JP2018085081A - Fusion furnace operation plan creation device, computer program for the same, computer-readable recording medium recording program, and fusion furnace operation plan creation method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To plan, in a fusion furnace operation plan creation device including a fusion furnace for melting and holding a metal material and a casting machine for manufacturing a cast by molten metal of the fusion furnace, operation of the fusion furnace in a manner such as to control an amount of molten metal supplied to the fusion furnace in accordance with an amount of molten metal expected to be used in the casting machine, so that the amount of molten metal in the fusion furnace is made appropriate.SOLUTION: Provided are: plan creation means for creating an operation plan for manufacturing a cast based on a production plan including a kind and a quantity of the cast; and work instruction means for instructing a work for recognizing an amount of molten metal required for manufacturing the cast based on the operation plan and preparing the molten metal. The work instruction means, for performing operation simulation based on the operation plan, includes at least: condition calculation means for obtaining a total amount of metal materials introduced to a fusion furnace; and simulation means for performing the operation simulation from a start to an end of operation in a manner such that an amount of molten metal held becomes an appropriate value based on the plan creation means and the condition calculation means.SELECTED DRAWING: Figure 1

Description

  The present invention relates to an operation plan creation device for a melting furnace. The present invention also relates to a computer program for a melting furnace operation plan creation device, a computer-readable recording medium storing the program, and a melting furnace operation plan creation method.

  As shown in FIG. 26, the casting machine 20 is supplied with the molten metal 33 from the melting furnace 10 to produce a cast product. The melting furnace 10 includes a melting chamber 11 that melts the metal material 31, a holding chamber 12 that holds the molten metal 33, and a pumping chamber 13 that pumps the molten metal 33. Each chamber 11-13 is mutually connected, the molten metal 33 which melted the metal material 31 in the melting chamber 11 is hold | maintained in the holding chamber 12, and the molten metal 33 of the holding chamber 12 is cast from the pumping opening 13b of the pumping chamber 13. It pumps out toward the machine 20.

  In Patent Document 1, the amount of the molten metal 33 in the holding chamber 12 and the amount of the metal material 31 charged into the melting chamber 11 and the melting burner 11a of the melting chamber 11 are maintained based on the signal from the full sensor 13a. The output is feedback controlled. Moreover, the target amount of the metal material 31 put into the melting chamber 11 is increased or decreased depending on whether or not the casting machine 20 is operating based on the production plan.

JP 2005-76972 A

  However, the control in Patent Document 1 is merely feedback control, and there is a possibility that an excess or deficiency of the molten metal amount occurs in an actual casting site. For example, when the casting machine 20 is in operation and the input amount of the metal material 31 is small, the molten metal amount is insufficient depending on the consumption amount of the molten metal 33 used in the casting machine 20. In addition, when the operation of the factory is finished and casting is stopped and the molten metal 33 is not consumed for a long time, the amount of the molten metal 33 held in the holding chamber 12 is energy saving. When the input amount of 31 is increased, the amount of the molten metal 33 remaining in the holding chamber 12 after the operation is ended increases.

  An object of the present invention is to make the amount of molten metal in the melting furnace an appropriate amount by planning to control the amount of molten metal in the melting furnace in accordance with the amount of molten metal scheduled to be used in the casting machine.

  A first invention includes a melting furnace that melts a metal material to form a molten metal, and holds the molten metal, and a casting machine that receives the molten metal from the melting furnace to produce a cast product, the melting furnace comprising a metal material A melting furnace operation plan creation device comprising a melting heat source for melting the molten metal and a holding heat source for maintaining the temperature of the molten metal, the type and quantity of the cast product to be produced per unit quantity of the cast product A plan creation means for creating an operation plan for producing the cast product using the casting machine based on a production plan including the casting weight of the casting, and the casting product is produced based on the operation plan by the plan creation means And a work instruction means for instructing a work for preparing the molten metal by grasping an amount of the molten metal necessary for the operation. The work instruction means performs an operation simulation based on an operation plan by the plan creation means, and therefore, at least a condition calculation means for obtaining a total amount of metal material input to the melting furnace, the plan creation means, and the condition calculation means Based on the simulation means for performing the operation simulation from the operation start to the end so that the molten metal holding amount becomes an appropriate value based on the simulation result by the simulation means, the instruction of the charging time and the charging amount of the metal material to the melting furnace And a calorific value calculation means for calculating a melting heat amount of the melting heat source at each time and a holding heat amount of the holding heat source at each time based on a simulation result by the simulation means.

  In the first invention, the condition calculating means is a molten metal pumped from the melting furnace to the casting machine per unit time based on production plan information such as the type and quantity of the cast product and the casting weight per unit quantity of the cast product. Means for calculating the quantity shall be provided.

  According to the first invention, the total amount of metal material input to the melting furnace is obtained based on the operation plan of the foundry, and the simulation from the start to the end is performed so that the molten metal holding amount of the melting furnace becomes an appropriate value. Based on the result of this simulation, the time and amount of metal material input to the melting furnace are instructed. Further, the amount of heat of dissolution of the heat source for melting and the amount of heat of retention of the heat source for holding are calculated based on the result of the simulation. Therefore, an appropriate amount of metal material can be input at each time of manufacture without excess or deficiency, and the amount of molten metal in the melting furnace can be set to an appropriate value.

  According to a second aspect of the present invention, in the first aspect of the present invention, the monitoring collection for monitoring and collecting in real time the amount of metal material charged into the melting furnace, the time of charging, the amount of heat of melting of the melting heat source, and the amount of heat retained of the holding heat source And an evaluation unit that compares and evaluates the result of monitoring and collecting by the monitoring and collecting unit with respect to the instruction content instructed by the work instruction unit.

  In the second invention, the metal material input amount monitoring and collecting means includes not only direct monitoring but also means for calculating the material input amount setting means and the input time.

  According to the second aspect of the invention, the monitoring and collecting means monitors and collects the charging time and amount of the metal material into the melting furnace, the melting heat amount of the melting heat source, and the holding heat amount of the holding heat source. These monitoring results are compared and evaluated against the instruction content of the work instruction means. Therefore, the operation state of the melting furnace is evaluated for the contents instructed by the work instruction means. Accordingly, the operation state of the melting furnace is corrected so as to approach the instruction content, and the operation of the melting furnace can be performed efficiently.

  According to a third invention, in the first or second invention, the condition calculation means includes material input amount setting means for setting the metal material input amount to the melting furnace in consideration of the amount of return material or defective product. The return material is removed when the cast product is taken out at a site associated with the cast product, and returned to the melting furnace and returned to the molten metal, and the defective product was not manufactured as designed. It is a cast product that is returned to the melting furnace and returned to the molten metal.

  According to the third aspect of the invention, the amount of the metal material input to the melting furnace is determined in consideration of the amount of return material or defective product and the casting weight pumped from the melting furnace to the casting machine. Therefore, the amount of metal material input can be made more appropriate.

  According to a fourth aspect of the present invention, in any one of the first to third aspects of the present invention, the condition calculation means is configured such that after the start of the pumping of the molten metal from the melting furnace to the casting machine, the molten metal holding amount of the melting furnace And a melting start time determining means for determining a melting start time of the metal material in consideration of a time required for melting so that the metal material can be melted by being introduced into the melting furnace before reaching the above.

  According to the fourth aspect of the invention, the melting start time of the metal material is determined in consideration of the time required for melting until the metal material is charged into the melting furnace and melted. For this reason, it is possible to avoid a situation in which the molten metal holding amount falls below the lower limit value by preventing the melting start time from being delayed and delaying the melting of the metal material.

  According to a fifth invention, in any one of the first to fourth inventions, the simulation means calculates the amount of molten metal retained in the melting furnace at each time based on the required casting amount at each time given by the condition calculation means. Molten metal holding amount calculating means, and material weight calculating means for calculating the weight of the metal material put into the melting furnace at each time. The material input instructing unit instructs the metal material input time and the input amount based on the weight transition of the metal material set by the material weight calculating unit, and the heat amount calculating unit is operated by the molten metal holding amount calculating unit. Based on the calculated molten metal holding amount, the melting heat amount of the melting heat source at each time and the holding heat amount of the holding heat source at each time are calculated.

  According to the fifth invention, when performing the simulation from the start to the end of the operation, the molten metal holding amount at each time is calculated based on the casting weight from the melting furnace to the casting machine at each time, and this molten metal holding amount Based on the above, the amount of heat of the melting heat source and the holding heat source at each time is calculated. Further, the weight of the metal material at each time in the melting furnace is calculated, and the time and amount of the metal material charged into the melting furnace are instructed based on the weight of the metal material. Therefore, an appropriate amount of metal material can be input without excess or deficiency at each time of manufacture, and the amount of molten metal retained in the melting furnace can be set to an appropriate value.

  In a sixth aspect based on the fifth aspect, the weight of the metal material calculated by the material weight calculating means is A, which is the casting weight at each time given by the condition calculating means, and the molten metal holding amount calculating means. Assuming that the calculated molten metal holding amount is B and the preset target value of the molten metal holding amount is C, the metal material charging time and the charging amount before the end of the operation of the casting machine on that day at the timing when A = BC is satisfied. And an operation plan is created so that the molten metal holding amount of the melting furnace approaches the target value C at the end of the operation of the casting machine.

  According to the sixth invention, when this melting furnace operation is performed, the amount of material input before the end of the operation of the casting machine is only the return material, and the molten metal retention amount B resulting from the melting of only the return material at each time and the target value Since the operation with the difference from C almost equal to the casting weight A at each time is continued, and finally the return material becomes zero at the end of the operation of the casting machine, the melting retention amount B of the melting furnace is the target value. Matches C and ends. Therefore, the molten metal holding amount can be brought close to the target value at the end of the operation of the casting machine. Therefore, the energy consumption of the melting furnace holding heat source after the operation of the casting machine can be suppressed.

  The seventh invention comprises a melting furnace for melting a metal material to hold the molten metal, and a casting machine for producing a cast product by receiving the molten metal from the melting furnace, the melting furnace comprising a metal material In the computer program for a melting furnace operation plan creation device comprising a melting heat source for melting the molten metal and a holding heat source for maintaining the temperature of the molten metal, Plan creation means for creating an operation plan for producing the cast product using the casting machine based on a production plan including a casting weight of the casting, and producing the cast product based on the operation plan by the plan creation means It is a program for causing a computer to function as work instruction means for instructing work for preparing the molten metal by grasping the amount of molten metal necessary for the operation, and the work instruction means is the plan creation means. In order to perform an operation simulation based on the operation plan according to the above, a condition calculation means for obtaining at least the total amount of metal material charged into the melting furnace, and the molten metal retention amount becomes an appropriate value based on the plan creation means and the condition calculation means The simulation means for performing the operation simulation from the start to the end of the operation, the material input instruction means for instructing the input time and the input amount of the metal material to the melting furnace based on the simulation result by the simulation means, and the simulation And a calorific value calculating means for calculating a melting heat amount of the melting heat source at each time and a holding heat amount of the holding heat source at each time based on a simulation result by the means.

  According to the seventh aspect, the same effect as that of the first aspect can be achieved.

  An eighth invention includes a melting furnace that melts a metal material into a molten metal and holds the molten metal, and a casting machine that receives the molten metal from the melting furnace to produce a cast product, the melting furnace comprising a metal material In the computer program for a melting furnace operation plan creation device comprising a melting heat source for melting the molten metal and a holding heat source for maintaining the temperature of the molten metal, Plan creation means for creating an operation plan for producing the cast product using the casting machine based on a production plan including a casting weight of the casting, and producing the cast product based on the operation plan by the plan creation means A computer-readable recording medium storing a program for causing a computer to function as work instruction means for grasping the amount of molten metal necessary for the preparation and instructing work for preparing the molten metal And the work instruction means performs an operation simulation based on the operation plan by the plan creation means, so that at least a condition calculation means for obtaining a total amount of metal material charged into the melting furnace, the plan creation means and the condition calculation Simulation means for performing an operation simulation from the start to the end of the operation so that the molten metal holding amount becomes an appropriate value based on the means, and the charging time and amount of the metal material to the melting furnace based on the simulation result by the simulation means A material input instructing unit for instructing the above, and a calorific value calculating unit for calculating a melting heat amount of the melting heat source at each time and a holding heat amount of the holding heat source at each time based on a simulation result by the simulation unit. .

  According to the eighth aspect, the same effect as the first aspect can be achieved.

  A ninth invention includes a melting furnace that melts a metal material into a molten metal and holds the molten metal, and a casting machine that receives the molten metal from the melting furnace to produce a cast product, the melting furnace comprising a metal material A melting furnace operation plan creation method comprising a melting heat source for melting a molten metal and a holding heat source for maintaining the temperature of the molten metal, wherein the type of cast product to be produced, quantity, A plan creation procedure for creating an operation plan for producing the cast product using the casting machine based on a production plan including a casting weight, and the cast product is produced based on an operation plan based on the plan creation procedure. And a work instruction procedure for instructing a work for preparing the molten metal, and the work instruction procedure is for performing an operation simulation based on an operation plan according to the plan creation procedure. Little In addition, based on the condition calculation procedure for obtaining the total amount of metal material input to the melting furnace, and the operation simulation from the start to the end of the operation so that the molten metal retention amount becomes an appropriate value based on the plan creation procedure and the condition calculation procedure A simulation procedure, a material input instruction procedure for instructing an input time and an input amount of the metal material to the melting furnace based on a simulation result by the simulation procedure, and the melting at each time based on a simulation result by the simulation procedure And a calorific value calculation procedure for calculating a calorific value of the heat source for melting and a calorific value of the heat source for retention at each time.

  According to the ninth aspect, the same effect as that of the first aspect can be achieved.

It is a functional block diagram which shows one Embodiment of this invention. It is a system configuration figure of the above-mentioned embodiment. It is a flowchart which is a part of computer program of the said embodiment, and shows the production schedule creation process content. It is a part of computer program of the said embodiment, and is a flowchart which shows the initial condition calculation process content. It is a part of computer program of the said embodiment, and is a flowchart which shows the operation simulation process content. It is a detailed flowchart of the molten metal holding | maintenance amount estimation step in the flowchart of FIG. It is a detailed flowchart of the melt | dissolution chamber material weight transition calculation step before the melt | dissolution start in the flowchart of FIG. It is a detailed flowchart of the melt | dissolution chamber material weight transition calculation step after the melt | dissolution start in the flowchart of FIG. It is a plan figure which shows the plan which produces using a some casting_mold | template from the operation start to the completion | finish in the said embodiment. In the said embodiment, it is a plan figure which shows the mode of the casting total weight calculation to each casting_mold | template from the operation start to completion | finish, and a metal material injection plan. It is a time chart which shows the number of shots of each casting machine from the operation start to the end in the above embodiment, and the cumulative value of the number of shots. It is a time chart which shows the weight transition of the return material from the operation start to the end in the said embodiment. It is a time chart similar to FIG. 12, and is an enlarged view showing an operation end portion in an enlarged manner. It is a time chart which shows the casting weight accumulation value from the operation start to the end in the said embodiment. It is a time chart which shows the residual amount of the casting weight total value from the operation start to an end in the said embodiment. It is a time chart which shows transition of the molten metal holding | maintenance amount from the operation start to the completion | finish in the said embodiment. It is a time chart which shows transition of the melting chamber material weight from the operation start in the said embodiment to completion | finish. It is a display figure which shows the display image of the computer of the said embodiment, and is used at the time of production plan preparation. Like FIG. 18, it is a display figure used at the time of production plan preparation, and the confirmation figure of the produced production plan is shown. It is a display figure which shows the display image of the computer of the said embodiment, and shows the result of the production simulation based on production plan preparation. It is a display figure of the work instruction which shows the display picture of the computer of the above-mentioned embodiment. It is a display figure which shows the display image of the computer of the said embodiment, and represents the gas consumption of the gas burner for melting | dissolving of a melting furnace, and a holding | maintenance. It is a display figure which shows the display image of the computer of the said embodiment, and represents the progress of production. It is a display figure which shows the display image of the computer of the said embodiment, and represents production performance. It is a display figure which shows the display image of the computer of the said embodiment, and compares and shows a plan and a performance. It is explanatory drawing which shows an example of a melting furnace.

  FIG. 1 illustrates one embodiment of the present invention. This embodiment is an operation support system for a melting furnace 10 used in a factory that manufactures a cast product using a plurality of melting furnaces 10 and a casting machine 20, and includes an operation plan creation device for the melting furnace 10, Based on the operation plan, a work instruction is given to the worker so that the material is charged into the melting furnace 10. In addition, the actual operation status of the melting furnace 10 is monitored, and evaluation based on the deviation from the work instruction is performed. In addition, the melting furnace 10 and the casting machine 20 are the same as what was demonstrated in FIG.

  FIG. 2 shows the system configuration of the operation support system. The computer 41 includes a display 42 and is connected to a LAN cable 43. The LAN cable 43 is connected to a measuring device 46 that measures the metal material charging time, charging amount, molten metal amount, etc. of each melting furnace 10. Some of the measuring devices 46 are connected to the LAN cable 43 via wireless communication devices 45 and 46.

  The operation support system according to the embodiment includes a plan creation means for creating an operation plan for producing a cast product using the casting machine 20 based on a production plan including the type and quantity of the cast product to be produced, and plan creation. And a work instruction means for grasping the amount of molten metal necessary for producing a cast product based on the operation plan by the means and instructing the work for preparing the molten metal. Since the work instruction means performs an operation simulation based on the operation plan by the plan creation means, at least a condition calculation means for obtaining the total amount of metal material charged into the melting furnace 10, and a molten metal holding based on the plan creation means and the condition calculation means A simulation means for performing an operation simulation from the start to the end of the operation so that the amount becomes an appropriate value, and a material input instruction for instructing an input time and an input amount of the metal material to the melting furnace 10 based on a simulation result by the simulation means And a gas supply amount (corresponding to the heat of dissolution in the present invention) 11a at each time based on the simulation results of the means and the simulation means, and a holding gas at each time Burner (corresponding to the heat source for holding in the present invention) 12a And a heat calculator for calculating the gas supply amount (corresponding to the holding amount of heat in the present invention).

  The condition calculation means includes material input amount setting means for setting the metal material input amount to the melting furnace 10 in consideration of the amount of return material or defective product. As will be described later, in the melting furnace 10, in addition to the ingot as a virgin material as a metal material, a return material and a defective product are input. The return material is a part associated with the cast product, and is removed when the cast product is taken out, returned to the melting furnace 10 and returned to the molten metal. The defective product is a cast product that is not manufactured as designed, and is returned to the melting furnace 10 and returned to the molten metal.

  The simulation means includes a molten metal holding amount calculating means for calculating a molten metal holding amount of the melting furnace 10 at each time based on a required casting amount at each time given by the work instruction means, and a metal material charged into the melting furnace 10. Material weight calculating means for calculating the weight at each time. The material input instructing unit instructs the input time and the input amount of the metal material based on the weight transition of the metal material calculated by the material weight calculating unit. The calorific value calculating means calculates the gas supply amount of the melting gas burner 11a at each time and the gas supply amount of the holding gas burner 12a at each time based on the molten metal holding amount calculated by the molten metal holding amount calculating means. To do.

  The operation support system of the embodiment includes the amount of metal material input to the melting furnace 10 at each time, the gas supply amount of the melting gas burner 11a at each time, and the gas supply amount of the holding gas burner 12a at each time. Monitoring means for monitoring, and evaluation means for comparing and evaluating the results monitored by the monitoring means with respect to the instruction content instructed by the work instruction means. The monitoring means is configured by a part that processes measurement data of the melting furnace 10 taken into the computer 41 from the measuring device 46.

  According to the embodiment, the total amount of metal material input to the melting furnace 10 is obtained based on the operation plan of the foundry, and a simulation from the start to the end is performed so that the molten metal holding amount of the melting furnace 10 becomes an appropriate value. Based on the result of the simulation, an instruction of the charging time and the charging amount of the metal material to the melting furnace 10 is performed. Further, the gas supply amount of the dissolving gas burner 11a and the gas supply amount of the holding gas burner 12a are calculated based on the result of the simulation. Therefore, an appropriate amount of metal material can be input at each time of manufacture without excess or deficiency, and the amount of molten metal in the melting furnace 10 can be set to an appropriate value.

  In addition, the amount of metal material input to the melting furnace 10 is determined in consideration of the amount of return material or defective products. Therefore, the amount of metal material input can be made more appropriate.

  Furthermore, when performing a simulation from the start to the end of operation, the amount of molten metal held in the melting furnace 10 at each time is calculated based on the casting weight from the melting furnace 10 to the casting machine 20 at each time, and based on this amount of molten metal held. The gas supply amount of the dissolving gas burner 11a and the gas supply amount of the holding gas burner 12a at each time are set. Further, the weight of the metal material at each time in the melting furnace 10 is set, and the time and amount of the metal material charged into the melting furnace 10 are instructed based on the weight of the metal material. Therefore, an appropriate amount of metal material can be input without excess or deficiency at each time of manufacture, and the amount of molten metal in the melting furnace 10 can be set to an appropriate value.

  Furthermore, the amount of metal material charged into the melting furnace 10, the gas supply amount of the melting gas burner 11a, and the gas supply amount of the holding gas burner 12a are monitored by the monitoring means. These monitoring results are compared and evaluated against the instruction content of the work instruction means. Therefore, the operation state of the melting furnace 10 is evaluated for the contents instructed by the work instruction means. Therefore, the operation state of the melting furnace 10 is corrected so as to approach the instruction content, and the operation of the melting furnace 10 can be performed efficiently.

  3-8 shows the program content of the computer 41 which functions the operation assistance system of embodiment. When the production schedule creation is selected by the computer 41, the production schedule creation processing routine of FIG. 3 is started, and the production plan input screen of FIG.

  In step S1 of FIG. 3, the model number, quantity, and number of defective products are input for each melting furnace 10 on the production plan input screen of FIG. The model number means a mold different for each type of cast product, and the defective product is a cast product that is not manufactured as designed, and is returned to the melting furnace 10 and returned to the molten metal. In addition, the defective product is generated in the past manufacturing process. In step S2, the production schedule creation time is set as the operation start time. In step S3, it is determined whether or not the model number n produced at this time is the same as the model number produced immediately before. If a negative determination is made in step S3, the mold changing time is added to the production schedule in step S4. If step S3 is positively determined, step S4 is skipped, and in step S5, the rounding time is added to the production schedule. Next, in step S6, the production time is added to the production schedule. In step S7, it is determined whether n has reached the number of types of model numbers. That is, it is determined whether or not the production schedule settings for all model numbers have been completed. If a negative determination is made in step S7, the process returns to step S3, and the remodeling time, discard time, and production time are continuously added to the production schedule. FIG. 9 shows the production schedule set in this way. Here, a case where there are 10 types of molds is shown.

  If the determination in step S7 is affirmative, in step S8, work overlapping with the break time is extracted. The break time is the time when the casting machine 20 stops, and the break time is determined in advance as the start time and time. In step S9, the time from the start of the work with the break time on the way to the start of the break is calculated. For example, the time indicated as production 2 before break 1 in FIG. 9 is calculated. In step S10, the production time from the end of the break is calculated. For example, the time indicated as production 2 after break 1 in FIG. 9 is calculated. In step S11, the end time of the work time overlapping with the break time is calculated. For example, the end time of production 2 in FIG. 9 is calculated. In step S12, the production time including the break time is added to the production schedule. In step S13, it is determined whether or not all considerations for the predetermined break time have been completed. When a negative determination is made in step S13, the process returns to step S8, and another break time is set in the same manner as described above. If the determination in step S13 is affirmative, it is determined in step S14 whether the production schedule end time is earlier than the operation end time. If the end time of the production schedule is later than the operation end time, a negative determination is made in step S14, the process returns to step S1, and the production plan is input again. On the other hand, if the end time of the production schedule is earlier than the operation end time, an affirmative determination is made in step S14 and the process of the production schedule creation processing routine is ended. This completes the production schedule setting.

  When the setting of the production schedule is completed as described above, the set schedule is displayed as shown in FIG. In FIG. 18, 51 is a production schedule creation date, 52 is a registration button, 53 is a production schedule registration column, and 54 is a defective product registration column. In FIG. 19, 61 is a production plan display button (indicating that the production plan display screen is displayed), 62 is a button for selecting today or tomorrow, and 63 is a correction input button (a “correction” button is pressed). If the "Enter" button is pressed, the production plan edit screen for the next day or later is opened.) 64 is a start button (simulation of the day selected in 62 above) The result is displayed on the screen of FIG. 20), and 65 indicates a production plan display (displays the production plan for each facility on the day selected in 62 above).

Next, the calculation of the initial condition for performing the operation simulation is performed by the initial condition calculation processing routine of FIG. First, in step S21, the number of shots is calculated based on the production schedule. The state of this calculation is shown in the upper time chart of FIG. In the time chart, a plurality of clusters 1 to 10 in which the number of shots rises represent the number of shots of each casting machine. Among them, the region indicated by a with a small number of shots is a portion corresponding to discarding, and the region indicated by b with a large number of shots is a portion corresponding to production. In the next step S22, the transition of the cumulative value of the number of shots is calculated. Here, the number of shots calculated in step S21 is accumulated, and the result is as shown in the lower time chart of FIG. In step S23, the total casting weight based on the production schedule is calculated. That is, the total casting weight is calculated from the number of shots calculated in step S21 and the casting weight per shot. In step S24, the total weight of defective products is calculated. That is, the weight of defective products for each casting machine (model number) that has already occurred is calculated. In step S25, the total weight of the return material is calculated. That is, the total weight of the return material is calculated from the number of shots calculated in step S21 and the weight of the return material generated for each shot. In step S26, the weight of the next straight return material is calculated. Even if the return material is generated, it is returned to the melting furnace and consumed so that it is lost at the end of the operation. FIG. 12 shows the transition of the return material weight. As shown in FIG. 13, when the return material decreases and becomes equal to or less than a preset weight of the next direct return material, the remaining return material at that time is stored as the next direct return material. In step S27, the total input amount of the ingot as the virgin material of the metal material is calculated. FIG. 10 shows a calculation method. The total casting weight value in FIG. 10 is calculated in step S23, and the next straight return weight (the previous straight portion and the next straight portion), the defective product (total value), and the return weight in the material calculation in FIG. (1-10) is calculated in steps S24-26. From these data, the total amount of ingot is calculated by the following formula.
Total ingot input amount = total casting weight value-next straight return material weight (front straight portion)-defective product input amount-return material weight (1 to 10) + next straight return material weight (next straight portion)

  In steps S28 and 29, the melting chamber material weight and the material input amount are set to zero as initial conditions. In step S30, the molten metal holding amount is set as an initial condition to any one of the immediately preceding molten metal holding amount estimated value, set value, or correction value. In step S31, the dissolved gas amount is set to zero as an initial condition, and in step S32, the retained gas amount is set as the retained gas amount in the immediately preceding estimated molten metal retained amount. In step S33, a dissolution start time is calculated. A calculation method will be described with reference to FIG. A difference value between the molten metal holding amount calculated in step S30 and the lower limit value (set value) of the molten metal holding amount is obtained. On the other hand, the cumulative value of the casting weight is obtained by multiplying the transition of the cumulative value of the number of shots calculated in step S22 by the casting weight of each casting machine. From the cumulative value of the casting weight and the difference value, a time at which the cumulative value of the casting weight does not exceed the difference value is obtained as a holding amount limit time. The melting start time is obtained by going back from the holding amount limit time by a time necessary for melting the metal material in the melting furnace. Thereby, the processing of the initial condition calculation processing routine ends.

  Next, when the operation simulation is started, the operation simulation processing routine of FIG. 5 is executed. Hereinafter, a description will be given with reference to FIG.

  In step S41, the total casting weight is calculated. This is the same as step S23 described above. In step S42, the total casting weight obtained in step S41 is set as an initial value, and the casting weight at each time calculated in step S41 is subtracted to calculate the remaining casting weight at each time. The calculation result of step S42 is as shown in FIG.

In the next step S50, the molten metal holding amount is estimated. Details of the processing content of step S50 will be described with reference to FIG. In step S51, the molten metal holding amount is set to the initial value set in step S30 described above. In step S52, the unit time is added to the calculation time. In step S53, it is determined whether or not the retention amount limit time obtained in step S33 described above has been reached. If the holding amount limit time has not been reached and a negative determination is made in step S33, the current molten metal holding amount is calculated by the following equation 1 in step S54, and the processes in steps S52 to S54 are performed until a positive determination is made in step S53. repeat.
Current molten metal holding amount = Mold molten metal holding amount−Casting weight at current time Formula 1

When the holding amount limit time is reached and the determination in step S33 is affirmative, in step S55, it is determined whether or not the remaining casting weight is greater than the difference between the molten metal holding amount and its target value. Here, the target value is a value close to the lower limit value. As a result, the molten metal holding amount at the end of the operation is set to the target value, and the gas consumption amount of the holding gas burner can be suppressed. When a negative determination is made in step S55, the current molten metal holding amount is calculated by the above equation 1 in step S56. On the other hand, when an affirmative determination is made in step S55, the current molten metal holding amount is calculated by the following equation 2 in step S57. At this time, since melting in the melting furnace has already started, the amount of melting is added in Equation 2.
Current molten metal holding amount = the previous molten metal holding amount−the casting weight at the current time + the molten amount per unit time.

  In step S58, it is determined whether or not the current molten metal holding amount has reached the upper limit value of the molten holding amount. Until this step S58 is positively determined, the unit time is added by step S59, and the processing of steps S55 and S57 is repeated. If an affirmative determination is made in step S58, the dissolved gas burner is stopped in step S60, and the current molten metal holding amount is calculated by the above equation 1 in the time obtained by adding the required melting time to the preset dissolved gas burner stop time. . Thereafter, the processing after step S55 is repeated.

  When the molten metal holding amount estimation process in FIG. 6 is completed as described above, the gas amount of the holding gas burner is calculated in step S43 in FIG. Here, the gas amount is determined according to the molten metal holding amount determined in step S50. In step S44, the amount of gas in the dissolving gas burner is calculated. Here, the melting gas burner is operated at a time that is back by the time required for melting with respect to the time when the molten metal holding amount obtained in step S50 increases. The gas amount at this time is a gas amount set in advance. The melting gas burner is stopped at the time when the molten metal holding amount decreases.

  In step S70, the transition of the melting chamber material weight before the start of melting is calculated. Details of the processing content of step S70 will be described with reference to FIG. In step S71, it is determined whether there is a defective product at this time. If there is a defective product, an affirmative determination is made in step S71, and in step S72, a material input time taking into account the defective product is calculated. That is, in order to load the next straight return material (previous straight part), defective products and ingots by the melting start time, the time earlier than the melting start time by the charging interval time is the ingot charging time and the charging interval time from the ingot charging time. The time that is earlier by the minute is the defective product input time, and the time that is earlier than the defective product input time by the input interval time is the next direct return material (previous direct component) input time. In step S73, the melting chamber material weight taking into account defective products is calculated. That is, the weight in the melting chamber until the melting start time is the next straight return material (front straight portion) from the time when the next direct return material (previous direct portion) is input to immediately before the defective product input time, and the ingot is input from the defective product input time. Immediately before the time, add the amount of defective products to the next straight return material (the previous straight portion), and add the next direct return material (the previous straight portion) and the amount of defective products to the start time of melting from the defective product introduction time. Add the basic ingot amount.

  If there is no defective product, a negative determination is made in step S71, and in step S74, the material input time without defective products is calculated. That is, since the next straight return material (the previous straight portion) and the ingot are charged before the melting start time, the time earlier than the melting start time by the charging interval time is earlier than the ingot charging time and the charging time by the charging interval time. The time is set as the time of the next straight return material (previous direct). In step S75, the weight of the melting chamber material without defective products is calculated. That is, the weight in the melting chamber until the melting start time is from the time when the next straight return material (previous straight portion) is charged to the time immediately before the ingot charging time until the next straight return material (prior straight portion), from the ingot charging time to the melting start time. Adds the ingot basic input amount to the next straight return material (front straight).

When the melting chamber material weight transition calculation process before the start of melting in FIG. 7 ends as described above, the melting chamber material weight transition after the start of melting is calculated in step S80 of FIG. Details of the processing content of step S80 will be described with reference to FIGS. In step S81, the material input amount excluding the material input before the start of melting is calculated. In step S82, the time is set as the melting start time, and in step S83, the time obtained by adding the time required for melting is set as the current time. In step S84, it is determined whether or not the defective product input amount is greater than or equal to the defective basic input amount among the material input amounts calculated in step S81. The basic amount of defective products refers to the basic amount when defective products are charged into the melting furnace. If the determination in step S84 is affirmative, it is determined in step S85 whether or not the difference between the preset melting chamber material weight upper limit value and the melting chamber material weight at that time is equal to or greater than the defective basic input amount. If a positive determination is made in step S85, a defective product is introduced in step S86. In step S87, the unit time is added, and in step S88, the melting chamber material weight is calculated by the following equation 3. Thereafter, steps S86 to 88 are executed until a negative determination is made in step S85, and steps S85 to 88 are executed until a negative determination is made in step S84.
Dissolving chamber material weight = Dissolving chamber material weight before unit time-Dissolving time within unit time x Dissolving amount Formula 3

  If a negative determination is made in step S85, it is determined in step S89 whether or not the difference between the melting chamber material weight upper limit value and the melting chamber material weight at that time is equal to or greater than the ingot basic input amount. If the determination in step S89 is affirmative, in step S90, the ingot basic input amount is added to the melting chamber material weight, and the ingot basic input amount is subtracted from the ingot total value. In step S91, the unit time is added, and in step S92, the melting chamber material weight is calculated by the above equation 3. In step S93, it is determined whether or not the total value of the ingot is equal to or greater than the ingot basic input amount. Thereafter, the processes in steps S89 to S93 are executed until a negative determination is made in step S89 or step S93.

  If a negative determination is made in step S89 or step S93, in step S94, it is determined whether or not the difference between the melting chamber material weight upper limit value and the melting chamber material weight at that time is equal to or greater than the return material basic input amount. If the determination in step S94 is affirmative, in step S95, the return material basic input amount is added to the melting chamber material weight, and the return material basic input amount is subtracted from the return material accumulated value. In step S96, the unit time is added, and in step S97, the melting chamber material weight is calculated by the above equation 3. In step S98, it is determined whether the return material accumulated value is equal to or greater than the return material basic input amount. Thereafter, the processes in steps S94 to S98 are executed until a negative determination is made in step S98.

  When the molten metal holding amount estimation process in FIG. 8 is completed as described above, in step S45 in FIG. 5, the material input instruction obtained in steps S70 and S80 is issued. When the operation simulation is completed as described above, the simulation result is displayed on the display 42 as shown in FIG. In FIG. 20, 71 is an equipment selection button (used to switch the equipment to be displayed), 72 is a change in the amount of gas used in the dissolving gas burner, 73 is a change in the material weight of the melting chamber, 74 is a material input signal, 75 is It shows the transition of the amount of molten metal retained.

  FIG. 21 shows a screen for performing an operation instruction. The lower left side of the screen is an area for instructing work, and the lower right side of the screen is an area for enabling manual change of work contents as needed. 22 to 24 are screen displays for monitoring the actual operation state of the casting machine. In FIG. 22, the gas usage of the melting gas burner is displayed so as to be comparable with the planned value. In FIG. 23, the number of shots is displayed so as to be comparable with the planned value. In FIG. 24, the production quantity and the gas usage are tabulated and displayed. FIG. 25 shows the operation results for the plan in comparison.

  The correspondence between the processing contents of the computer program described in the above flowchart and each means and each procedure of the present invention is as follows.

  The processing in steps S1 to S14 in FIG. 3 corresponds to the plan creation means of the present invention. 4 corresponds to the work instruction means of the present invention, the processes of steps S21 to S27 correspond to the material input amount setting means of the present invention, and the process of step S33 corresponds to the present process. This corresponds to the dissolution start time determining means of the invention. Further, the processes of steps S41, S42, S50, S70, and S80 in FIG. 5 correspond to the simulation means of the present invention, and the process of step S50 corresponds to the molten metal holding amount calculation means of the present invention, and steps S70 and S80. This process corresponds to the material weight calculating means of the present invention. The processing of steps S43 and S44 in FIG. 5 corresponds to the material input instruction means of the present invention, and the processing of step S45 corresponds to the heat quantity calculation means of the present invention.

  As mentioned above, although specific embodiment was described, this invention is not limited to those external appearances and structures, A various change, addition, and deletion are possible in the range which does not change the summary of this invention. For example, in the above embodiment, the operator is instructed by the material input instructing means and the heat amount calculating means, but the material is instructed by the material input instructing means using an actuator, and the heat amount calculating means is applied to the heat source. The amount of heat may be controlled.

10 Melting furnace 11 Melting chamber 11a Gas burner for melting (heat source for melting)
12 Holding chamber 12a Gas burner for holding (Heat source for holding)
13 Pumping chamber 13a Pumping opening 13b Full sensor 20 Casting machine 31 Metal material 32 Return material 33 Molten metal 41 Computer 42 Display 43 LAN cables 44, 45 Wireless communication device 46 Measuring equipment

Claims (9)

A melting furnace that melts a metal material into a molten metal and holds the molten metal, and a casting machine that receives the molten metal from the melting furnace to produce a cast product, the melting furnace for melting the metal material A melting furnace operation plan creation device comprising a heat source and a holding heat source for maintaining the temperature of the molten metal,
A plan creation means for creating an operation plan for producing the cast product using the casting machine based on a production plan including a type and a quantity of the cast product to be produced and a casting weight per unit quantity of the cast product; ,
Grasping the amount of molten metal necessary for producing the cast product based on the operation plan by the plan creating means, and comprising work instruction means for instructing work for preparing the molten metal,
The work instruction means includes
In order to perform an operation simulation based on the operation plan by the plan creation means, at least a condition calculation means for obtaining the total amount of metal material input to the melting furnace,
Simulation means for performing an operation simulation from the operation start to the end so that the molten metal retention amount becomes an appropriate value based on the plan creation means and the condition calculation means,
Material input instruction means for instructing the input time and the input amount of the metal material to the melting furnace based on the simulation result by the simulation means,
A melting furnace operation plan creation apparatus, comprising: a calorific value calculating means for calculating a calorific value of the melting heat source at each time and a calorific value of the holding heat source at each time based on a simulation result by the simulation means. In claim 1,
Monitoring and collecting means for monitoring and collecting in real time the amount of metal material charged into the melting furnace, the time of charging, the amount of heat of melting of the melting heat source, and the amount of heat of holding of the holding heat source;
An apparatus for creating an operation plan for a melting furnace, comprising: evaluation means for comparing and evaluating results monitored and collected by the monitoring and collecting means with respect to the instruction contents instructed by the work instruction means. In claim 1 or 2,
The condition calculation means includes material input amount setting means for setting the metal material input amount to the melting furnace in consideration of the amount of return material or defective product,
The return material is removed when the cast product is taken out at a site associated with the cast product, returned to the melting furnace and returned to the molten metal,
The defective product is a casting product that has not been manufactured as designed, and is returned to the melting furnace and returned to the molten metal. In any one of Claims 1-3,
The condition calculation means is capable of melting by pouring a metal material into the melting furnace until the molten metal holding amount of the melting furnace reaches a lower limit after the pumping of the molten metal from the melting furnace to the casting machine is started. A melting furnace operation plan creation device comprising melting start time determining means for determining a melting start time of a metal material in consideration of a required melting time. In any one of Claims 1-4,
The simulation means includes
A molten metal holding amount calculating means for calculating a molten metal holding amount of the melting furnace at each time based on a required casting amount at each time given by the condition calculating means;
A material weight calculating means for calculating a weight at each time of the metal material put into the melting furnace,
The material input instruction means instructs the input time and the input amount of the metal material based on the weight transition of the metal material set by the material weight calculation means,
The calorific value calculation means is a melting furnace for calculating the melting heat amount of the melting heat source at each time and the holding heat amount of the holding heat source at each time based on the molten metal holding amount calculated by the molten metal holding amount calculating means. Operation plan creation device. In claim 5,
The weight of the metal material calculated by the material weight calculating means is A, which is the casting weight at each time given by the condition calculating means, and B is the molten metal holding amount calculated by the molten metal holding amount calculating means. Assuming that the set target value of the molten metal holding amount is C, the metal material charging time and the charging amount before the end of the casting machine operation on the day are controlled at the timing when A = B−C is established, and at the end of the casting machine operation A melting furnace operation plan creation device that creates an operation plan that brings the molten metal holding capacity of the melting furnace closer to the target value. A melting furnace that melts a metal material into a molten metal and holds the molten metal, and a casting machine that receives the molten metal from the melting furnace to produce a cast product, the melting furnace for melting the metal material In a computer program for a melting furnace operation plan creation device comprising a heat source and a holding heat source for maintaining the temperature of the molten metal,
A plan creation means for creating an operation plan for producing the cast product using the casting machine based on a production plan including the type and quantity of the cast product to be produced and a casting weight per unit quantity of the cast product,
It is a program that causes a computer to function as work instruction means for grasping the amount of molten metal necessary for producing the cast product based on the operation plan by the plan creating means and instructing work for preparing the molten metal,
The work instruction means includes
In order to perform an operation simulation based on the operation plan by the plan creation means, at least a condition calculation means for obtaining the total amount of metal material input to the melting furnace,
Simulation means for performing an operation simulation from the operation start to the end so that the molten metal retention amount becomes an appropriate value based on the plan creation means and the condition calculation means,
Material input instruction means for instructing the input time and the input amount of the metal material to the melting furnace based on the simulation result by the simulation means,
A computer program for a melting furnace operation plan creation apparatus, comprising: a calorific value calculating means for calculating a calorific value of the melting heat source at each time and a calorific value of the holding heat source at each time based on a simulation result by the simulation means . A melting furnace that melts a metal material into a molten metal and holds the molten metal, and a casting machine that receives the molten metal from the melting furnace to produce a cast product, the melting furnace for melting the metal material In a computer program for a melting furnace operation plan creation device comprising a heat source and a holding heat source for maintaining the temperature of the molten metal,
A plan creation means for creating an operation plan for producing the cast product using the casting machine based on a production plan including the type and quantity of the cast product to be produced and a casting weight per unit quantity of the cast product,
A program for causing the computer to function as work instruction means for grasping the amount of molten metal necessary for manufacturing the cast product based on the operation plan by the plan creating means and instructing work for preparing the molten metal was recorded. A computer-readable recording medium,
The work instruction means includes
In order to perform an operation simulation based on the operation plan by the plan creation means, at least a condition calculation means for obtaining the total amount of metal material input to the melting furnace,
Simulation means for performing an operation simulation from the operation start to the end so that the molten metal retention amount becomes an appropriate value based on the plan creation means and the condition calculation means,
Material input instruction means for instructing the input time and the input amount of the metal material to the melting furnace based on the simulation result by the simulation means,
A computer program for a melting furnace operation plan creation apparatus, comprising: a calorific value calculating means for calculating a calorific value of the melting heat source at each time and a calorific value of the holding heat source at each time based on a simulation result by the simulation means A computer-readable recording medium on which is recorded. A melting furnace that melts a metal material into a molten metal and holds the molten metal, and a casting machine that receives the molten metal from the melting furnace to produce a cast product, the melting furnace for melting the metal material A melting furnace operation plan creation method comprising a heat source and a holding heat source for maintaining the temperature of the molten metal,
A plan creation procedure for creating an operation plan for producing the cast product using the casting machine based on a production plan including a type, a quantity, and a casting weight per unit quantity of the cast product to be manufactured;
Grasping the amount of molten metal necessary for producing the cast product based on the operation plan by the plan creation procedure, and comprising a work instruction procedure for instructing work for preparing the molten metal,
The work instruction procedure includes:
In order to perform an operation simulation based on the operation plan by the plan creation procedure, at least a condition calculation procedure for obtaining the total amount of metal material input to the melting furnace,
A simulation procedure for performing an operation simulation from the operation start to the end so that the molten metal retention amount becomes an appropriate value based on the plan creation procedure and the condition calculation procedure,
A material input instruction procedure for instructing an input time and an input amount of a metal material to the melting furnace based on a simulation result by the simulation procedure,
A melting furnace operation plan creation method comprising: a melting amount of heat of the melting heat source at each time based on a simulation result of the simulation procedure; and a heat amount calculation procedure of calculating a holding heat amount of the holding heat source at each time.

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