CN202239559U - Novel automatic proportioning energy saver for die casting machine mould release agent - Google Patents
Novel automatic proportioning energy saver for die casting machine mould release agent Download PDFInfo
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- CN202239559U CN202239559U CN2011203228168U CN201120322816U CN202239559U CN 202239559 U CN202239559 U CN 202239559U CN 2011203228168 U CN2011203228168 U CN 2011203228168U CN 201120322816 U CN201120322816 U CN 201120322816U CN 202239559 U CN202239559 U CN 202239559U
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Abstract
The utility model relates to an automatic proportioning energy saver for a die casting machine mould release agent, which has the advantages of high automation and control accuracy. The energy saver comprises a liquid level sensor, a flow sensor, a pressure sensor, an electric energy transmitter, a liquid level module, a flow module, a pressure module, an electric energy module, an original system feedback, an HMI (Human Machine Interface) monitoring system, a communication module, an input interface, a central processing unit, a frequency converter communication data interface, an output interface, a frequency converter I, a frequency converter II, a proportioning valve and an external execution unit, wherein the flow sensor, the liquid level sensor and the pressure sensor are used for acquiring mould release agent raw material flow, water flow, mould release agent dosing tank liquid level and pressure on a dosing pump master pipe in real time; and after the processing and adjustment of the central processing unit, accurate execution is performed by the execution unit. The energy saver has the characteristics of saving mould release agent raw materials, increasing die casting machine production efficiency, saving electric energy, reducing pollution, making the production management automatic, reducing impact on national power grid and the like.
Description
Technical field
The utility model relates to the electricity-saving appliance of releasing agent proportioning and batching conveying automation energy-conserving control technology and automatic energy saving.
Background technology
In die casting machine releasing agent batching and the induction system, adopt the artificial mode that is in harmonious proportion the releasing agent ratio to make the releasing agent batching can not satisfy the demand of various foundry goods, make the qualification rate of die casting machine casting die receive very big influence.Simultaneously, in order to satisfy the foundry goods demoulding smoothly, will inevitably artificially strengthen releasing agent raw material consumption.Make it to cause the waste of very big raw material and water.Releasing agent batching delivery pump designs according to maximum use amount and equipment pressure demand farthest in addition, and is engraved in variation during on-the-spot equipment ruuning situation, and the releasing agent of demand is prepared burden also and to be changed along with the working condition of the die casting machine at scene.This just forms two-part affluence amount (the affluence amount in rich amount of design and the use).The releasing agent matching system causes wastage of material, energy consumption increase, maintenance to strengthen many.And only use converter technique, then do not reach high-precision demand.Also can't carry out effectively simultaneously energy consumption, real time measure.
Summary of the invention
The purpose of the utility model provides a kind of qualification rate of producing foundry goods that improves, and reduces staff labor intensity, reduces releasing agent raw material use amount, reduces the use amount of water, reduces electric weight, reduces the energy-saving appliance of maintenance cost.
The utility model adopts following technical scheme to achieve these goals:
The new type auto proportioning energy-saving appliance of die casting machine releasing agent comprises liquid level sensor, flow sensor, pressure sensor, electric energy transmitter, liquid level module, flow module, modular pressure, power module, original system feedback, HMI monitoring system, communication module, input interface, central processing unit, inverter communication data-interface, output interface circuit, frequency converter I, frequency converter II, proportioning valve and outside performance element.
Wherein, Liquid level sensor is gathered the liquid level signal and is imported central processing unit through the liquid level module from input interface; Flow sensor is gathered flow signal Q and is imported central processing unit through flow module from input interface; Pressure sensor is gathered pressure signal P and is imported central processing unit through modular pressure from input interface, and the signal of electric energy transmitter collection is imported central processing unit through power module from input interface, and feedback data is imported central processing unit through the original system feedback from input interface; Central processing unit is through output interface circuit control ratio valve.
Said HMI monitoring system connects communication module with the twisted-pair feeder of band shielding, communicates with the RS232 port with central processing unit; Central processing unit is connected with frequency converter I and frequency converter II with the RS485 port through the inverter communication data-interface and adopts standard MODBUS communications protocol to communicate;
Said frequency converter I and frequency converter II are regulated the rotating speed that output frequency is regulated connected releasing agent dosing pump and releasing agent feedstock pump according to input signal; Through proportioning data and data on flows, control the flow output that outside performance element proportioning valve is realized and the releasing agent raw material matees by central processing unit.
Said outside performance element comprises the execution loop that is made up of breaker, reactor, wave filter, frequency converter, contactor.
The outside performance element of central processing unit control connection releasing agent dosing pump and releasing agent feedstock pump is still worked with the frequency conversion mode with the work of power frequency mode, realizes interlock function.
The utility model has the advantages that:
1, save the releasing agent raw material, because the part of the different die castings of die casting machine is different, the releasing agent raw material of use and the ratio of water are also different, lean on artificial rough maximized allotment before.The utility model can reach saves the releasing agent raw material more than 20%.
2, improve die casting machine production efficiency, after accurate proportioning.The demoulding fully of the foundry goods of die casting machine, and cast(ing) surface is smooth.Product qualified rate is more than 99%.
3, save electric energy, behind the new type auto proportioning energy-saving appliance of use die casting machine releasing agent, change the operating mode of the demoulding of maximum pressure conveying in the past batching.Realized coming the running speed of adjusting delivery pump automatically according to on-the-spot pressure demand.And needing to keep pressure constant with terminal.The energy of saving in this way is more than 35%.
4, the automation of production management through putting into operation of the utility model, except the monitoring management to self, has also realized the effective management to producing.The monitoring management of self is that the operation conditions to various components and parts in the energy-saving appliance detects inquiry in real time, realizes OBD, self-protection, fault alarm.Production management, the utility model can be analyzed the creation data of gathering, store, print.Mode through the webpage issue uploads to the production management center.For producing and management provides reliable analysis foundation.The raising of production efficiency and the raising of productivity effect have better been realized.And reduced maintenance cost.
5, minimizing is to the impact of national grid, and equipment reduces the impact to electrical network with startup level and smooth, that linear mode is realized equipment.
6, reduce labour intensity, the utility model changes labor operation mode in the past, through on the HMI monitoring system, realizing the accurate control to the releasing agent batching, need not artificial the participation.Reduce the maintenance cost of malfunction elimination time and equipment, perfect fault detect and defencive function energy-saving appliance have two position protection, height traffic protection, height pressure protect; Supply voltage overvoltage protection, under-voltage protection, overcurrent protection, short-circuit protection, open-phase protection make the operating personnel to investigate fault, handling failure fast according to the HMI monitoring system.
7, reduce pollution, the utility model has also reduced the sewage discharge after the releasing agent raw material uses when the releasing agent raw material is saved.
8, the utility model energy-saving appliance is applied widely, is not only applicable to die casting machine releasing agent batching automatic mixing system, and is applicable to the batching of all fluids.
Description of drawings
The utility model can further specify through the non-limiting enforcement example that accompanying drawing provides.
Fig. 1 is the utility model structure chart;
Fig. 2 is executive component (releasing agent feed proportioning system) connection layout of the utility model;
Fig. 3 is executive component (releasing agent raw material system) connection layout of the utility model;
Fig. 4 is the operated from a distance figure of the utility model;
Fig. 5 is the short-range operation figure of the utility model;
Fig. 6 is the communication unit wiring diagram of the utility model.
The specific embodiment
Further specify below in conjunction with accompanying drawing.
Referring to Fig. 1, the new type auto proportioning energy-saving appliance of die casting machine releasing agent comprises liquid level sensor, flow sensor, pressure sensor, electric energy transmitter, liquid level module 1, flow module 2, modular pressure 3, power module 4, original system feedback 5, HMI monitoring system 6, communication module 7, input interface 8, central processing unit 9, inverter communication data-interface 10, output interface circuit 11, frequency converter I 12, frequency converter II 13, proportioning valve 14 and outside performance element.Wherein, Liquid level sensor is gathered the liquid level signal and is imported central processing units 9 through liquid level module 1 from input interface 8; Flow sensor is gathered flow signal Q and is imported central processing units 9 through flow module 2 from input interface 8; Pressure sensor is gathered pressure signal P and is imported central processing units 9 through modular pressure 3 from input interface 8; From input interface 8 input central processing units 9, feedback data feeds back 5 from input interface 8 input central processing units 9 through original system to the signal that the electric energy transmitter is gathered through power module 4; Central processing unit 9 is through output interface circuit 11 control ratio valves 14.
The twisted-pair feeder of said HMI monitoring system 6 usefulness band shielding connects communication module 7, communicates with the RS232 port with central processing unit 9; Central processing unit 9 is connected with frequency converter I 12 and frequency converter II 13 with the RS485 port through inverter communication data-interface 10 and adopts standard MODBUS communications protocol to communicate.Said frequency converter I 12 and frequency converter II 13 are regulated the rotating speed that output frequency is regulated connected releasing agent dosing pump and releasing agent feedstock pump according to input signal.Through proportioning data and data on flows, by the flow output that the outside performance element proportioning valve 14 of central processing unit 9 controls is realized and the releasing agent raw material matees.
Flow sensor, liquid level sensor, pressure sensor are to the real-time collection of the pressure on releasing agent material flow, discharge, releasing agent dosing chamber liquid level and the dosing pump house steward; The data of setting on the data of 9 pairs of collections of central processing unit and the HMI monitoring system 6 are analyzed, are relatively reached multiple PID and calculate, and are exchanged each other by the service data and PLC central processing unit 9 data of inverter communication data-interface 10 with frequency converter again.Accurately carry out according to the service data of data processing unit output by performance element then.Monitoring software and touch-screen through the HMI monitoring system at last, the data that control institute with economize on electricity that data are directly perceived, soft to be reflected.
PLC pulse input end I0.0 connects the pulse input signal of flow transmitter.I0.1 to I3.2 connects the digital quantity input signal of all controls.The analog input AI1 to AI7 of 4-20MA current signal is the aperture feedback signal of pressure input signal, flow input signal, liquid level input signal and the proportioning valve of the utility model.In the wiring of output, digital output area is Q0.0 to Q1.8, and the switching value output for the utility model is used to start and stop, break-make, the interlocking of the system that controls.The analog signal output area is AQ0 to AQ3, is used for as analogue data output control releasing agent feedstock pump frequency converter II 13, releasing agent batching frequency converter I 12, feedwater proportioning valve 14.The connection of PORT COM is following: port one (PORT1) is used to connect releasing agent raw material frequency converter II 13 and releasing agent batching frequency converter I 12; Adopting RS485 communications protocol and physical connection line is connector with the RS232 port; Carrying out with PLC is main website, and frequency converter is that the mode of slave station is communicated by letter; Port two (PORT2) is used to connect HMI monitoring system 6, and both communicate with the communications protocol of RS485 and the physical connection of the twisted-pair feeder of band shielding equally.
The input of PLC, output connect form and are:
the utility model is when batching; Adopt manual or automatic mode; Manually during proportioning, keeps original artificial control model or operator scheme of preparing burden.Automatically the time, then use model to carry out automatic blending according to a series of automatic data collection and on-the-spot die casting machine mould.Automatic pressure, Flow-rate adjustment remain the constant of on-the-spot supply pressure.Selecting when manual, the releasing agent dosing pump adopts be original power frequency operation mode and automatically operational mode be subsequent use each other, chain each other relation, the actuating signal through digital input point I1.2 and I1.3 and I0.2 and I0.3 realizes." system reset I1.5 " input point is that the initialization after accomplishing as error protection and troubleshooting is used.
The utility model is all realized through the high speed communication transmission means on exchanges data.PLC central processing unit 9, frequency converter and HMI monitoring system 6 with the transmission side communication formula that remote client is realized are:
Communication one is the PLC main website, and the data communication form is a standard MODBUS communications protocol form.On PLC central processing unit 9, do communication program and realize communication two frequency converters.The baud rate that is provided with is 19.2KBPS, and releasing agent feedstock pump frequency converter is No. 1 station, and releasing agent dosing pump frequency converter is No. 2 stations.What be provided with is verified as even parity check, 8 data bit, and 1 is position of rest.The PLC main website adopts broadcast mode to realize data interaction.Mainly be that fault-signal to running frequency, running current, working voltage, running time and the operation of two frequency converters reads; To the frequency that frequency converter will move, the acceleration time that move, deceleration time, frequency limits, start and stop and overload quantity carry out given.
Communication two, PLC central processing unit 9 is communicated by letter with HMI monitoring system 6, and both communication is that the mode of main website is each other carried out exchanges data.The communication connector of PLC central processing unit 9 ends is the PORT1 mouth, and setting of ports is a default setting.HMI end, the converter of RS485 RS 232 serial ports are connected to the RS232 end of computer.The traffic rate of computer terminal port must be consistent with PLC central processing unit 9 ends, adopts 9600KBP speed.Also must be set to identical connection speed and the corresponding serial ports that is connected on the monitor system software that adopts.
The performance element of the utility model is made up of reactor, breaker, proportioning valve, plunger displacement pump that contactor, auxiliary reclay, isolating transformer, frequency converter upper and lower side connect referring to Fig. 2, Fig. 3.Concrete connection is made up of three parts, releasing agent feedstock pump part, releasing agent clear water proportioning valve part, releasing agent dosing pump part.Releasing agent feedstock pump frequency conversion part connects circuit breaker Q F1, A.C. contactor KM1, wave filter ACL1, converter power supply input (R, S, T), inverter output terminal (U, V, W), reactor AL1, A.C. contactor KM2, frequency conversion plunger displacement pump through external power source A, B, C three-phase 380V ac power input end.This part mainly realizes given to the releasing agent raw material through the flow-control to plunger displacement pump.Reach the ratio target of being controlled, the control of precision is to adopt multiple PID control emphatically, and the very high mass flowmenter of utilization precision feeds back foundation as data.Releasing agent dosing pump part, syndeton is the same with the releasing agent feedstock pump, and just feedback data is a pressure data.Realize the purpose of the constant voltage control of pressure.In the main purpose of inverter output terminal device reactor is in order to reduce the impact of high order current harmonics to motor, and reduces high frequency carrier to motor noise.And the purpose that wave filter is installed in frequency converter upper end mainly is to reduce harmonic wave that frequency converter produces to the interference to other equipment of the influence of electrical network and high subcarrier.Releasing agent water proportioning valve then is to realize the given of water and control through feedback releasing agent material flow and releasing agent proportion scale.This part is employed on the outlet pipe installs electromagnetic flowmeter and comes water is measured and feeds back.After PLC control, its precision reaches need use standard.
Said HMI monitoring system 6 is made up of dynamic visualization interface, comes control object directly perceived, vivid, reaction reality mildly with the control object and the device distribution of simulated field, and analyzes the energy consumption of this energy-saving appliance, forms the complete energy management system of a cover.
The protection part of the utility model; The autoprotection of this energy-saving appliance; Because frequency converter has kinds of protect function (overcurrent, overvoltage, short circuit, phase shortage, over the ground, three-phase equilibrium protection), has constituted perfect defencive function with this, other adds the various interlockings of original control and existing energy-saving appliance; And the various protections of program software; Formed the complete protection system of a cover, changed or the like from broken string, the damage of components and parts, pressure, flow, the given abnormal proportion of control circuit to control, can both be on the monitoring system the mode of voice and literal carry out alarm.Audible-visual annunciator also is installed on energy-saving appliance simultaneously.When the rank of reporting to the police reaches severity level, energy-saving appliance will automatically lock shutdown.Must etc. fault get rid of, through HMI monitoring system 6 confirm or energy-saving appliance on the SR action after, just put into operation.
The electricity principle of the utility model, energy-conservation main channel are to save rich amount.One is the static rich amount of equipment, and another is the dynamically rich amount of equipment.Static rich amount is the difference of equipment allocating power and actual power demand.The difference that dynamically rich amount then is the dynamic load of required peak power power of equipment and actual motion.The utility model integrated application intelligent data acquisition technology, intelligent data treatment technology, PLC control technology, the parameter of electric machine from survey technology, frequency conversion control technique, man-machine conversation technology and economize on electricity control program.Realize dynamic prediction, adjustment in advance, optimize synchronously, finally regulate the parameters such as pressure, flow, releasing agent proportioning of releasing agent feed system.The accuracy of the required releasing agent proportioning of assurance field apparatus and terminal die casting machine equipment are to the requirement of pressure, flow.
Three aspects of the energy-conservation branch of the new type auto proportioning energy-saving appliance of die casting machine releasing agent, the one, the saving of releasing agent dosing pump electric energy, the 2nd, to the saving of releasing agent raw material and water, the 3rd, production, the management of this equipment component are saved.The judgment basis of power saving is active watt-hour meter to be installed or/and confirm through the energy spectrometer table on the HMI monitoring system 6 at the power input of energy-saving appliance, and the parameter of saving electric weight is that the mode with power saving rate realizes.Concrete Computer Corp. is: the electric weight power saving rate=meritorious electric weight of (the meritorious electric weight of the meritorious electric weight-electricity-saving appliance of former operation)/former operation * 100%.The condition of both operations must be consistent, i.e. the time that requirement puts into operation is consistent, and the produced on-site amount is identical, and the releasing agent batching pressure of field demand is identical.Through the data contrast, the power saving rate of generation is more than 35%.The comparison of releasing agent raw material and water consumption is installed water meter at the port of export of releasing agent feedstock pump, and the proportioning valve port of export on water-main is installed water meter.Contrast according to the computing formula and the service condition of saving electric weight respectively, the ratio of saving releasing agent feed ratio and saving water is all more than 25%.Automation control through energy-saving appliance has reduced staff's labour intensity, has improved efficient and quality that on-the-spot die casting machine is produced, the storage through monitoring system and data analysis has improved the whole production efficiency of managing or/and the production management mode.
The beneficial effect that this practical utility model reaches has:
Realize the automatic mixing of releasing agent raw material and water, water and releasing agent feed proportioning scope are in 1:1 to 150:1 water high accuracy batching, and accuracy error is ± 1.
The selection of power frequency/frequency conversion has realized that energy-saving appliance and original controller form subsequent use each other, chain each other.
Have perfect defencive function, have protections such as short-circuit protection, overload protection, ground protection, lightning protection, open-phase protection, route protection.
Automatically adjust output according to on-the-spot technology ruuning situation, realize that optimization is energy-conservation.
Energy-saving appliance applied widely except the suitable mold release agent proportioning, also is applicable to the place of all fluids batchings.Just selection is different on sensor and corresponding pid parameter and fuzzy control Mathematical Modeling.
What the utility model adopted is the sensor signal distributed collection, the mode that focuses on.Realized the reliable collection of all data and reliably crossed.Gather signal and all isolate, guaranteed the true collection and the long-distance transmissions of data through photoelectricity.
The utility model is to be the control core with PLC, removes to control frequency converter and proportioning valve with communication mode.Realize quick data in synchronization exchange.Satisfy control accuracy and technological requirement.
Man-machine interface and long distance control system have formed reliable man-machine conversation, make corresponding technology can in time be able to adjustment.Simultaneously corresponding data are published to remote client through the mode of WEB.For management provides reliable information platform.
The utility model relates to the optimization of the quality of power supply, can improve the plant capacity factor.Make it to bring up to original power factor 0.6 more than 0.95.Reduced the cable line loss to a great extent.Also improved simultaneously the meritorious use capacity of transformer.Energy-saving appliance is through installing reactor and wave filter, thoroughly changed the harmful effect of frequency converter harmonic wave, High-frequency Interference.Make it to reach below the national grid harmonic wave setting.
Claims (3)
1. the new type auto proportioning energy-saving appliance of die casting machine releasing agent is characterized in that: comprise liquid level sensor, flow sensor, pressure sensor, electric energy transmitter and pairing liquid level module (1), flow module (2), modular pressure (3), power module (4), original system feedback (5), HMI monitoring system (6), communication module (7), input interface (8), central processing unit (9), inverter communication data-interface (10), output interface circuit (11), frequency converter I (12), frequency converter II (13), proportioning valve (14) and outside performance element;
Wherein, Liquid level sensor is gathered the liquid level signal and is imported central processing unit (9) through liquid level module (1) from input interface (8); Flow sensor is gathered flow signal Q and is imported central processing unit (9) through flow module (2) from input interface (8); Pressure sensor is gathered pressure signal P and is imported central processing unit (9) through modular pressure (3) from input interface (8); From input interface (8) input central processing unit (9), feedback data is fed back (5) from input interface (8) input central processing unit (9) through original system to the signal that the electric energy transmitter is gathered through power module (4); Central processing unit (9) is through output interface circuit (11) control ratio valve (14);
Said HMI monitoring system (6) connects communication module (7) with the twisted-pair feeder of band shielding, communicates with the RS232 port with central processing unit (9); Central processing unit (9) is connected with frequency converter I (12) and frequency converter II (13) with the RS485 port through inverter communication data-interface (10) and adopts standard MODBUS communications protocol to communicate;
Said frequency converter I (12) and frequency converter II (13) are regulated the rotating speed that output frequency is regulated connected releasing agent dosing pump and releasing agent feedstock pump according to input signal; Through proportioning data and data on flows, by the flow output that central processing unit (9) the outside performance element proportioning valve of control (14) is realized and the releasing agent raw material matees.
2. according to the new type auto proportioning energy-saving appliance of the said die casting machine releasing agent of claim 1, it is characterized in that: said outside performance element comprises the execution loop that is made up of breaker, reactor, wave filter, frequency converter, contactor.
3. according to the new type auto proportioning energy-saving appliance of the said die casting machine releasing agent of claim 1, it is characterized in that: the said outside performance element of central processing unit (9) control is still worked with the frequency conversion mode with the work of power frequency mode.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN2011203228168U CN202239559U (en) | 2011-08-31 | 2011-08-31 | Novel automatic proportioning energy saver for die casting machine mould release agent |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN2011203228168U CN202239559U (en) | 2011-08-31 | 2011-08-31 | Novel automatic proportioning energy saver for die casting machine mould release agent |
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| Publication Number | Publication Date |
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| CN202239559U true CN202239559U (en) | 2012-05-30 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN2011203228168U Withdrawn - After Issue CN202239559U (en) | 2011-08-31 | 2011-08-31 | Novel automatic proportioning energy saver for die casting machine mould release agent |
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| Country | Link |
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| CN (1) | CN202239559U (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102303109A (en) * | 2011-08-31 | 2012-01-04 | 重庆溢希恩真节能电力设备有限公司 | Automatic releasing agent proportioning economizer for die casting machine |
| CN105864481A (en) * | 2016-05-13 | 2016-08-17 | 无锡星月科技有限公司 | Full closed-loop type proportional valve positioning and speed regulating control circuit |
| CN110293213A (en) * | 2018-03-22 | 2019-10-01 | 上海胜僖汽车配件有限公司 | A kind of device for preventing production process from interrupting release agent |
-
2011
- 2011-08-31 CN CN2011203228168U patent/CN202239559U/en not_active Withdrawn - After Issue
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102303109A (en) * | 2011-08-31 | 2012-01-04 | 重庆溢希恩真节能电力设备有限公司 | Automatic releasing agent proportioning economizer for die casting machine |
| CN105864481A (en) * | 2016-05-13 | 2016-08-17 | 无锡星月科技有限公司 | Full closed-loop type proportional valve positioning and speed regulating control circuit |
| CN110293213A (en) * | 2018-03-22 | 2019-10-01 | 上海胜僖汽车配件有限公司 | A kind of device for preventing production process from interrupting release agent |
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Legal Events
| Date | Code | Title | Description |
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| C14 | Grant of patent or utility model | ||
| GR01 | Patent grant | ||
| AV01 | Patent right actively abandoned |
Granted publication date: 20120530 Effective date of abandoning: 20130306 |
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| RGAV | Abandon patent right to avoid regrant |