TWI405627B - Casting abnormal monitoring method - Google Patents

Abstract

Disclosed is a casting anomaly monitoring method, comprising: first determining whether the casting length of metal blank under casting has reached a preset casting length; and if the casting length determination does not pass, carrying out steps of determining leakage, die-sticking, and casting pipe rupture according to a casting metal liquid level, a level control target, a level control output, and a casting speed. In this way, it is able to automatically determine and provide early warning on abnormal conditions of the casting process, thereby effectively reducing frequency of terminating production in casting production line due to abnormal production process, and reducing the number of return and lessening return losses.

Description

Casting abnormal monitoring method

The invention relates to a device abnormality judging method, in particular to a casting abnormality monitoring method.

In the conventional casting process, an aluminum preform 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 into a mold through a casting hole at the bottom of the pouring basin. Inside, and gradually moving downward from the bottom mold, the cooled solidified metal is drawn into the embryo body, and the liquid flow control system controls the flow of the aluminum soup into the mold to avoid the aluminum level of the liquid level being too high or too low. Spill or unexpected soup.

However, because aluminum has a large thermal expansion coefficient and a high heat transfer coefficient, the solidification surface state is difficult to control during the cooling and solidification process of the aluminum blank. At the same time, the aluminum alloy cleanliness and surface oxides also affect the stability of the casting process. . Therefore, in the conventional aluminum embryo casting process, especially at the beginning of the casting stage, the production is often interrupted due to the occurrence of abnormal conditions (such as aluminum leakage, card mold, or pipe rupture, etc.), which affects the operating rate.

Leakage aluminum means that the liquid aluminum soup in the mold flows out near the contact surface between the mold and the aluminum embryo, forming an uneven surface of the aluminum embryo, and more severely, the high-temperature aluminum soup flows out in the casting, and the cooling water under the mold is contacted, which may cause The danger of a large number of splashes; the card mold means that the aluminum embryo shell in the mold is stuck in the mold and cannot be drawn into the body, which causes the casting to be interrupted; the rupture of the tube causes the aluminum soup in the upper pot to flow into the mold. There is a danger of overflowing aluminum soup.

Most of the conventional casting equipment control systems can only perform process safety protection by a single process signal, such as mold level control error or liquid level control output change. For example, during the casting process, the liquid level control error is greater than the warning value, and the control system forcibly suspends production. The prior art technology can not effectively distinguish the type of the situation by using a single process signal and the warning value. In the early stage of the situation, the operator cannot provide a clear message to the operator for remedial measures, resulting in the conventional casting line. There is an error in the type of abnormality, or the situation is not serious, but the control system determines that it is necessary to suspend the casting in an emergency, resulting in additional production delays and capacity loss.

Therefore, it is necessary to provide an innovative and progressive casting anomaly monitoring method to solve the above problems.

The invention provides a casting abnormality monitoring method for monitoring a casting process when casting a metal blank, the method comprising the following steps: (a) performing a casting length judging step to determine whether the casting length of the metal embryo to be cast reaches one The predetermined casting length; and (b) if the determination 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 control output, and a casting The speed performs a liquid leakage judging step (b1), a card mold judging step (b2), and a tube cracking judging step (b3), wherein the liquid level control target minus the mold metal liquid level difference is defined as the liquid level control The error, wherein: the liquid leakage determining step (b1) comprises the following steps: (b11) performing a first liquid leakage determining step of determining whether the liquid level control output is greater than a first set value;

(b12) if the first liquid leakage determination is not established, returning to step (a), if the first liquid leakage determination is established but does not exceed a first set time, returning to step (b11), if the first liquid leakage is judged Established and exceeded the first set time, and issued a liquid leakage warning;

(b13) after issuing the liquid leakage warning, performing a second liquid leakage determining step to determine whether the liquid level control output is greater than a second set value;

(b14) If the second liquid leakage determination is not established, return to step (b11), if the second liquid leakage determination is established but does not exceed a second set time, return to step (b13), if the second liquid leakage is judged Establishing and exceeding the second set time, performing a third liquid leakage determining step of determining whether the liquid level control error is greater than a first setting error;

(b15) if the third liquid leakage determination is established, the casting is stopped, and if the third liquid leakage determination is not established and the second liquid leakage determination is established but does not exceed a third set time, the process returns to step (b13), if the The three liquid leakage determination is not established, the second liquid leakage determination is established, and the third set time is exceeded, and the casting is suspended;

The card mode determining step (b2) includes the following steps:

(b21) performing a first card mode determining step of determining whether the liquid level control output is less than a third set value and the liquid level control error is greater than a second setting error;

(b22) If the first card mode determination is not established, return to step (a), if the first card mode determination is established but does not exceed a fourth set time, return to step (b21), if the first card mode is judged Establishing and exceeding the fourth set time, performing a second card mode determining step of determining whether the liquid level falling amount is less than a first set liquid level falling amount, wherein the liquid level falling amount is determined after the first card mode determination is established The amount of molten metal liquid level in the mold;

(b23) if the second card mode determination is established, issuing a card mode warning, if the second card mode determination is not established, and the first card mode determination is established but does not exceed a fifth set time, returning to step (b21), if The second card mode determination is not established, the first card mode determination is established, and the fifth set time is exceeded, and a card mode warning is issued;

(b24) after issuing the card mode warning, if the first card mode determination is established but does not exceed a sixth set time, returning to step (b21), issuing a card mode warning and if the first card mode determination is established, the number is exceeded. 6 setting time, performing a third card mode determining step, determining whether the liquid level falling amount is less than a second set liquid level falling amount; and

(b25) if the third card mode determination is established, the casting is suspended, and if the third card mode determination is not established, and the first card mode determination is established but does not exceed a seventh set time, returning to step (b21), if the The three-card mode judgment is not established, the first card mode judgment is established, and the seventh set time is exceeded, and the casting is suspended;

The pipe rupture judging step (b3) includes the following steps:

(b31) performing a first pipe rupture judging step of determining 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 setting error, the molten metal The filling rate is the product of the cross-sectional area of the mold and the casting speed;

(b32) If the first pipe rupture determination is not established, return to step (a), if the first pipe rupture determination is established but does not exceed an eighth set time, return to step (b31), if the first pouring The pipe rupture judgment is established and exceeds the eighth set time, and an early warning of the pipe rupture is issued;

(b33) after issuing the pipe rupture warning, performing a second pipe rupture judging step, determining whether the first spout rupture judgment is established whether a ninth set time is exceeded and the liquid level control error is greater than a fourth set error; and

(b34) If the second pipe cracking determination is not satisfied, the process returns to the step (b31), and if the second pipe cracking judgment is established, the casting is suspended.

For the abnormal condition of the casting process, the casting abnormal monitoring method of the invention can automatically determine and early warning, can effectively determine the type of the abnormal situation, and immediately issue an early warning at the initial stage of the abnormal situation, appropriately prolong the reaction time, so that the operator can quickly find the difference. Reasons and remedial measures to effectively reduce the frequency of production of the casting line due to abnormal process, and reduce the number of furnaces and reduce the loss of furnace.

1 shows a schematic diagram of casting a metal embryo; FIG. 2 shows a flow chart of the casting abnormality monitoring method of the present invention; FIG. 3 to FIG. 5 respectively show the liquid leakage judgment, the card mode judgment and the tube fracture judgment logic of the casting abnormality monitoring method of the present invention. flow chart.

The casting anomaly monitoring method of the present invention can be used to monitor the abnormal condition of the casting process while casting the metal blank. In this embodiment, the casting abnormality monitoring method is applied to an aluminum blank casting process. Referring to FIG. 1, 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 11 into the mold 13 to prevent the aluminum soup 11 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 to determine whether the casting length of the metal embryo to be cast reaches a predetermined casting length; and step S2, if the casting length is judged When the normal casting is completed, if the judgment of the casting length is not established, a liquid leakage judging step S21 and a card mold judging step are performed according to a mold metal liquid level, a liquid level control target, a liquid level control output, and a casting speed. S22 and a tube rupture determination step S23. Wherein, the difference between the liquid level control target and the liquid level of the mold metal is defined as a liquid level control error.

In step S2, the liquid level of the mold is obtained by a liquid level measuring device; the falling speed of the bottom mold 14 of the mold is measured by a speed measuring device to calculate the casting speed; and the liquid level monitoring system obtains the The liquid level control target and the liquid level control output, the liquid level monitoring system controls the liquid level control system 17 according to the liquid level control target and the liquid level control output to control the flow rate of the aluminum soup 11 into the mold 13 .

Referring to FIG. 1 , FIG. 2 and FIG. 3 , the liquid leakage determining step S21 includes the following steps: Step S211 , performing a first liquid leakage determination (marked as determination 1 in FIG. 3 ), determining whether the liquid level control output is greater than a first set value A%; if the first liquid leakage determination (judgment 1) is not established, returning to step S1, if the first liquid leakage determination (judgment 1) is established but does not exceed a first set time, returning to the First liquid leakage determination (judgment 1) in step S211, if the first liquid leakage determination (judgment 1) is established and exceeds the first set time (step S212), a liquid leakage warning is issued (step S213); after the liquid leakage warning is issued And performing a second liquid leakage determination (marked as judgment 2 in FIG. 3), 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 established, returning Up to the first liquid leakage determination (judgment 1) step S211, if the second liquid leakage determination (determination 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 (judgment 2) is satisfied and exceeds the second set time (step S215), performing a third liquid leakage determination step In step S216, it is determined whether the liquid level control error is greater than a first setting error; if the third liquid leakage determination is not established, and the second liquid leakage determination (determination 2) is satisfied and exceeds the third set time (step S217), the suspension is terminated. Casting (step S218), if the third liquid leakage determination is established, the casting is stopped (step S218), if the third liquid leakage determination is not established, and the second liquid leakage determination is established but does not exceed a third set time (step S217) And returning to the second liquid leakage determination (judgment 2) step S214.

Preferably, in step S21, the first set value A% is 50-70%; the first set time is 2~5 seconds; the second set value B% is 70-90%; The second set time is 8~12 seconds, and the first set error is 12~18mm; the third set time is 18~22 seconds.

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 80%; the second set time The system is 10 seconds, and the first setting error is 15 mm; the third setting time is 20 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 (note in FIG. 4 as the judgment 3) step of determining whether the liquid level control output is smaller than a third set value C% and whether the liquid level control error is greater than a second set error; if the first card mode determination (judgment 3) is not established, returning to step S1, if the first card mode determination (judgment 3) is established However, it does not exceed a fourth set time (step S222), and returns to the first card mode determination (decision 3) step S221, if the first card mode determination (judgment 3) is established and exceeds the fourth set time (step S222) And performing a second card mode determining step S223, determining whether the liquid level falling amount is less than a first set liquid level falling amount, wherein the liquid level falling amount is a mold metal after the first card mode determining (determination 3) is established The liquid level drop amount; if the second card mode determination is not established, the first card mode determination is established but does not exceed a fifth set time (step S224), returning to the first card mode determination (decision 3) step S221, If the second card mode determination is established, a card mode warning is issued (step S225), if the second card mode If the first card mode determination (judgment 3) is established and exceeds the fifth set time (step S224), the card mode warning is issued (step S225); after the card mode warning is issued, if the first card mode is judged (determined) 3) is established but does not exceed a sixth set time (step S226), returns to the first card mode determination (decision 3) step S221, after the card mode warning is issued, and if the first card mode judgment (judgment 3) is established The sixth set time (step S226), performing a third card mode determining step S227, determining whether the liquid level drop amount is less than a second set liquid level decrease amount; if the third card mode determination is not established, the first card The mode determination (judgment 3) is established but does not exceed a seventh set time (step S228), and returns to the first card mode determination (decision 3) step S221, and if the third card mode determination is established, the casting is suspended (step S229) If the third card mode determination is not satisfied, the first card mode determination (judgment 3) is satisfied and the seventh set time is exceeded (step S228), the casting is suspended (step S229).

Preferably, in step S22, the third set value C% is 1~5%, the second set error is -8~-12mm; the fourth set time is 2~5 seconds, the first The set liquid level drop amount is 1~2mm; the fifth set time is 4~6 seconds; the sixth set time is 8~12 seconds, and the second set liquid level drop is 1~2mm; The seventh set time is 18 to 22 seconds.

In this embodiment, in step S22, the third set value C% is 2%, the second set error is -10 mm; the fourth set time is 3 seconds, and the first set liquid level is decreased. The amount is 1 mm; the fifth set time is 5 seconds; the sixth set time is 10 seconds, the second set liquid level drop is 1 mm; and the seventh set time is 20 seconds.

Referring to FIG. 1, FIG. 2 and FIG. 5, the pipe rupture determination step S23 includes the following steps: Step S231, performing a first pipe rupture determination (marked as judgment 4 in FIG. 5), and determining whether the molten metal filling rate is If the liquid filling rate exceeds a first set percentage, and the liquid level control error is greater than a third setting error, the metal liquid filling rate is a product of a cross-sectional area of the mold and the casting speed; The tube rupture determination (judgment 4) is not established, and the process returns to step S1. If the first pipe rupture determination (decision 4) is established but does not exceed an eighth set time (step S232), the first pipe rupture judgment is returned ( Judging 4) Step S231, if the first pipe breakage determination (judgment 4) is satisfied and exceeds the eighth set time (step S232), the pipe cracking warning is issued (step S233); after the pipe cracking warning is issued, a a second pouring pipe rupture determining step (step S234), determining whether the first pouring pipe breaking determination (decision 4) is established whether a ninth set time is exceeded and the liquid level control error is greater than a fourth setting error; if the second The judgment of the pipe rupture is not established. Pouring tube back to the first burst is determined (decision 4) in step S231, if the decision is affirmative second pouring tube rupture, suspension casting (step S235).

Preferably, in step S23, the first set percentage is 25~35%, the third set error is -5~-9mm; the eighth set time is 3~7 seconds; the ninth setting The time is 9~12 seconds, and the fourth setting error is -13~-18mm.

In this embodiment, in step S23, the first set percentage is 30%, the third set error is -7 mm; the eighth set time is 5 seconds; the ninth set time is 10 seconds. The fourth setting error is -15 mm.

Regarding the early warning method, in the casting abnormality monitoring method of the present invention, the liquid leakage warning, the jamming warning or the pipe rupture warning may be issued by the warning action of the sound, the light number or the device, and the severity of the abnormal warning may be urgently suspended. Casting process.

For the abnormal condition of the casting process, the casting abnormality monitoring method of the invention can be automatically determined and early warning, and has been tested for a long time on the actual casting production line, and the result shows that the control system can effectively determine the type of the abnormal situation, and at the beginning of the abnormal situation Immediately issue an early warning and appropriately extend the reaction time so that the operator can quickly find out 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 reducing the number of times of returning the furnace and shortening the loss of the furnace.

The above embodiments are merely illustrative of the principles and effects of the present invention, and are not intended to limit the scope of the present invention. The scope of the invention should be as set forth in the appended claims.

11. . . Aluminum soup

12. . . Watering pot

13. . . Molding

14. . . Counter

15. . . Cooling water

16. . . Aluminum metal body

17. . . Liquid level control system

121. . . Cast hole

Figure 1 shows a schematic view of casting a metal embryo;

2 is a flow chart showing a method for monitoring abnormal casting in accordance with the present invention; and

FIG. 3 to FIG. 5 respectively show logic flow diagrams of liquid leakage judgment, card mold determination and tube break determination of the casting abnormality monitoring method of the present invention.

(no component symbol description)

Claims (9)

A casting abnormality monitoring method for monitoring a casting process when casting a metal blank, the method comprising the steps of: (a) performing a casting length judging step to determine whether a casting length of the cast metal embryo reaches a predetermined casting length; And (b) if the judgment of the casting length is established, the normal casting is finished, and if the judgment of the casting length is not established, a leak is performed according to a mold metal liquid level, a liquid level control target, a liquid level control output, and a casting speed. a liquid determining step (b1), a card mode determining step (b2), and a tube rupture determining step (b3), wherein the difference between the liquid level control target minus the mold metal liquid level is defined as a liquid level control error, wherein: The liquid leakage determining step (b1) includes the following steps: (b11) performing a first liquid leakage determining step of determining whether the liquid level control output is greater than a first set value; (b12) if the first liquid leakage determination is not established, Returning to step (a), if the first liquid leakage determination is established but does not exceed a first set time, returning to step (b11), if the first liquid leakage determination is established and exceeds the first set time, the liquid leakage is issued. Early warning; (b13) After the leakage liquid warning, a second liquid leakage determination step is performed to determine whether the liquid level control output is greater than a second set value; (b14) if the second liquid leakage determination is not established, return to step (b11), if The second liquid leakage determination is established but does not exceed a second set time, and returns to step (b13). If the second liquid leakage determination is established and exceeds the second set time, a third liquid leakage determination step is performed to determine the liquid. Whether the bit control error is greater than a first setting error; and (b15) if the third liquid leakage determination is established, the casting is suspended, and if the third liquid leakage determination is not established, the second liquid leakage determination is established but does not exceed a third setting Time, returning to step (b13), if the third liquid leakage determination is not established, the second liquid leakage determination is established and exceeds the third set time, the casting is suspended; the card mode determining step (b2) comprises the following steps: (b21 Performing a first card mode determining step of determining whether the liquid level control output is less than a third set value and the liquid level control error is greater than a second setting error; (b22) if the first card mode determination is not established, returning to Step (a), if the first card model is judged But not exceeding a fourth set time, returning to step (b21), if the first card mode determination is established and exceeds the fourth set time, performing a second card mode determining step to determine whether the liquid level drop amount is less than one The first set liquid level drop amount, the liquid level drop amount is a mold metal liquid level drop amount after the first card mode determination is established; (b23) if the second card mode judgment is established, a card mode warning is issued, if The second card mode determination is not established, the first card mode determination is established but does not exceed a fifth set time, and the process returns to step (b21). If the second card mode determination is not established, the first card mode determination is established and exceeds the The fifth set time, the card mode warning is issued; (b24) after the card mode warning is issued, if the first card mode judgment is established but does not exceed a sixth set time, return to step (b21), issue a card mode warning and if Determining that the first card mode is established exceeds the sixth set time, performing a third card mode determining step, determining whether the liquid level falling amount is less than a second set liquid level falling amount; and (b25) if the third card mode Judging is established, the casting is suspended, if the third card model is not judged If the first card mode is judged but not longer than a seventh set time, returning to step (b21), if the third card mode determination is not established, the first card mode determination is established and the seventh set time is exceeded, the suspension is terminated. Casting; the tube rupture judging step (b3) comprises the following steps: (b31) performing a first pouring rupture judging step to determine whether the filling rate of the molten metal exceeds a set metal 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 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 (a), if The first pipe rupture determination is established but does not exceed an eighth set time, and returns to step (b31). If the first pipe rupture determination is established and exceeds the eighth set time, an early warning of the pipe rupture is issued; (b33) After the pipe rupture warning is issued, a second pipe rupture judging step is performed to determine whether the first spout rupture judgment is established whether a ninth set time is exceeded and the liquid level control error is greater than a fourth set error; and (b34 If The second pipe rupture judgment is not established, and the process returns to the step (b31). If the second pipe rupture judgment is established, the casting is suspended. The method of claim 1, wherein in the step (b), the molten metal liquid level is obtained by a liquid level measuring device; and the bottom mold falling speed of the casting mold is measured by a speed measuring device to calculate the casting Speed; the liquid level control target and the liquid level control output are obtained by a liquid level control system. The method of claim 1, wherein in the step (b11), the first set value is 50-70%; in the step (b12), the first set time is 2~5 seconds; in the step (b13) The second set value is 70-90%; in the step (b14), the second set time is 8~12 seconds, and the first set error is 12~18mm in the step (b15), The third set time is 18 to 22 seconds. The method of claim 3, wherein in the step (b11), the first set value is 60%; in the step (b12), the first set time is 3 seconds; in the step (b13), the step (b13) The second set value is 80%; in the step (b14), the second set time is 10 seconds, the first set error is 15 mm; in the step (b15), the third set time is 20 second. The method of claim 1, wherein in the step (b21), the third setting value is 1 to 5%, and the second setting error is -8 to -12 mm; in the step (b22), the fourth The set time is 2~5 seconds, the first set liquid level drop is 1~2mm; in step (b23), the fifth set time is 4~6 seconds; in step (b24), the step The sixth set time is 8 to 12 seconds, and the second set liquid level is 1 to 2 mm; in the step (b25), the seventh set time is 18 to 22 seconds. The method of claim 5, wherein in the step (b21), the third set value is 2%, the second set error is -10 mm; and in the step (b22), the fourth set time is 3 Second, the first set liquid level drop amount is 1 mm; in step (b23), the fifth set time is 5 seconds; in step (b24), the sixth set time is 10 seconds, the first The set liquid level drop amount is 1 mm; in the step (b25), the seventh set time is 20 seconds. The method of claim 1, wherein in the step (b31), the first set percentage is 25 to 35%, and the third setting error is -5 to -9 mm; in the step (b32), the eighth The set time is 3~7 seconds; in step (b33), the ninth set time is 9~12 seconds, and the fourth set error is -13~-18mm. The method of claim 7, wherein in the step (b31), the first set percentage is 30%, the third set error is -7 mm; and in the step (b32), the eighth set time is 5 Second; in step (b33), the ninth set time is 10 seconds, and the fourth set error is -15 mm. The method of claim 1, wherein in step (b), the liquid leakage warning, the jam warning or the tube rupture warning is issued by a warning action of a sound, a light number or a device.