201139011 六、發明說明： 【發明所屬之技術領域】 本發明係關於一種裝置異常判斷方法，特別是—種庚鎮 異常監控方法。 【先前技術】201139011 VI. Description of the invention: [Technical field to which the invention pertains] The present invention relates to a method for judging abnormality of a device, in particular, a method for monitoring an abnormality of a Geng town. [Prior Art]
在習知洗鑄製程中，以鋁胚澆鑄製程為例，其是藉由緩 慢傾斜靜置爐，將靜置爐内高溫熔融之鋁湯傾倒至開放流 道中，再經由澆盆底部鑄孔流入鑄模内，並由底模逐漸向 下移動，將冷卻固化之金屬引拔成胚體，同時藉由液位控 制系統控制鋁湯注入鑄模内之流量，避免液位過高或過低 而發生鋁湯外溢或爆湯意外。 然而，因為鋁之熱膨脹係數較大且熱傳係數較高，在鋁 胚冷卻固化過程中，凝固面狀態難m m呂湯清 淨度與表面氧化物等問冑，也都會影響淹缚製程穩定性。 所以在習知銘胚洗濤過程中’尤其在剛開始起轉階段，常 常因為異況（例如漏紹、卡模’或逢管破裂等）發生而緊急 中止生產’影響作業率。 漏铭是指轉模内液狀銘湯於鑄模與銘胚接觸面附近流 出丄形成㈣表面隆凸不平整’更嚴重則於_中大量流 出面溫銘湯，接觸到鎊棍下古 埼模下方冷郃水，可能造成大量喷濺 的危險；卡模是指鑄模内鋁 、門鋁胚凝喊卡住鑄模，無法引拔成 胚體’而造成；堯鑄中斷.渙其 所’ w破裂則會造成上方液盆内之 讀大量流入鑄模内，有銘湯外溢的危險。 習知洗鑄設備控制系統大多僅能由單-製程訊號，例如 m 147060.doc 201139011 鑄模液位控制誤差或液位控制輸出變化， 保護°例如料過程中，液位控制誤差大於警戒值= 系統即強制中止生產。習知技術利用單一製程訊號及警戒 值之方式，無法有效分辨異況種類，而且在異況發生初 期，無法提供操作人M明確之異況訊息讓操作人員進行補 救措施4致I知堯鑄產線時常有異況種類判斷錯誤或 異況不嚴重但控制系統卻判定需緊急中止澆鑄之現象，造 成額外的生產延誤與產能損失。 因此’有必要提供__創新且具進步性的洗鎊異常監控方 法’以解決上述問題。 【發明内容】 本發明係提供一種澆鑄異常監控方法，用以在澆鑄一金 屬胚時監控澆鑄製程，該方法包括以下步驟： Ο)進订一澆鑄長度判斷步驟，判斷澆鑄之該金屬胚之 堯鑄長度是否達一預定澆鑄長度；及 (b)若該澆鑄長度之判斷成立，正常澆鑄結束，若該澆 鑄長度之判斷不成立，依據一鑄模金屬液液位、一 液位控制目標、一液位控制輸出及一澆鑄速度進行 一漏液判斷步驟（bi)、一卡模判斷步驟（b2)及一澆管 破裂判斷步驟（b3)，該液位控制目標減該鑄模金屬液 液位之差值百分比定義為液位控制誤差，其中： 該漏液判斷步驟（b 1)包括以下步驟： (b 11)進行—第一漏液判斷步驟，判斷該液位控制輸 出是否大於一第一設定值； 147060.doc -4- 201139011 (b 12)若該第一漏液判斷不成立，回至步驟（a)，若該 第一漏液判斷成立但不超過一第一設定時間， 回至步驟（bll) ’若該第一漏液判斷成立且超過 該第一設定時間，發出漏液預警；In the conventional washing and casting process, an aluminum embryo casting process is taken as an example, in which a high-temperature molten aluminum soup in a static furnace is poured into an open flow path by a slow tilting static furnace, and then flows through a casting hole at the bottom of the pouring basin. Inside the mold, and gradually moving downward from the bottom mold, the cooled and solidified metal is drawn into the embryo body, and the flow rate of the aluminum soup into the mold is controlled by the liquid level control system to prevent the liquid from being too high or too low. The soup overflowed or burst into the soup accident. However, because aluminum has a large thermal expansion coefficient and a high heat transfer coefficient, during the cooling and solidification process of the aluminum embryo, the solidification surface state is difficult to understand, and the surface oxide is also affected. Therefore, in the process of the well-known embryo washing process, especially in the beginning of the turn-up phase, it is often because of the occurrence of abnormal conditions (such as leakage, jamming, or rupture of the pipe) that the production is interrupted. Leaking Ming refers to the liquid-like soup in the mold, which flows out near the contact surface between the mold and the original embryo. (4) The surface is uneven. 'More serious, then a large amount of effluent in the _ medium, the contact with the pound stick The cold water below may cause a lot of splashing danger; the card mold means that the aluminum in the mold, the aluminum door of the door slams into the mold, and cannot be drawn into the embryo body; the casting is interrupted. This will cause a large amount of reading in the upper liquid basin to flow into the mold, and there is a danger of overflowing the soup. Most of the conventional cleaning and casting equipment control systems can only be controlled by single-process signals, such as m 147060.doc 201139011 mold liquid level control error or liquid level control output change, protection, for example, during the process, the liquid level control error is greater than the warning value = system That is, the production is forcibly suspended. The conventional technology uses a single process signal and a warning value to effectively distinguish the type of abnormality, and in the early stage of the abnormal situation, it is impossible to provide the operator M with a clear message to allow the operator to carry out remedial measures. There are often irregularities in the line, or the situation is not serious, but the control system determines that it is necessary to suspend the casting, resulting in additional production delays and capacity losses. Therefore, it is necessary to provide an innovative and progressive method for monitoring the abnormality of the pounds to solve the above problems. SUMMARY OF THE INVENTION The present invention provides a casting abnormality monitoring method for monitoring a casting process when casting a metal blank, the method comprising the steps of: Ο) ordering a casting length judging step to determine the casting of the metal embryo Whether the casting length reaches a predetermined casting length; and (b) if the judgment of the casting length is established, the normal casting is finished, if the judgment of the casting length is not established, according to a mold metal liquid level, a liquid level control target, a liquid level Controlling the output and a casting speed to perform a liquid leakage judging step (bi), a card mold judging step (b2), and a tube cracking judging step (b3), wherein the liquid level control target subtracts the difference between the molten metal liquid level of the mold The percentage is defined as the liquid level control error, wherein: the liquid leakage determining step (b 1) comprises the following steps: (b 11) performing a first liquid leakage determining step of determining whether the liquid level control output is greater than a first set value; 147060.doc -4- 201139011 (b 12) If the first liquid leakage determination is not established, return to step (a), if the first liquid leakage determination is established but does not exceed a first set time, return to step (Bll) 'If the decision is affirmative, and the first leak exceeds the first set time, leakage warning issued;
(b 13)發出漏液預警後’進行一第二漏液判斷步驟， 判斷該液位控制輸出是否大於一第二設定值； (b 14)若該第二漏液判斷不成立，回至步驟（bu)，若 該第二漏液判斷成立但不超過一第二設定時 間’回至步驟（M3)，若該第二漏液判斷成立且 超過該第二設定時間，進行一第三漏液判斷步 驟，判斷該液位控制誤差是否大於一第一設定 誤差；及 (b 1 5)右該第三漏液判斷成立，中止澆鑄，若該第三(b 13) After issuing the liquid leakage warning, a second liquid leakage determination step is performed to determine whether the liquid level control output is greater than a second set value; (b 14) if the second liquid leakage determination is not established, return to the step ( Bu), if the second liquid leakage determination is established but does not exceed a second set time 'return to the step (M3), if the second liquid leakage determination is established and exceeds the second set time, performing a third liquid leakage determination a step of determining whether the liquid level control error is greater than a first set error; and (b 1 5) right third liquid leakage determination is established, stopping casting, if the third
漏液判斷不成立、該第二漏液判斷成立但不超 過一第二設定時間，回至步驟（Μ3)，若該第三 漏液判斷不成立、該第二漏液判斷成立且超過 該第三設定時間，中止澆鑄； 該卡模判斷步驟（b2)包括以下步驟： 147060.doc (b21) (b22) 進行一第一卡模判斷步驟，判斷該液位控制輸 出疋否小於一第三設定值且液位控制誤差是否 大於一第二設定誤差； 若該第—卡模判斷不成立，回至步驟⑷，若該 第一卡模判斷成立但不超過一第四設定時間， 回至步驟（b21)， 若該第一卡模判斷成立且超過 [S] 201139011 該第四設定時間’進行-第二卡模判斷步驟， 判斷液位下降量是否小於一―呵夕驟 直，該液位下降量係為 降 之鱗模金屬液液位下降量第—卡模判斷成立後 ㈨3)若該第二卡模判斷成立1出卡模預警，若該 第一卡模判斷不成立、該第—卡模判斷成立但 不超過一第五設定時間，回至步驟_)，若；If the liquid leakage determination is not established, the second liquid leakage determination is established but does not exceed a second set time, and the process returns to step (Μ3). If the third liquid leakage determination is not established, the second liquid leakage determination is established and the third setting is exceeded. Time, the casting is suspended; the card mode determining step (b2) includes the following steps: 147060.doc (b21) (b22) performing a first card mode determining step to determine whether the liquid level control output is less than a third set value and Whether the liquid level control error is greater than a second setting error; if the first card mode determination is not established, returning to step (4), if the first card mode determination is established but not exceeding a fourth set time, returning to step (b21), If the first card mode determination is established and exceeds [S] 201139011, the fourth set time 'go-second card mode determining step, determining whether the liquid level drop amount is less than one-hour, the liquid level drop amount is The falling scale mold liquid level drop amount - after the card model is judged (9) 3) If the second card model is judged to be 1 out of the card mode warning, if the first card mode judgment is not established, the first card mode judgment is established but No more than a fifth setting Inter back to step _), if;
第二卡模判斷不成立、該第一卡模判斷成立： 超過該第五設定時間，發出卡模預邀. 發出卡模預警後’若該第一卡模判斷成立伸不 超過一第六設定時間，回至步驟（b2i)，發出卡 模預警後且若該第—卡模判斷成立超過該第六 設定時間，進行一第三卡模判斷步驟，判斷該 液位下降量是否小於-第二設定液位下降量； 及 剛若該第三卡模判斷成立，中止澆鑄，若該第三 卡模判斷不成立、該第-卡模判斷成立但不超 過一第七設定時間，回至步驟（b2丨），若該第三 卡模判斷不成立、該第-卡模判斷成立且超過 該第七設定時間，中止澆鑄； 該澆管破裂判斷步驟（b3)包括以下步驟： (b31)進行一第一洗管破裂判斷步驟判斷金屬液填 充率疋否超過一設定金屬液填充率達一第一設 定百分比，且該液位控制誤差是否大於一第三 m 147060.doc 201139011 設定誤差，該金屬液填充率係為鑄模截面積與 該澆鑄速度之乘積； (b32)若該第一澆管破裂判斷不成立，回至步驟⑷， 若該第一澆管破裂判斷成立但不超過—第八設 定時間，回至步驟_)，若該第一洗管破裂判 斷成立且超過該第八設定時間，發出澆管破裂 預警； (b33)發出洗管破裂預警後’進行一第二澆管破裂判 斷步驟，判斷該第一澆管破裂判斷成立是否超 過一第九設定時間且該液位控制誤差是否大於 一第四設定誤差；及 (b34)若該第二澆管破裂判斷不成立，回至步驟 (b31)，若該第二澆管破裂判斷成立，中止澆 對於澆鑄製程之異常狀況，本發明之澆鑄異常監控方法 可自動地判定及預警，可有效判定異況種類’並於異況發 生初期立即發出預警，適當延長反應時間，使得操作人員 能快速發現異況原因並進行補救措施，有效降低澆鑄產線 因製程異常而中止生產之發生頻率，且減少回爐次數與縮 短回爐損失。 【實施方式】 圖1顯示澆鑄一金屬胚之示意圖；圖2顯示本發明澆鑄異 常〇£控方法之流程圖’圖3至圖5分別顯示本發明濟轉異常 監控方法之漏液判斷、卡模判斷及澆管破裂判斷邏輯流程 147060.doc [S] 201139011 圖。 本發明之澆鑄異常監控方法可用以在澆鱗金屬胚時監控 澆鑄製程之異常狀況。在本實施例中，該澆鑄異常監控方 法應用於一鋁胚澆鑄製程。參考圖丨，在本實施例之鋁胚 澆鑄製程中，藉由緩慢傾斜靜置爐（圖中未示），將靜置爐 内高溫熔融之鋁湯11傾倒至開放流道中再至澆盆12中，鋁 湯11再經由澆盆12底部鑄孔121流入鑄模13内，並由底模 14逐漸向下移動，將經冷卻水15冷卻固化之鋁金屬引拔成 胚體（鋁胚）16，同時藉由液位控制系統17控制鋁湯丨丨注入 鑄模13内之流量，避免铸模13内之鋁湯丨丨液位過高或過低 而發生鋁湯外溢或爆湯意外。 配合參考圖1及圖2，該方法包括以下步驟：步驟S1，進 行一澆鑄長度判斷步驟’判斷澆鑄之該金屬胚之澆鑄長度 疋否達一預定澆鑄長度；及步驟S2,若該澆鑄長度之判斷 成立，正常澆鑄結束，若該澆鑄長度之判斷不成立，依據 一鑄模金屬液液位、一液位控制目標、一液位控制輸出及 淹鑄速度進行一漏液判斷步驟S21---^模判斷步驟S22 及-澆管破裂判斷步驟S23。其中，該液位控制目標減該 錄模金屬液液位之差值百分比定義為液位控制誤差。 在步驟S2中係以-液位量測器取得該鑄模金屬液液位； 以速度量測器量測鑄模之底模14下降速度，以計算該澆 鑄速度，由一液位監控系統取得該液位控制目標及該液位 控制輸出，該液位監控系統依據該液位控制目標及該液位 制㈣㈣㈣統17’以控雜湯⑴主入禱模 147060.doc [S3 201139011 1 3内之流量β 配合參考圖1、圖2及圖3,該漏液判斷步驟S21包括以下 步驟.步驟S211 ’進行一第一漏液判斷（圖3中註記為判斷 〇步驟，判斷該液位控制輸出是否大於一第一設定值 Α /〇 ’ 4該第一漏液判斷（判斷1)不成立，回至步驟s丨，若 該第—漏液判斷（判斷1)成立但不超過一第一設定時間，回 至該第一漏液判斷（判斷1)步驟S211，若該第一漏液判斷 (判斷1)成立且超過該第一設定時間（步驟S212)，發出漏液 預警（步驟S213);發出漏液預警後，進行一第二漏液判斷 (圖3中δ主記為判斷2)步驟S214，判斷該液位控制輸出是否 大於一第二設定值B% ;若該第二漏液判斷（判斷2)不成 古 _ ，回至該第一漏液判斷（判斷1)步驟S211，若該第二漏液 判斷（判斷2)成立但不超過一第二設定時間，回至該第二漏 液判斷（判斷2)步驟S214，若該第二漏液判斷（判斷2)成立 且超過該第二設定時間（步驟S215)，進行一第三漏液判斷 步驟S216，判斷該液位控制誤差是否大於一第一設定誤 差，右該第二漏液判斷不成立、該第二漏液判斷（判斷2)成 且超過該第二設定時間（步驟S217)，中止繞鑄（步驟 18)若該第二漏液判斷成立，中止洗鑄（步驟S218)，若 該第三漏液判斷不成立、該第二漏液判斷成立但不超過一 第三設定時間（步驟S217)，回至該第二漏液判斷（判斷2)步 驟 S214。 較佳地在步驟S21中，該第一設定值a%係為50_70〇/〇 ; h第°又疋時間係為2-5秒；該第二設定值B%係為7〇· [S1 147060.doc -9- 201139011 90% ;該第二設定時間係為8〜丨2秒，該第一設定誤差係為 12〜18 mm ;該第三設定時間係為18〜22秒。 在本實施例中，在步驟S21中，該第一設定值A%係為 60%;該第一設定時間係為3秒；該第二設定值B%係為 該第二設定時間係為10秒，該第一設定誤差係為u mm ;該第三設定時間係為2〇秒。 配合參考圖1、圖2及圖4，該卡模判斷步驟S22包括以下 步驟：步驟S221，進行一第一卡模判斷（圖4中註記為判斷 3)步驟，判斷該液位控制輸出是否小於一第三設定值 且液位控制誤差是否大於一第二設定誤差；若該第一卡模 判斷(判斷3)不成立’回至步驟S1，若該第一卡模判斷(判 斷3)成立但不超過一第四設定時間（步驟s222)，回至該第 一卡模判斷（判斷3)步驟S221，若該第—卡模判斷（判斷3) 成立且超過該第四設定時間（步驟S222)，進行一第二卡模 判斷步驟S223 ’判斷液位下降量是否小於—第—設定液位 下降量，該液位下降量係為該第—卡模判斷（判斷3)成立後 之轉模金屬液液位下降量；若該第二卡模判斷不成立、該 第—卡模判斷成立但不超過—第五設定時間（步驟㈣）， 回至該第-卡模判斷（判斷3)步驟咖，若該第二卡模判 :成立，發出卡模預警（步驟S225)，若該第二卡模判斷不 成立、該第一卡模判斷（判斷3)成立且超過該第五設定時間 步驟聊，發出卡模預警（步驟S225);發出卡模預警 二若該第一卡模判斷(判斷3)成立但不超過-第六設定時 (步驟S226)，回至該第-卡模判斷（判斷3)步驟則，發 1 S1 147060.doc -10- 201139011 出卡模預警後且若該第—卡 <定蚌卩” + 1斷判斷3)成立超過該第六 δ又疋時間（步驟S226)，進行_笛_上上 _ 第二卡模判斷步驟S227 ,判 斷該液位下降量是否小於一# -κ ^ ^ 罘—°又疋液位下降量丨若該第 二卡模判斷不成立、該第_去 弟卡模判斷（判斷3)成立但不超過 一第七設定時間（步驟S228)， ^ W至該第一卡模判斷（判斷3) 步驟S221，若該第三卡模 模斷成立，中止澆鑄（步驟 9)，若該第三卡模判斷不成立、該第一卡模判斷(判斷The second card mode judgment is not established, and the first card mode judgment is established: the card mode pre-invitation is issued after the fifth set time is exceeded. After the card mode warning is issued, if the first card mode judgment is established, the extension does not exceed a sixth set time. Going back to step (b2i), after issuing the card mode warning and if the first card mode judgment is established beyond the sixth set time, performing a third card mode determining step to determine whether the liquid level drop amount is less than - the second setting The liquid level drop amount; and if the third card mode is judged to be established, the casting is suspended, and if the third card mode judgment is not established, the first card mode judgment is established but does not exceed a seventh set time, returning to the step (b2丨) If the third card mode determination is not satisfied, the first card mode judgment is established and exceeds the seventh set time, the casting is suspended; the pipe cracking determining step (b3) includes the following steps: (b31) performing a first washing The tube rupture determination step determines whether the metal liquid filling rate exceeds a set metal liquid filling rate by a first set percentage, and whether the liquid level control error is greater than a third m 147060.doc 201139011 setting error, the metal liquid filling The charging rate is the product of the cross-sectional area of the mold and the casting speed; (b32) if the first pipe cracking determination is not established, return to step (4), if the first pipe cracking determination is established but does not exceed the eighth set time, Returning to step _), if the first wash pipe rupture judgment is established and exceeds the eighth set time, the pipe rupture warning is issued; (b33) after issuing the wash pipe rupture warning, performing a second pipe rupture judgment step, judging Whether the first spout rupture determination is greater than a ninth set time and whether the liquid level control error is greater than a fourth set error; and (b34) if the second spout rupture determination is not established, returning to step (b31), If the second pipe rupture judgment is established, the abnormal condition of the casting process is suspended, and the casting abnormality monitoring method of the invention can automatically determine and early warning, and can effectively determine the abnormal condition type and immediately issue an early warning at the initial stage of the abnormal situation. Appropriately prolonging the reaction time, enabling the operator to quickly detect the cause of the abnormality and carry out remedial measures, effectively reducing the frequency of the production of the casting line due to abnormal process, and Times less melted melted shortening and loss. [Embodiment] FIG. 1 shows a schematic diagram of casting a metal embryo; FIG. 2 shows a flow chart of a casting abnormality control method of the present invention. FIGS. 3 to 5 respectively show a liquid leakage judgment and a card model of the method for monitoring abnormality of the present invention. Judgment and pipe rupture judgment logic flow 147060.doc [S] 201139011 Figure. The casting anomaly monitoring method of the present invention can be used to monitor the abnormal condition of the casting process while the scaled metal embryo is being poured. In this embodiment, the casting anomaly monitoring method is applied to an aluminum blank casting process. Referring to the drawing, in the aluminum blank casting process of the present embodiment, the aluminum soup 11 which is melted in the static furnace is poured into the open flow path and then poured into the pouring basin 12 by slowly tilting the static furnace (not shown). The aluminum soup 11 is further flowed into the mold 13 through the bottom casting hole 121 of the pouring pot 12, and is gradually moved downward by the bottom mold 14, and the aluminum metal cooled and solidified by the cooling water 15 is drawn into the embryo body (aluminum embryo) 16, At the same time, the liquid level control system 17 controls the flow rate of the aluminum soup into the mold 13 to prevent the aluminum soup liquid level in the mold 13 from being too high or too low to cause aluminum soup overflow or bursting accident. Referring to FIG. 1 and FIG. 2, the method includes the following steps: Step S1, performing a casting length judging step 'determining whether the casting length of the metal embryo to be cast is up to a predetermined casting length; and step S2, if the casting length is The judgment is established, and the normal casting is finished. If the judgment of the casting length is not established, a liquid leakage judging step S21---^ is performed according to a mold metal liquid level, a liquid level control target, a liquid level control output, and a flood casting speed. The step S22 and the - tube rupture determination step S23 are judged. Wherein, the percentage of the difference between the liquid level control target and the liquid level of the recording metal is defined as the liquid level control error. In step S2, the molten metal liquid level is obtained by using a liquid level measuring device; the falling speed of the bottom mold 14 of the casting mold is measured by a speed measuring device to calculate the casting speed, and the liquid is obtained by a liquid level monitoring system. The position control target and the liquid level control output, the liquid level monitoring system according to the liquid level control target and the liquid level system (4) (4) (four) unified 17' to control miscellaneous soup (1) main prayer mode 147060.doc [S3 201139011 1 3 flow Referring to FIG. 1, FIG. 2 and FIG. 3, the liquid leakage determining step S21 includes the following steps. Step S211' performs a first liquid leakage determination (indicated as a determination step in FIG. 3, determining whether the liquid level control output is greater than a first set value Α /〇' 4 the first liquid leakage determination (judgment 1) is not established, and returns to step s丨, if the first liquid leakage determination (judgment 1) is established but does not exceed a first set time, back To the first liquid leakage determination (judgment 1) step S211, if the first liquid leakage determination (judgment 1) is satisfied and exceeds the first set time (step S212), a liquid leakage warning is issued (step S213); After the warning, a second liquid leakage judgment is made (the δ main record is judged in Fig. 3) 2) Step S214, determining whether the liquid level control output is greater than a second set value B%; if the second liquid leakage determination (judgment 2) is not _, returning to the first liquid leakage determination (judgment 1) step S211 If the second liquid leakage determination (judgment 2) is established but does not exceed a second set time, returning to the second liquid leakage determination (decision 2) step S214, if the second liquid leakage determination (determination 2) is established and After the second set time is exceeded (step S215), a third liquid leakage determining step S216 is performed to determine whether the liquid level control error is greater than a first setting error, and the right second liquid leakage determination is not established, and the second liquid leakage determination is performed. (Judgement 2) If the second set time is exceeded (step S217), the casting is stopped (step 18). If the second liquid leakage determination is established, the washing is stopped (step S218), and if the third liquid leakage determination is not established, The second liquid leakage determination is established but does not exceed a third set time (step S217), and returns to the second liquid leakage determination (judgment 2) step S214. Preferably, in step S21, the first set value a% The system is 50_70 〇 / 〇; h ° ° 疋 time is 2-5 seconds; the second set value B% The system is 7〇·[S1 147060.doc -9- 201139011 90%; the second set time is 8~丨2 seconds, the first setting error is 12~18 mm; the third set time is 18 〜22秒。 In this embodiment, in step S21, the first set value A% is 60%; the first set time is 3 seconds; the second set value B% is the second setting The time is 10 seconds, and the first setting error is u mm; the third setting time is 2 〇 seconds. Referring to FIG. 1 , FIG. 2 and FIG. 4 , the card mode determining step S22 includes the following steps: step S221 Performing a first card mode determination (denoted as judgment 3 in FIG. 4), determining whether the liquid level control output is less than a third set value and whether the liquid level control error is greater than a second set error; if the first card The mode judgment (judgment 3) does not hold 'return to step S1, and if the first card mode judgment (judgment 3) is established but does not exceed a fourth set time (step s222), return to the first card mode judgment (judgment 3) Step S221, if the first card mode determination (judgment 3) is satisfied and exceeds the fourth set time (step S222), perform a second card mode determination. Step S223 'determining whether the liquid level falling amount is less than - the first setting liquid level falling amount, the liquid level falling amount is the falling amount of the mold metal liquid level after the first card mode judgment (judgment 3) is established; The second card mode judgment is not established, the first card mode judgment is established but does not exceed the fifth set time (step (4)), and returns to the first card mode judgment (decision 3) step coffee, if the second card mode judgment: Forming, issuing a card mode warning (step S225), if the second card mode determination is not established, the first card mode determination (judgment 3) is established and exceeds the fifth set time step chat, issuing a card mode warning (step S225); If the first card mode judgment (judgment 3) is established but does not exceed the sixth setting (step S226), returning to the first card mode judgment (decision 3) step, send 1 S1 147060. Doc -10- 201139011 After the card mode warning and if the first card < fixed 蚌卩 + + 1 is judged 3) is established beyond the sixth δ 疋 time (step S226), the _ flute _ up _ The second card mode determining step S227 determines whether the liquid level drop amount is less than a # -κ ^ ^ 罘 - ° and the liquid level drops丨If the second card mode determination is not established, the first card mode determination (judgment 3) is established but does not exceed a seventh set time (step S228), ^ W to the first card mode determination (decision 3) step S221, if the third card mode is established, the casting is stopped (step 9), and if the third card mode determination is not established, the first card mode is judged (determination)
3)成立且超過該第七設定時間(步驟s228)，中止澆鑄㈣ S229)〇 該第三設定值C%係為1〜5%， mm ;該第四設定時間係為2〜5 較佳地，在步驟S22中， 該第二設定誤差係為·8〜_12 秒，該第-設定液位下降量係為卜2脑；該第五設定時 間係為4〜6秒；該第六設定時間係為^秒，該第二設定 液位下降量係為〗〜2 mm ;該第七設定時間係為18〜22秒。 在本實施例中，在步驟S22中，該第三設定值c%係為 2 /〇該第一设疋誤差係為-1 〇 mm ;該第四設定時間係為3 私該第一设疋液位下降量係為1 mm ;該第五設定時間係 為5秒）該第六設定時間係為1〇秒，該第二設定液位下降 量係為1 mm ;該第七設定時間係為2〇秒。 配合參考圖1、圖2及圖5，該澆管破裂判斷步驟s23包括 以下步驟：步驟S23 1，進行一第一澆管破裂判斷（圖5中註 此為判斷4)步驟’判斷金屬液填充率是否超過一設定金屬 液填充率達一第一設定百分比，且該液位控制誤差是否大 於一第三設定誤差，該金屬液填充率係為鑄模截面積與該 [S] 147060.doc • 11 · 201139011 澆鑄速度之乘積；若該第一澆管破裂判斷（判斷4)不成立， 回至步驟si，若該第一澆管破裂判斷（判斷4)成立但不超 過一第八設定時間（步驟S232)，回至該第一澆管破裂判斷 (判斷4)步驟S231，若該第一澆管破裂判斷（判斷4)成立且 超過該第八6又疋時間（步驟S23 2)，發出洗管破裂預警（步驟 S233);發出澆管破裂預警後，進行一第二澆管破裂判斷 步驟（步驟S234)’判斷該第一澆管破裂判斷（判斷4)成立是 否超過一第九設定時間且該液位控制誤差是否大於一第四 又疋誤差，若該第一洗管破裂判斷不成立，回至該第一繞 管破裂判斷（判斷4)步驟S231，若該第二洗管破裂判斷成 立’中止澆鑄（步驟S235)。 較佳地，在步驟S23中’該第一設定百分比係為 25〜，該第三設定誤差係為_5〜_9爪爪；該第八設定時 間係為3〜7秒；該第九設定時間係為9〜12秒，該第四設定 误差係為·13〜-18 πππ。 • 。在本實施财步驟S23中’該第-設定百分比係為 30% ’該第三設定誤差係為_7 該第八設定時間係為$ 衫’該第九設定時間係為10秒，該第四設定誤差係為·Η mm 〇 ^於預警方式’在本發明之繞鑄異常監控方法中係可以 聲曰、燈號或裝置之警示動作發出該漏液預警、該卡模預 警或該濟管破裂預警，並且可視異常預警之嚴重程度緊急 中止澆鑄製程。 對於繞鑄製程之異常狀況，本發明之祕異常監控方法 147060.doc -12· [S] 201139011 可自動地判定及預警，且已於實際澆鑄產線進行長時間測 試’結果顯示控制系統可有效判定異況種類，並於異況發 生初期立即發出預警，適當延長反應時間，使得操作人員 能快速發現異況原因並進行補救措施，有效降低洗鑄產線 因製程異常而中止生產之發生頻率，且減少回爐次數與縮 短回爐損失。 上述實施例僅為說明本發明之原理及其功效，並非限制 本發明’因此習於此技術之人士對上述實施例進行修改及 變化仍不脫本發明之精神。本發明之權利範圍應如後述之 申請專利範圍所列。 【圖式簡單說明】 圖1顯示洗鑄一金屬胚之示意圖； 圖2顯示本發明澆鑄異常監控方法之流程圖；及 圖3至圖5分別顯示本發明洗鑄異常監控方法之漏液判 斷、卡模判斷及澆管破裂判斷邏輯流程圖。 【主要元件符號說明】 11 鋁湯 12 洗盆 13 鑄模 14 底模 15 冷卻水 16 鋁金屬胚體 17 液位控制系統 121 鑄孔 147060.doc m -13·3) is established and exceeds the seventh set time (step s228), suspending casting (4) S229), the third set value C% is 1 to 5%, mm; the fourth set time is 2 to 5, preferably In step S22, the second setting error is ·8~_12 seconds, the first setting liquid level falling amount is the brain 2; the fifth setting time is 4~6 seconds; the sixth setting time is The system is ^ seconds, the second set liquid level drop is 〖~2 mm; the seventh set time is 18~22 seconds. In this embodiment, in step S22, the third set value c% is 2 / 〇 the first set error is -1 〇 mm; the fourth set time is 3 private. The liquid level drop amount is 1 mm; the fifth set time is 5 seconds) the sixth set time is 1 second, and the second set liquid level drop is 1 mm; the seventh set time is 2 leap seconds. Referring to FIG. 1 , FIG. 2 and FIG. 5 , the pipe rupture determination step s23 includes the following steps: Step S23 1 , performing a first pipe rupture determination (in FIG. 5 , the determination is 4), the step of determining the molten metal filling. Whether the rate exceeds a set metal liquid filling rate by a first set percentage, and whether the liquid level control error is greater than a third setting error, the metal liquid filling rate is a mold cross-sectional area and the [S] 147060.doc • 11 · 201139011 The product of the casting speed; if the first pipe rupture judgment (judgment 4) is not established, return to step si, if the first pipe rupture determination (judgment 4) is established but does not exceed an eighth set time (step S232) Returning to the first pipe rupture determination (decision 4) step S231, if the first pipe rupture determination (decision 4) is established and exceeds the eighth 6th 疋 time (step S23 2), the wash tube is broken. Early warning (step S233); after issuing the pipe rupture warning, performing a second pipe rupture determination step (step S234) 'determining whether the first pipe rupture determination (decision 4) is established for more than a ninth set time and the liquid Is the bit control error large? And a fourth error piece goods, if the first determination is not satisfied washing tube rupture, around the tube back to the first burst is determined (decision 4) in step S231, if the second washing tube rupture is determined to establish 'abort casting (step S235). Preferably, in step S23, the first set percentage is 25~, the third set error is _5~_9 claws; the eighth set time is 3~7 seconds; the ninth set time The system is 9 to 12 seconds, and the fourth setting error is ·13 to -18 πππ. • . In the implementation step S23, the 'the first set percentage is 30%'. The third set error is _7. The eighth set time is $ ́. The ninth set time is 10 seconds, the fourth The setting error is Ηmm 〇^ in the early warning mode. In the method for monitoring the abnormality of the casting of the present invention, the warning of the squeaking, the signal or the device may be issued, the warning of the leakage, the warning of the clamping or the rupture of the tube. Early warning, and the severity of the abnormal warning can be used to urgently stop the casting process. For the abnormal condition of the winding process, the secret monitoring method of the present invention 147060.doc -12· [S] 201139011 can be automatically determined and early warning, and has been tested for a long time on the actual casting line. The result shows that the control system can be effective. Determine the type of irregularity, and issue an early warning immediately after the occurrence of the abnormal situation, and appropriately extend the reaction time, so that the operator can quickly find out the cause of the abnormality and carry out remedial measures, thereby effectively reducing the frequency of the production of the washing and casting production line due to abnormal process. And reduce the number of furnaces and reduce the loss of furnace. The above-described embodiments are merely illustrative of the principles of the present invention and the advantages thereof, and are not intended to limit the present invention. The scope of the invention should be as set forth in the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic view showing the process of washing a metal embryo; FIG. 2 is a flow chart showing the method for monitoring the abnormality of casting of the present invention; and FIG. 3 to FIG. 5 respectively showing the liquid leakage judgment of the method for monitoring the abnormality of the casting of the present invention. Card mode judgment and tube breakage judgment logic flow chart. [Main component symbol description] 11 Aluminum soup 12 Wash basin 13 Mold 14 Bottom mold 15 Cooling water 16 Aluminum metal body 17 Liquid level control system 121 Cast hole 147060.doc m -13·