model is as follows: wherein/> Other influencing factors representing the overall efficacy value of low sulfur smelting.
Preferably, the pickling data comprise pickling solution concentration, pickling temperature, sample weight change after pickling, and pickling treatment time, which are respectively marked as、/>、/>And/>The sulfur content measurement data includes sulfur analyzer measurement value, standard value at the time of sulfur analyzer calibration, room temperature at the time of measurement, and relative humidity at the time of measurement, which are respectively labeled as/>、/>、And/>The equipment performance data includes the sulfur content of the standard sample in the verification experiment and the measurement value of the sulfur analyzer on the standard sample, which are respectively marked as/>And/>。
Preferably, the pickling data analysis unit is configured to establish a pickling data analysis model, and the specific mathematical model is:，/> represents the pickling efficiency coefficient of the ith monitored sample,/> Represents the concentration of pickling solution of the ith monitored sample,/>Indicating the pickling temperature of the ith monitored sample,Indicating the change in sample weight after pickling of the ith monitored sample,/>The pickling treatment time of the ith monitored sample is shown.
Preferably, the sulfur content measurement data analysis unit is used for establishing a sulfur content measurement data analysis model, and the specific mathematical model is as follows:，/> Represents the sulfur content determination environmental calibration coefficient of the ith monitored sample,/> Represents the sulfur analyzer measurement value of the ith monitored sample,/>Represents the standard value of the ith monitored sample when the sulfur analyzer is calibrated,/>The room temperature at the time of measurement of the ith monitoring sample is shown,Indicating the relative humidity at the time of measurement of the ith monitored sample.
Preferably, the device performance data analysis unit is configured to build a device performance data analysis model, and the specific mathematical model is:，/> representing sulfur analyzer accuracy,/> Represents the sulfur content of a standard sample in a verification experiment,/>The measurement value of the sulfur analyzer on the standard sample is shown.
Preferably, the sample processing data analysis module calculates a sample processing sulfur analysis coefficient of the ith monitored sample through the pickling efficiency coefficient of the ith monitored sample, the sulfur content measurement environment calibration coefficient of the ith monitored sample and the accuracy of the sulfur analyzer, and the specific mathematical model is as follows: wherein/> Other influencing factors representing the sample processing sulfur analysis coefficients.
Preferably, the comprehensive low-sulfur analysis model is specifically expressed as:，/> Comprehensive low sulfur evaluation value representing the ith monitored sample,/> Indicating the low sulfur smelting integrated efficiency value of the ith monitored sample,Sample treatment Sulfur analysis coefficient representing the ith monitoring sample,/>The weight of the low-sulfur smelting comprehensive efficiency value is expressed,Weights representing sample treatment Sulfur analysis coefficients,/>Other influencing factors representing the integrated low sulfur evaluation value.
Preferably, the comprehensive low-sulfur early warning value is marked asWhen/>When the comprehensive low-sulfur evaluation value of the ith monitoring sample is smaller than the comprehensive low-sulfur early warning value, the fact that the ith monitoring sample does not have an abnormal condition is indicated, monitoring on each monitoring sample is kept, and when/>And when the comprehensive low-sulfur evaluation value of the ith monitored sample is larger than the comprehensive low-sulfur early warning value, indicating that the ith monitored sample is abnormal, marking the ith monitored sample as an abnormal state and sending out an early warning signal.
The invention has the technical effects and advantages that:
According to the invention, the nickel-based superalloy to be monitored is divided into a plurality of monitoring samples through the monitoring sample dividing module and is marked in sequence, so that the sulfur content of each sample can be accurately monitored, the sample can be fully concerned and accurately analyzed, meanwhile, the marked sample is convenient for subsequent data acquisition, processing and analysis, and the working efficiency and accuracy are improved; various data in the smelting process, including fluxing agent data, blank value data and smelting condition data, can be comprehensively acquired through the smelting process data acquisition module, the acquisition of the data is helpful for deeply knowing the change condition of the sulfur content in the smelting process, rich data support is provided for subsequent data analysis, and the influence of the smelting process on the sulfur content can be more accurately evaluated through accurate data acquisition, so that the smelting process is optimized, and the product quality is improved; the mathematical model is built through the smelting process data analysis module, the collected smelting process data is deeply analyzed, the fluxing sulfur control coefficient, blank sulfur base value and smelting aging coefficient of each monitoring sample can be calculated, the control condition of the sulfur content in the smelting process can be reflected, the problems in the smelting process can be found out in time, a scientific basis is provided for optimizing the smelting process, meanwhile, the data analysis result can be used for an early warning module, timely early warning of abnormal sulfur content is realized, and the quality safety of products is ensured; the early warning module can timely early warn the abnormal situation of the sulfur content according to the result of the smelting process data analysis module, and when the sulfur content is monitored to exceed the preset threshold value, the early warning module can give an alarm to remind operators to take corresponding measures, so that potential quality problems can be found and processed in time, and product defects or potential safety hazards caused by the fact that the sulfur content is too high are avoided.
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 system for measuring and monitoring the low sulfur in the nickel-based superalloy comprises a monitoring sample dividing module, a smelting process data acquisition module, a smelting process data analysis module, a sample processing data acquisition module, a sample processing data analysis module, a comprehensive low sulfur analysis module and an early warning module.
The monitoring sample dividing module is used for dividing the nickel-based superalloy to be monitored into all monitoring samples according to the mode of dividing the monitoring samples, and the monitoring samples are marked as 1 and 2 … … n in sequence.
The smelting process data acquisition module is used for acquiring the fluxing agent data, the blank value data and the smelting condition data of each monitoring sample, and transmitting the acquired data to the smelting process data analysis module.
The flux data comprises the sulfur content of the flux, the using amount of the flux, the mixing proportion of the flux and the nickel-based alloy, the temperature when the flux is added, and the sulfur content change of the nickel-based alloy after the addition of the flux, which are respectively marked as、/>、、/>And/>The blank value data comprises blank sample sulfur content, blank sample processing temperature, blank sample storage environment humidity and blank value measuring instrument reading, which are respectively marked as/>、/>、/>And/>The smelting condition data comprise smelting temperature, smelting time, oxygen content in the smelting process and time required for the nickel-base alloy to be cooled to room temperature after smelting, which are respectively marked as/>、/>、/>And/>。
The smelting process data analysis module comprises a fluxing agent data analysis unit, a blank value data analysis unit and a smelting condition data analysis unit, wherein each analysis unit is used for establishing a corresponding mathematical model, importing data transmitted by the smelting process data acquisition module into the corresponding analysis unit, calculating fluxing sulfur control coefficients, blank sulfur base values and smelting aging coefficients of each monitoring sample, and transmitting the fluxing sulfur control coefficients, the blank sulfur base values and the smelting aging coefficients to the comprehensive low-sulfur analysis module.
The flux data analysis unit is used for establishing a flux data analysis model, and the specific mathematical model is as follows:，/> indicating the fluxing sulfur control coefficient of the ith monitored sample, Represents the flux sulfur content of the ith monitored sample,/>Represents the flux usage of the ith monitored sample,/>Indicating the mixing ratio of the flux and the nickel-based alloy of the ith monitoring sample,/>Represents the temperature at which flux of the ith monitored sample was added,/>Indicating the change in sulfur content of the nickel-base alloy after flux addition for the ith monitored sample.
The blank value data analysis unit is used for establishing a blank value data analysis model, and the specific mathematical model is as follows:，/> represents blank thio value of ith monitored sample,/> Represents the blank sulfur content of the ith monitored sample,/>Blank sample processing temperature representing the ith monitored sample,/>Blank sample storage ambient humidity representing the ith monitored sample,/>Blank value measuring instrument reading representing the ith monitored sample,/>Represents the maximum value of sulfur content of blank sample of each monitoring sample,/>The minimum sulfur content of the blank sample for each monitored sample is shown.
The smelting condition data analysis unit is used for establishing a smelting condition data analysis model, and the specific mathematical model is as follows:，/> representing the smelting ageing coefficient of the ith monitoring sample,/> Representing the smelting temperature of the jth smelting time zone of the ith monitored sample,/>Represents the smelting time of the ith monitoring sample,/>Represents the oxygen content in the smelting process of the jth smelting time zone of the ith monitoring sample,/>The time required for cooling the nickel-base alloy to room temperature after smelting of the ith monitoring sample is represented, j represents the jth smelting time zone, the smelting time of each monitoring sample is divided into each smelting time zone by means of equal time division, and j=1 and 2 … … m.
The smelting process data analysis module calculates a low-sulfur smelting comprehensive efficiency value of the ith monitoring sample through a fluxing sulfur control coefficient of the ith monitoring sample, a blank sulfur base value of the ith monitoring sample and a smelting aging coefficient of the ith monitoring sample, and the specific mathematical model is as follows: wherein/> Other influencing factors representing the overall efficacy value of low sulfur smelting.
The sample processing data acquisition module is used for acquiring pickling processing data, sulfur content measurement data and equipment performance data of each monitoring sample, and transmitting the acquired data to the sample processing data analysis module.
The pickling data comprise pickling solution concentration, pickling temperature, sample weight change after pickling and pickling treatment time, which are respectively marked as、/>、/>And/>The sulfur content measurement data includes sulfur analyzer measurement value, standard value at the time of sulfur analyzer calibration, room temperature at the time of measurement, and relative humidity at the time of measurement, which are respectively labeled as/>、/>、/>A kind of electronic deviceThe equipment performance data includes the sulfur content of the standard sample in the verification experiment and the measurement value of the sulfur analyzer on the standard sample, which are respectively marked as/>And/>。
The sample processing data analysis module comprises an acid washing data analysis unit, a sulfur content measurement data analysis unit and an equipment performance data analysis unit, wherein each analysis unit is used for establishing a corresponding mathematical model, importing data transmitted by the sample processing data acquisition module into the corresponding analysis unit, calculating the acid washing efficiency coefficient, the sulfur content measurement environment calibration coefficient and the sulfur analyzer accuracy of each monitoring sample, and transmitting the data to the comprehensive low-sulfur analysis module.
The pickling data analysis unit is used for establishing a pickling data analysis model, and the specific mathematical model is as follows:，/> represents the pickling efficiency coefficient of the ith monitored sample,/> Represents the concentration of pickling solution of the ith monitored sample,/>Indicating the pickling temperature of the ith monitored sample,Indicating the change in sample weight after pickling of the ith monitored sample,/>The pickling treatment time of the ith monitored sample is shown.
The sulfur content measurement data analysis unit is used for establishing a sulfur content measurement data analysis model, and the specific mathematical model is as follows:，/> Represents the sulfur content determination environmental calibration coefficient of the ith monitored sample,/> Represents the sulfur analyzer measurement value of the ith monitored sample,/>Represents the standard value of the ith monitored sample when the sulfur analyzer is calibrated,/>Room temperature at the time of measurement representing the ith monitoring sample,/>Indicating the relative humidity at the time of measurement of the ith monitored sample.
The equipment performance data analysis unit is used for establishing an equipment performance data analysis model, and the specific mathematical model is as follows:，/> representing sulfur analyzer accuracy,/> Represents the sulfur content of a standard sample in a verification experiment,/>The measurement value of the sulfur analyzer on the standard sample is shown.
The sample processing data analysis module calculates a sample processing sulfur analysis coefficient of the ith monitored sample through the pickling efficiency coefficient of the ith monitored sample, the sulfur content measurement environment calibration coefficient of the ith monitored sample and the accuracy of a sulfur analyzer, and the specific mathematical model is as follows: wherein/> Other influencing factors representing the sample processing sulfur analysis coefficients.
The comprehensive low-sulfur analysis module is used for establishing a comprehensive low-sulfur analysis model, importing the data transmitted by the smelting process data analysis module and the sample processing data analysis module into the comprehensive low-sulfur analysis model, calculating a comprehensive low-sulfur evaluation value of each monitoring sample, and transmitting the comprehensive low-sulfur evaluation value to the early warning module.
The comprehensive low-sulfur analysis model is specifically expressed as follows:，/> Comprehensive low sulfur evaluation value representing the ith monitored sample,/> Representing the low sulfur smelting comprehensive efficiency value of the ith monitoring sample,/>Sample treatment Sulfur analysis coefficient representing the ith monitoring sample,/>Weight representing the value of the overall effectiveness of low sulfur smelting,/>Weights representing sample treatment Sulfur analysis coefficients,/>Other influencing factors representing the integrated low sulfur evaluation value.
The early warning module is used for judging the comprehensive low-sulfur evaluation value of each monitoring sample according to the comprehensive low-sulfur early warning value and sending an early warning signal according to a judgment result.
The comprehensive low-sulfur early warning value is marked asWhen/>When the comprehensive low-sulfur evaluation value of the ith monitoring sample is smaller than the comprehensive low-sulfur early warning value, the fact that the ith monitoring sample does not have an abnormal condition is indicated, monitoring on each monitoring sample is kept, and when/>And when the comprehensive low-sulfur evaluation value of the ith monitored sample is larger than the comprehensive low-sulfur early warning value, indicating that the ith monitored sample is abnormal, marking the ith monitored sample as an abnormal state and sending out an early warning signal.
According to the invention, the nickel-based superalloy to be monitored is divided into a plurality of monitoring samples through the monitoring sample dividing module and is marked in sequence, so that the sulfur content of each sample can be accurately monitored, the sample can be fully concerned and accurately analyzed, meanwhile, the marked sample is convenient for subsequent data acquisition, processing and analysis, and the working efficiency and accuracy are improved; various data in the smelting process, including fluxing agent data, blank value data and smelting condition data, can be comprehensively acquired through the smelting process data acquisition module, the acquisition of the data is helpful for deeply knowing the change condition of the sulfur content in the smelting process, rich data support is provided for subsequent data analysis, and the influence of the smelting process on the sulfur content can be more accurately evaluated through accurate data acquisition, so that the smelting process is optimized, and the product quality is improved; the mathematical model is built through the smelting process data analysis module, the collected smelting process data is deeply analyzed, the fluxing sulfur control coefficient, blank sulfur base value and smelting aging coefficient of each monitoring sample can be calculated, the control condition of the sulfur content in the smelting process can be reflected, the problems in the smelting process can be found out in time, a scientific basis is provided for optimizing the smelting process, meanwhile, the data analysis result can be used for an early warning module, timely early warning of abnormal sulfur content is realized, and the quality safety of products is ensured; the early warning module can timely early warn the abnormal situation of the sulfur content according to the result of the smelting process data analysis module, and when the sulfur content is monitored to exceed the preset threshold value, the early warning module can give an alarm to remind operators to take corresponding measures, so that potential quality problems can be found and processed in time, and product defects or potential safety hazards caused by the fact that the sulfur content is too high are avoided.
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 (9)
1. A nickel-based superalloy medium-low sulfur determination monitoring system, comprising:
Monitoring a sample dividing module: the method is used for dividing the nickel-based superalloy to be monitored into monitoring samples according to the mode of dividing the monitoring samples, and sequentially marking the nickel-based superalloy as 1 and 2 … … n;
The smelting process data acquisition module: the system comprises a flux data acquisition module, a smelting process data analysis module, a blank value data acquisition module and a smelting condition data acquisition module, wherein the flux data acquisition module is used for acquiring flux data, blank value data and smelting condition data of each monitoring sample;
a smelting process data analysis module: the smelting process data acquisition module is used for acquiring smelting process data, and the smelting process data acquisition module is used for acquiring smelting process data of each monitored sample;
Sample processing data acquisition module: the system comprises a sample processing data analysis module, a sample processing data acquisition module, a sample processing data analysis module and a sample processing data analysis module, wherein the sample processing module is used for acquiring pickling processing data, sulfur content measurement data and equipment performance data of each monitoring sample;
Sample processing data analysis module: the system comprises an acid washing data analysis unit, a sulfur content measurement data analysis unit and a device performance data analysis unit, wherein each analysis unit is used for establishing a corresponding mathematical model, importing data transmitted by a sample processing data acquisition module into the corresponding analysis unit, calculating the acid washing efficiency coefficient, the sulfur content measurement environment calibration coefficient and the sulfur analyzer accuracy of each monitoring sample, and transmitting the data to a comprehensive low-sulfur analysis module;
And (3) a comprehensive low-sulfur analysis module: the system is used for establishing a comprehensive low-sulfur analysis model, importing data transmitted by a smelting process data analysis module and a sample processing data analysis module into the comprehensive low-sulfur analysis model, calculating a comprehensive low-sulfur evaluation value of each monitoring sample, and transmitting the comprehensive low-sulfur evaluation value to an early warning module;
And the early warning module is used for: and the comprehensive low-sulfur evaluation value judgment module is used for judging the comprehensive low-sulfur evaluation value of each monitoring sample according to the comprehensive low-sulfur early warning value and sending an early warning signal according to a judgment result.
2. The nickel-base superalloy medium and low sulfur determination monitoring system as in claim 1, wherein: the flux data comprises the sulfur content of the flux, the using amount of the flux, the mixing proportion of the flux and the nickel-based alloy, the temperature when the flux is added, and the sulfur content change of the nickel-based alloy after the addition of the flux, which are respectively marked as、/>、/>、/>And/>The blank value data comprises blank sample sulfur content, blank sample processing temperature, blank sample storage environment humidity and blank value measuring instrument reading, which are respectively marked as/>、/>、/>And/>The smelting condition data comprise smelting temperature, smelting time, oxygen content in the smelting process and time required for the nickel-base alloy to be cooled to room temperature after smelting, which are respectively marked as/>、、/>And/>。
3. The nickel-base superalloy medium and low sulfur determination monitoring system as in claim 1, wherein: the flux data analysis unit is used for establishing a flux data analysis model, and the specific mathematical model is as follows:，/> indicating the fluxing sulfur control coefficient of the ith monitored sample, Represents the flux sulfur content of the ith monitored sample,/>Represents the flux usage of the ith monitored sample,/>Indicating the mixing ratio of the flux and the nickel-based alloy of the ith monitoring sample,/>Represents the temperature at which flux of the ith monitored sample was added,/>Indicating the change in sulfur content of the nickel-base alloy after flux addition for the ith monitored sample.
4. The nickel-base superalloy medium and low sulfur determination monitoring system as in claim 1, wherein: the blank value data analysis unit is used for establishing a blank value data analysis model, and the specific mathematical model is as follows:，/> represents blank thio value of ith monitored sample,/> Represents the blank sulfur content of the ith monitored sample,/>Blank sample processing temperature representing the ith monitored sample,/>Blank sample storage ambient humidity representing the ith monitored sample,/>Blank value measuring instrument reading representing the ith monitored sample,/>Represents the maximum value of sulfur content of blank sample of each monitoring sample,/>The minimum sulfur content of the blank sample for each monitored sample is shown.
5. The nickel-base superalloy medium and low sulfur determination monitoring system as in claim 1, wherein: the smelting condition data analysis unit is used for establishing a smelting condition data analysis model, and the specific mathematical model is as follows:，/> representing the smelting ageing coefficient of the ith monitoring sample,/> Representing the smelting temperature of the jth smelting time zone of the ith monitored sample,/>Represents the smelting time of the ith monitoring sample,/>Represents the oxygen content in the smelting process of the jth smelting time zone of the ith monitoring sample,/>The time required for cooling the nickel-base alloy to room temperature after smelting of the ith monitoring sample is represented, j represents the jth smelting time zone, the smelting time of each monitoring sample is divided into each smelting time zone by means of equal time division, and j=1 and 2 … … m.
6. The nickel-base superalloy medium and low sulfur determination monitoring system as in claim 1, wherein: the pickling data comprise pickling solution concentration, pickling temperature, sample weight change after pickling and pickling treatment time, which are respectively marked as、/>、/>And/>The sulfur content measurement data includes sulfur analyzer measurement value, standard value at the time of sulfur analyzer calibration, room temperature at the time of measurement, and relative humidity at the time of measurement, which are respectively labeled as/>、/>、/>And/>The equipment performance data comprises the sulfur content of the standard sample in the verification experiment and the measured value of the sulfur analyzer on the standard sample, which are respectively marked asAnd/>。
7. The nickel-base superalloy medium and low sulfur determination monitoring system as in claim 1, wherein: the pickling data analysis unit is used for establishing a pickling data analysis model, and the specific mathematical model is as follows:，/> represents the pickling efficiency coefficient of the ith monitored sample,/> Represents the concentration of pickling solution of the ith monitored sample,/>Indicating the pickling temperature of the ith monitored sample,Indicating the change in sample weight after pickling of the ith monitored sample,/>The pickling treatment time of the ith monitored sample is shown.
8. The nickel-base superalloy medium and low sulfur determination monitoring system as in claim 1, wherein: the sulfur content measurement data analysis unit is used for establishing a sulfur content measurement data analysis model, and the specific mathematical model is as follows:，/> Represents the sulfur content determination environmental calibration coefficient of the ith monitored sample,/> Represents the sulfur analyzer measurement value of the ith monitored sample,/>Represents the standard value of the ith monitored sample when the sulfur analyzer is calibrated,/>Room temperature at the time of measurement representing the ith monitoring sample,/>Indicating the relative humidity at the time of measurement of the ith monitored sample.
9. The nickel-base superalloy medium and low sulfur determination monitoring system as in claim 1, wherein: the comprehensive low-sulfur analysis model is specifically expressed as follows:，/> Comprehensive low sulfur evaluation value representing the ith monitored sample,/> Representing the low sulfur smelting comprehensive efficiency value of the ith monitoring sample,/>Sample treatment Sulfur analysis coefficient representing the ith monitoring sample,/>Weight representing the value of the overall effectiveness of low sulfur smelting,/>Weights representing sample treatment Sulfur analysis coefficients,/>Other influencing factors representing the integrated low sulfur evaluation value.
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