JP2014119440A - Alloy re-molten state detection method, alloy re-molten state detection device, and self-fluxing alloy re-melting device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a technology capable of quantitatively recognizing a re-molten state in work of fusing processing.SOLUTION: In a process of re-melting a self-fluxing alloy on the basis of heating by heating means, a radiation thermometer for measuring the intensity of infrared radiation detects a re-molten state of the self-fluxing alloy. The detection method includes a temperature recording process of temporally recording the temperature of an alloy surface; a temperature increment calculating process of calculating the temperature increment on the basis of the recording contents in the temperature recording process; a process of detecting that the temperature increment becomes a minus value; and a process of informing displaying means of the re-melting of the alloy.

Description

  The present invention relates to a temperature management / temperature control technique during remelting of a self-fluxing alloy, so-called fusing.

  Metals that have undergone remelting treatment of self-fluxing alloys are used in various fields due to their properties such as corrosion resistance, wear resistance, and heat resistance. For example, there are structural members of chemical plants that require corrosion resistance and gas turbine blades that require wear resistance and heat resistance. What is common to them is that they can maintain a reliable quality for a long period of time even under harsh usage environments. At the same time as the demand for high reliability, cost reduction is also required.

  Conventionally, as a method for remelting the self-fluxing alloy, a method using heating by a gas torch, a method using a furnace, and a method using high frequency induction heating have been proposed in recent years.

  The method using high-frequency induction heating is useful from the viewpoint of productivity improvement, but it is necessary to set the heating time using a test piece, and it is necessary to take into account changes in the external environment, material characteristics, etc. There were many tasks that depended on the experience of the workers.

Japanese Patent Laid-Open No. 2003-231909 JP 2006-193772 A JP 2006233331 A

  Among the prior arts, in the heating by gas torch or high frequency induction, the molten state of the surface is visually confirmed, and in the method using a furnace, the remelted state is managed at the furnace temperature. However, in these remelting state management methods, visual management requires the experience of an operator, and management based on the furnace temperature is difficult to manage based on a uniform furnace temperature.

  In the remelting of self-fluxing alloys, the temperature control is important, and excessive heating causes enlargement of the remelted structure. The enlargement of the remelted structure causes a decrease in the coating hardness, and there has also been a problem that the coating peels off from the base material.

  Under such circumstances, in actual work, the state of remelting cannot be quantitatively grasped, and management by temperature control or visual inspection by the experience of the worker has to be relied upon.

  In addition, from the viewpoint of productivity improvement, automation of fusing equipment was desired, but subtle changes during remelting could not be detected by the equipment, and detection of the remelted state was not possible with the prior art. Was not realized.

  The present invention has been made in view of the above circumstances, and the object of the present invention is to provide a technique for quantitatively measuring and managing remelting of a self-fluxing alloy regardless of the experience of the operator. is there.

  In order to solve the above-mentioned problem, the invention according to claim 1 of the present invention is characterized in that the self-fluxing is performed by a radiation thermometer that measures the intensity of infrared rays in the step of remelting the self-fluxing alloy based on heating by the heating means. An alloy remelt state detection method for detecting a remelt state of an alloy, a temperature recording step for recording the temperature of the alloy surface over time, and a temperature increase for calculating a temperature increase amount from the recorded contents in the temperature recording step And a step of detecting that the temperature increase amount has become a negative value, and a step of notifying the display means that the alloy has been remelted.

  Moreover, the invention according to claim 2 of the present invention includes a radiation thermometer for measuring the intensity of infrared rays, which is used when remelting a self-fluxing alloy based on heating by a heating means, and outputs the radiation thermometer. An alloy remelting state detection device for detecting a melting state of a self-fluxing alloy based on a control unit, a display unit, a temperature recording unit for recording the temperature of the alloy surface over time, and recording of the temperature recording unit A temperature increase amount calculation unit that calculates a temperature increase amount from the contents, and when the control unit detects that the temperature increase amount has become a negative value, the display unit has remelted the alloy, Is notified.

  Moreover, the invention according to claim 4 of the present invention includes a radiation thermometer that measures the intensity of infrared rays, and further includes a molten state detection unit that detects a molten state of the self-fluxing alloy based on the output of the radiation thermometer. A self-fluxing alloy remelting device, comprising: a heating unit that locally heats an alloy to be melted; and a heating control unit that controls the heating unit, wherein the molten state detection unit includes a control unit, and a display unit And a temperature recording unit that records the temperature of the alloy surface over time, and a temperature increase amount calculating unit that calculates a temperature increase amount from the recorded contents of the temperature recording unit, and the controller increases the temperature When it is detected that the amount has become a negative value, the display unit is notified that the alloy has been remelted.

  According to the first and second aspects of the present invention, it is possible to quantitatively manage the remelted state that has been managed by the visual observation of the worker who has experience so far and the overall temperature management. It is possible to reduce the risk of quality deterioration and defect occurrence due to work errors such as variations in quality due to differences in workers, work timing shifts, and button press errors.

  Further, according to the invention of claim 4, since the remelted state that has been relied on the experience of the operator can be handled quantitatively as electronic data, the fusing device can be automated and unmanned. Is possible.

It is a block diagram which shows the basic composition of this invention. It is an output graph of the radiation thermometer for demonstrating the principle of this invention. It is an operation | movement flowchart which shows the 1st Embodiment of this invention. It is a block diagram showing the outline | summary of the 1st Embodiment of this invention. It is a block diagram showing the outline | summary of the 2nd Embodiment of this invention. It is an operation | movement flowchart which shows the 2nd Embodiment of this invention. It is an operation | movement flowchart which shows the application example of the 2nd Embodiment of this invention.

  Embodiments of the present invention will be described below with reference to the drawings.

(First embodiment)
An embodiment according to the present invention will be described with reference to FIG. FIG. 1 is a block diagram showing a configuration of an alloy remelted state detection device 1 (hereinafter simply referred to as a molten state detection device). The molten state detection device 1 includes a molten state detection unit 11 and a radiation thermometer unit 13, and the molten state detection unit 11 further includes a control unit 111, a temperature storage unit 113, a temperature increase calculation unit 115, a display control unit 117, The radiation thermometer unit 13 includes a communication unit 119, and includes a measurement unit 131 and a signal processing unit 133.

  The control unit 111 of the molten state detection unit 11 controls each part of the molten state detection unit 11.

  The temperature storage unit 113 of the molten state detection unit 11 receives an electrical signal including temperature information from the radiation thermometer unit 13 and stores the temperature per unit time.

  The temperature increase calculation unit 115 of the molten state detection unit 11 receives an electrical signal including temperature information from the temperature storage unit 113 or the signal processing unit 133 of the radiation thermometer unit 13, and receives the latest temperature information and temperature information before unit time. From this, the amount of temperature increase is calculated.

  The display control unit 117 of the melted state detection unit 11 notifies the operator of the remelted state and the temperature via a display unit composed of a monitor such as a CRT or LCD. Although this display unit is not shown, it may be built in the molten state detection device 1 or may be arranged outside. The communication unit 119 communicates with an external device, for example, a fusing device described later.

  The measurement unit 131 of the radiation thermometer unit 13 detects infrared energy and converts it into an electrical signal. The signal processing unit 133 processes the temperature information detected by the measurement unit 131 and converted into an electric signal, and transmits the temperature information to the control unit 111 of the molten state detection unit 11.

(Principle explanation of remelting state detection)
A radiation thermometer uses “radiation”, which is one form of heat transfer, and uses an infrared sensor equipped with a radiation thermometer that emits infrared radiation energy emitted from the surface of the object being measured. The surface temperature of the object to be measured is measured. For this reason, the surface temperature of the object can be measured without contacting the object to be measured.

`` Radiation '' is a phenomenon that releases the thermal energy of the substance to the surroundings in the form of electromagnetic waves (visible light, infrared rays, etc.), and emissivity is when an object at a certain temperature emits thermal radiation, The ratio of the object to the black body radiation at the same temperature.

  The reason for using the ratio to black body radiation is that the amount of infrared radiation emitted from an object has a significant difference depending on the material and surface condition. This means, for example, that there is a difference in the amount of infrared energy radiated, that is, emissivity between iron and aluminum at the same temperature.

  Therefore, the emissivity can be grasped quantitatively by using an ideal black body (an ideal object with a radiation efficiency of 100%) as a reference.

  In the radiation thermometer, control such as comparing the output from the infrared sensor obtained by the input from the object with the reference temperature is performed, and correction is performed according to the individual emissivity of the normal object.

  However, an ideal black body that defines the relationship between infrared and temperature is based on the premise that it does not reflect infrared rays from other sources, but real substances reflect infrared rays from the outside. That is, the substance that is normally measured is radiating a mixture of infrared rays emitted from the measurement subject and infrared rays emitted and reflected from other objects.

  Therefore, when the temperature of a mixture of a plurality of types of metals having different melting points such as an alloy is measured, the emissivity changes depending on the melting state of each metal.

  The present invention has been conceived by utilizing the phenomenon that the emissivity changes with such a radiation thermometer. The outline will be described below.

  When the self-fluxing alloy is remelted, a film is formed on the surface to be treated, and the surface is covered with a gloss like a glass surface. This occurs when the object to be treated and the self-fluxing alloy are melted when the alloy is melted, and boron and silicon, which are constituents of the self-fluxing alloy, are recrystallized on the surface of the object.

  As shown in FIG. 2, the surface property changes such that the emissivity of the surface increases at a constant change rate as the temperature rises (dotted line change curve) from the start of heating the object to before remelting. However, the emissivity of the surface of the heated part of the object changes at the time of remelting, and the temperature detected by the radiation thermometer is apparently lowered as shown by the solid curve in FIG.

  That is, by detecting the inflection point in FIG. 2 which is “a state in which the accuracy of temperature measurement is out of order” by the radiation thermometer, it is determined that the surface is completely remelted. In other words, the state where the surface gloss is changed and the emissivity is changed by detecting that the alloy and the compound of the sprayed metal are completely melted by the remelting of the surface is detected.

  Since the state in which the emissivity has changed causes a change in the output signal in the radiation thermometer, the change is recorded and the increase per hour is calculated. When the increase amount turns negative, it represents a remelted state. Therefore, the remelted state can be detected by monitoring the change in the electrical signal from the calculation result.

  Next, operation | movement of the molten state detection apparatus 1 using the alloy remelt state detection method is demonstrated using FIG. FIG. 3 is a flowchart showing the operation of the molten state detection device 1.

(S101 Temperature measurement start)
The fusing object 3 subjected to thermal spraying is heated by a high frequency induction heating device or a gas torch comprising a high frequency coil for induction heating for locally heating. At this time, the measurement unit 131 of the radiation thermometer unit 13 is directed toward the heated portion of the fusing object 3 and temperature measurement of the heated alloy surface is started (S101).

(S102 Temperature memory)
For the heated portion of the fusing object 3, the temperature per unit time is stored in the temperature storage unit 113 of the molten state detection unit 11. The unit time at this time may be stored in the temperature storage unit 113 in advance, or may be set before work. The unit time is measured by the control unit 111 of the molten state detection unit 11, transmitted to the temperature storage unit 113, and stored together with the temperature. (S102)

(S103 Calculation and comparison of temperature increase)
The temperature increase amount calculation unit 115 calculates the temperature increase amount. This compares the temperature one unit time before stored in the temperature storage unit 113 with the current temperature, and calculates the amount of increase in the temperature by arithmetic processing. The controller 111 confirms the change in the temperature increase amount that is the calculation result. At this time, this calculation / comparison process (S103) is repeated until the temperature increase amount becomes negative. If it is calculated that the temperature increase amount has become negative, that is, the temperature has decreased as indicated by the inflection point in FIG. 2, the process proceeds to S104.

  As a result of the calculation by the temperature increase calculation unit 115 in S103, the fact that the temperature increase is negative corresponds to detecting that the emissivity of the measurement target has changed.

(S104 Notification of remelted state)
When the control unit 111 obtains that the temperature increase amount has turned negative through the process of S103, the display control unit 117 is notified that the remelt state has been entered. The operator who is notified to the display control unit 117 and knows that the heated part of the object is in the remelted state is the next work such as adjustment of the output of the high frequency induction heating device, gas torch, etc., or changing the heating position. I do.

  In S104, the temperature increase amount may be further monitored, and when the temperature increase amount further changes from minus to plus, a further warning may be given that an excessive heating state is entered. Further heating causes deterioration of the self-melting metal, and the gloss like the glass surface of the surface disappears, so that the measurement result of the radiation thermometer unit returns to an accurate state. By notifying this state, it is possible to prevent the occurrence of defective products due to processing failure.

  Next, a specific embodiment of the present invention will be described with reference to FIG. FIG. 4 shows an example of the configuration of the embodiment. The radiation thermometer unit 13 and the molten state detection unit 11 are connected through an interface such as USB or GPIB. As shown in FIG. 4, the radiation thermometer unit 13 may use a general-purpose radiation thermometer, and the molten state detection unit 11 may be constituted by a general-purpose data logger, sequencer, computer, or the like. At this time, each part of the molten state detection part 11 is comprised by a computer with a program, and it is also possible to mutually communicate and control with the control program of a radiation thermometer.

  The data logger is an electronic measuring instrument that measures a physical quantity using a sensor and stores the measurement result. In the present invention, it is used to record temperature changes over time, and is in charge of the function of performing communication control between the temperature storage unit 113 and the signal processing unit 133 as part of the control unit 111.

  A sequencer generally refers to a control device. In the present invention, the operation of the molten state detection device is controlled, and the temperature increase amount calculation unit 115, the display control unit 117, and the communication unit 119 are incorporated.

  According to the first embodiment, it is possible to quantitatively detect the remelted state of the self-fluxing alloy that has been determined based on the experience of the operator so far by the molten state detection device. As a result, it is possible to reduce the risk of quality deterioration and the occurrence of defects due to work errors such as variations in quality due to differences in workers, work timing shifts, and button press errors.

  In addition, as an application example of the first embodiment, by using a molten state detection device including two or more radiation thermometers, such as the radiation thermometer unit 13 in FIG. Alternatively, it is possible to efficiently control the processing of an object that requires continuous self-fluxing alloy processing. At the same time that the remelting point during work is measured by (1) (center part) of the radiation thermometer 13 which is a radiation thermometer, the surface temperature of the next work place is a radiation thermometer which is the second radiation thermometer By measuring by (2) (outer end part) of the part 13, the temperature leveled by heat conduction can be grasped, and a continuous remelting operation can be efficiently performed.

  When there are three or more radiation thermometer units 13 at different positions, (3) and (4) assist the main (1) ′ as in the radiation thermometer unit 13 ′ of FIG. 4B. You may comprise. The average value of (1) ', (3), and (4) may be used, and the measurement results of (1)', (3), and (4) are weighted mainly using (1) '. Then, the arithmetic processing may be performed.

(Second Embodiment)
Next, a second embodiment will be described with reference to FIG. In this embodiment, the control of the fusing device (alloy remelting device) is interlocked with the molten state detection device, so that the high-precision self-fluxing alloy can be remelted while preventing excessive heating of the fusing object 3. realizable.

  The fusing device shown in FIG. 5 is a combination of the heating unit 2A and the fusing control unit 2B constituting the fusing device 2 and the above-described molten state detection device. Here, the fusing control unit 2B corresponds to the heating control unit in the claims.

  The motor 21 is used to move the heating unit 2A or the fusing object 3 and change the heating location, and the high-frequency oscillator 23 is used for heating control. The touch panel 25 is an interface for an operator to operate the fusing device.

  The fusing device 2 in FIG. 5 is not limited to a high-frequency induction heating device, and may be configured by using a gas torch or other devices having similar functions. Further, the interface operated by the operator is not limited to the touch panel 25 in FIG. 5, and may be configured by an interface such as a monitor, a mouse, and a keyboard.

  Moreover, the temperature controller of the molten state detection part 11 of FIG. 5 notifies the temperature of the next work location of the next fusing object 3 to the high frequency oscillator 23, and information for controlling the heating temperature. To be sent. You may incorporate in the control part 111 and may comprise by a sequencer and a control program.

  Next, the operation of the second embodiment will be described with reference to FIG. FIG. 6 is a flowchart showing the operation of the second embodiment.

(S201 Temperature measurement start)
The fusing object 3 subjected to thermal spraying is heated by a heating unit 2A constituted by a high frequency induction heating device or a gas torch. At this time, the measurement unit 131 of the radiation thermometer unit 13 is directed toward the heating portion of the fusing object 3 to start temperature measurement (S201).

(S202 Temperature memory)
For the heated portion of the fusing object 3, the temperature per unit time is stored in the temperature storage unit 113 of the molten state detection unit 11. The unit time at this time may be stored in the temperature storage unit 113 in advance, or may be set before work. The unit time is measured by the control unit 111 of the molten state detection unit 11, transmitted to the temperature storage unit 113, and stored together with the temperature. (S202)

(S203 Calculation and comparison of temperature increase)
The temperature increase amount calculation unit 115 calculates the temperature increase amount. This compares the temperature one unit time before stored in the temperature storage unit 113 with the current temperature, and calculates the amount of increase in the temperature by arithmetic processing. The controller 111 confirms the change in the temperature increase amount that is the calculation result. At this time, this calculation / comparison process (S203) is repeated until the temperature increase amount becomes negative. If it is calculated that the temperature increase amount is negative, the process proceeds to S204.

(S204 Notification of remelted state)
When the control unit 111 acquires that the temperature increase amount has turned negative in step S203, the display control unit 117 is notified that the remelted state has been entered. The display control unit 117 is notified (S204).

(S205 Temperature control of fusing device)
When the molten state detection unit 11 detects that the heated portion of the fusing object 3 has entered the remelted state in S204, a control signal is sent to the fusing control unit 2B so as to adjust the output of the heating unit 2A. Send. In this case, the output of the heating device is stopped and the operation is terminated (S205).

  According to the second embodiment, since the control of the fusing device is controlled based on the detection result of the molten state detection device, the heating state of the fusing device can be adjusted at the optimum timing of the working state. This eliminates insufficient heating and overheating, and enables the reduction of defective products.

(Application example of the second embodiment)
As an application example corresponding to the second embodiment, a self-fluxing alloy remelting apparatus linked with a fusing apparatus capable of performing fusing processing on a molten state detection apparatus and a long fusing object 3 will be described with reference to FIG. . FIG. 7 is a flowchart of an application example corresponding to the second embodiment.

(S302 Temperature measurement start)
The fusing object 3 subjected to thermal spraying is heated by the heating unit 2A of the fusing apparatus configured by a high frequency induction heating apparatus or a gas torch (S301). At this time, the measurement unit 131 of the radiation thermometer unit 13 is directed toward the heating portion of the fusing object 3 to start temperature measurement (S302).

(S303 Temperature memory)
For the heated portion of the fusing object 3, the temperature per unit time is stored in the temperature storage unit 113 of the molten state detection unit 11. The unit time at this time may be stored in the temperature storage unit 113 in advance, or may be set before work. The unit time is measured by the control unit 111 of the molten state detection unit 11, transmitted to the temperature storage unit 113, and stored together with the temperature. (S303)

(S304 Calculation and comparison of temperature increase)
The temperature increase amount calculation unit 115 calculates the temperature increase amount. This compares the temperature one unit time before stored in the temperature storage unit 113 with the current temperature, and calculates the amount of increase in the temperature by arithmetic processing. The controller 111 confirms the change in the temperature increase amount that is the calculation result. At this time, this calculation / comparison process (S304) is repeated until the temperature increase amount becomes negative. If it is calculated that the temperature increase amount is negative, the process proceeds to S305.

(S305 Movement of fusing device)
When the control unit 111 acquires that the temperature increase amount has turned negative through the process of S203, the display control unit 117 is notified that the remelt state has been entered, and the refusion state is transmitted to the fusing device 2. To do. The fusing device 2 receives the information and starts moving the heating unit 2A of the fusing device (S305).

  The movement of the heating part of the fusing object 3 may be moved instead of the movement of the heating unit 2A of the fusing device.

(S306 Check the setting limit of the fusing part)
Check the processing target location of the processing target. The processing location of the processing object is set in advance in the fusing device 2 before work. Set the machining range according to the set value and check the limit. If the set limit has not been reached, the process returns to S303 and the operation is repeated. If the set limit is reached, the process proceeds to S307, the fusing device is stopped, and the operation is terminated.

  By applying the second embodiment, it is possible to handle the remelted state that has been relied on the experience of the operator as electronic data quantitatively and to cooperate with the fusing device, so that the fusing device can be automated. The accuracy of fusing can be increased. This not only reduces the number of defective products, but also makes it possible to automate the fusing device and enable unmanned operation.

  According to the second embodiment, it is possible to reduce the risk of quality deterioration and defect occurrence due to work errors such as variations in quality due to differences in workers, work timing shifts, and button press errors.

Further, since the state of remelting can be quantified, it is not necessary to prepare in advance using a test piece, and it is possible to reduce costs by reducing the number of test pieces for preparation and omitting the test.

DESCRIPTION OF SYMBOLS 1 Melting state detection apparatus 11 Melting state detection part 13 Radiation thermometer part 2 Fusing apparatus 21 Motor 23 High frequency oscillator 25 Touch panel

Claims (6)

In the step of remelting the self-fluxing alloy based on heating by the heating means, an alloy remelting state detection method for detecting the remelting state of the self-fluxing alloy with a radiation thermometer that measures the intensity of infrared rays,
A temperature storage step for storing the temperature of the alloy surface over time;
A temperature increase amount calculating step for calculating a temperature increase amount from the stored contents in the temperature storage step;
Detecting that the temperature increase amount has become a negative value, and notifying the display means that the alloy has been remelted,
A method for detecting a remelted state of an alloy. An alloy remelting unit equipped with a radiation thermometer that measures the intensity of infrared rays and is used to remelt a self-fluxing alloy based on heating by a heating means, and detects the melting state of the self-fluxing alloy based on the output of the radiation thermometer A state detection device,
A control unit;
A display unit;
A temperature storage unit for storing the temperature of the alloy surface over time;
A temperature increase amount calculation unit for calculating a temperature increase amount from the storage content of the temperature storage unit;
With
When the control unit detects that the temperature increase amount has become a negative value, the display unit has remelted the alloy,
The alloy remelting state detection device characterized by notifying. Comprising two or more radiation thermometers, one measuring the temperature of the target position of the object and the other measuring the temperature of the next target position,
The alloy remelting state detection device according to claim 1. A self-fluxing alloy remelting device comprising a radiation thermometer that measures the intensity of infrared rays, and a melting state detection unit that detects the melting state of the self-fluxing alloy based on the output of the radiation thermometer,
A heating section for locally heating the melting alloy;
A heating control unit for controlling the heating unit;
With
The molten state detection unit includes a control unit,
A display unit;
A temperature storage unit for storing the temperature of the alloy surface over time;
A temperature increase amount calculation unit for calculating a temperature increase amount from the storage content of the temperature storage unit;
Further comprising
When the control unit detects that the temperature increase amount has become a negative value, it informs the display unit that the alloy has been remelted,
A self-fluxing alloy re-melting device.   The self-fluxing alloy remelting device according to claim 4, wherein the heating unit is formed of a high frequency coil for induction heating.   The self-fluxing alloy remelting device according to claim 4, wherein the heating unit is made of a gas torch.

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