WO2016142983A1 - 注湯装置および注湯方法 - Google Patents
注湯装置および注湯方法 Download PDFInfo
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- WO2016142983A1 WO2016142983A1 PCT/JP2015/056615 JP2015056615W WO2016142983A1 WO 2016142983 A1 WO2016142983 A1 WO 2016142983A1 JP 2015056615 W JP2015056615 W JP 2015056615W WO 2016142983 A1 WO2016142983 A1 WO 2016142983A1
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- Prior art keywords
- pouring
- molten metal
- container
- weight
- tilting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D39/00—Equipment for supplying molten metal in rations
- B22D39/04—Equipment for supplying molten metal in rations having means for controlling the amount of molten metal by weight
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D35/00—Equipment for conveying molten metal into beds or moulds
- B22D35/04—Equipment for conveying molten metal into beds or moulds into moulds, e.g. base plates, runners
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D37/00—Controlling or regulating the pouring of molten metal from a casting melt-holding vessel
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D41/00—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like
- B22D41/06—Equipment for tilting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D47/00—Casting plants
Definitions
- the present invention relates to a pouring apparatus and a pouring method for pouring molten metal into a mold.
- the present invention relates to an automatic pouring apparatus and method for pouring at a casting flow rate suitable for various molds.
- the ladle capacity is 500 kg
- the casting weight is 10 to 50 kg
- the casting time is 4 to 12 seconds
- the casting flow rate is 1 to 5 kg / sec
- the ladle capacity is 1,000 kg.
- the casting weight is 30 to 150 kg
- the casting time is 6 to 15 seconds
- the casting flow rate is 5 to 10 kg / second.
- the molten metal is injected at an increased flow rate so as not to spill into the gate for about 2 seconds.
- the filling operation is performed while monitoring the vicinity of the pouring gate so as not to overflow from the pouring gate and adjusting the pouring flow rate in accordance with the swallowing of the molten metal. Skilled workers determine the completion of filling based on experience and end pouring.
- the present invention keeps the hot water surface level constant from the start to the end of pouring, does not spill, overflow or sink at the end of pouring, does not drain and put in, and is necessary and sufficient casting flow rate. It is an object of the present invention to provide a pouring apparatus and a method for pouring hot water in an appropriate pouring time.
- the pouring device is a pouring device 1 for pouring hot water from a container 2 onto a mold 100 fed in a row, for example, as shown in FIGS.
- a traveling carriage 10 that travels along a mold 100 that is fed in a shape; a forward / backward movement mechanism 20 that is provided on the traveling carriage 10 and moves the container 2 in a direction orthogonal to the traveling direction of the traveling carriage 10;
- a tilting mechanism 40 that tilts the container 2; a weight detection unit 50 that detects the weight of the molten metal in the container 2; and a pouring cup 110 of the casting mold 100 that is provided in the traveling carriage 10 and receives hot water from the container 2.
- a tilt level T of the container 2 is controlled by using a melt level detection unit 60 that detects a melt level, and a molten metal level detected by the melt level detection unit 60 and a molten metal weight detected by the weight detection unit 50. And a control unit 70.
- the front-rear moving mechanism 20 provided on the traveling carriage 10 or the front-rear moving mechanism 20 is not limited to the case of being provided directly on the traveling carriage 10. The case where it is provided in the provided lifting mechanism 30 shall be included.
- the tilt angle of the container is controlled using the level of the molten metal detected by the molten metal level detection unit and the weight of the molten metal detected by the weight detection unit, that is, the weight of the molten metal poured into the mold.
- the hot water level remains constant during the process from the initial filling of the pouring process to the end of the pouring process.
- the hot water level detection unit 60 is an image sensor. If comprised in this way, a hot_water
- the pouring cup 110 is provided with a taper 112
- the detection unit 60 detects the hot water level based on the area of the hot water surface. If comprised in this way, the hot_water
- the container 2 receives the molten metal from the furnace and the mold 100.
- the elevating mechanism 30 for elevating and lowering the ladle 2 is provided in the back-and-forth moving mechanism 20; the tilting mechanism 40 is provided in the elevating mechanism 30.
- the ladle can be tilted by the tilting mechanism and poured into the mold while the distance from the mold is adjusted by the forward / backward movement mechanism and the height difference from the mold is adjusted by the lifting mechanism.
- the pouring position can be kept correct.
- the pouring device according to the fifth aspect of the present invention is, for example, as shown in FIGS. 1 to 3 and FIG. 5, in the pouring device 1 according to the fourth aspect, the back-and-forth movement mechanism 20, the elevating mechanism 30, and the tilting mechanism. 40, the tilting mechanism 44 tilts the container 2 so that the tilting shaft 44 moves on the arc around the start point of the molten metal dropping at the pouring port 6 of the container 2 or the virtual point O set in the vicinity thereof. Then, the pouring position from the container 2 to the mold 100 is kept constant. If comprised in this way, since the tilting axis of a container moves on a circular arc centering on a virtual point, the pouring position from a container to a mold can be maintained accurately, and appropriate flow rate control is performed. Can do.
- the pouring device is such that, in the pouring device 1 according to the first to fifth aspects, the control unit 70 stores a flow rate pattern suitable for the mold 100. (96), and the flow rate pattern includes data of tilting angular velocity and casting weight for tilting the container 2 for each hour; the control unit 70 determines the tilting angle of the container 2 based on the tilting angular velocity (85). Control (86). If comprised in this way, it can pour with an appropriate pouring flow rate from the start of pouring to completion.
- the control unit 70 stores a flow rate pattern suitable for the mold 100. (96), and the flow rate pattern includes data of tilting angular velocity and casting weight for tilting the container 2 for each hour; the control unit 70 determines the tilting angle of the container 2 based on the tilting angular velocity (85). Control (86). If comprised in this way, it can pour with an appropriate pouring flow rate from the start of pouring to completion.
- the control unit 70 changes the tilt angular velocity of the flow rate pattern into the shape of the container 2.
- a correction function for adaptation is further stored (95), and a value obtained by multiplying the tilt angular velocity by the correction function is used. If comprised in this way, even if it uses a container from which a shape differs, it can pour with an appropriate casting flow rate.
- the pouring device is the pouring device 1 according to the seventh aspect, wherein the control unit 70 performs feedforward control using a value obtained by multiplying the tilt angular velocity by a correction function, Feedback control is performed using the surface level detected by the surface detector 60 and the weight of the molten metal detected by the weight detector 50.
- the pouring level is kept constant from the start to the end of pouring, there is no spilling, overflowing or sinking at the end of pouring, and there is no need to put in and out, and a necessary and sufficient casting flow rate is maintained. It can be ensured and can be poured reliably in an appropriate pouring time.
- the pouring device includes a pouring weight data (flow rate pattern casting data) in the pouring device 1 according to the first to eighth aspects ( 96) and the weight difference between the molten metal in the container (87) detected by the weight detector 50 (82), the correction amount of the tilting angular velocity of the container 2 is obtained (85) and controlled (86). ). If comprised in this way, since it controls using the difference of the data of the casting weight of a flow rate pattern, and the weight of the molten metal in a container, an appropriate casting flow volume can be ensured more reliably.
- the control unit 70 corrects the tilt angular velocity of the container 2 from the weight difference.
- the casting weight correction coefficient for calculating is calculated (93), and the weight difference is multiplied by the casting weight correction coefficient (82) to determine the correction amount of the tilting angular velocity of the container 2 (85). If comprised in this way, the correction amount of tilting angular velocity can be calculated
- the pouring device according to the eleventh aspect of the present invention is, for example, as shown in FIG. 6, in the pouring device 1 according to the first to tenth aspects, the control unit 70 is detected by the hot water level detection unit 60. (84) The correction amount of the tilting angular velocity of the container 2 is obtained (85) and controlled (86) so that the hot water level becomes a predetermined hot water level (94). If comprised in this way, since it controls using the difference of a predetermined hot_water
- the pouring device is, for example, as shown in FIG. 6, in the pouring device 1 according to the eleventh aspect, the control unit 70 detects the hot water level detected by the hot water level detection unit 60.
- a hot water surface level correction coefficient for calculating the correction amount of the tilting angular velocity of the container 2 from the level difference between the level and the predetermined hot water surface level (94) is stored (93), and the hot water surface level correction coefficient is stored in the level difference (84).
- the correction amount of the tilting angular velocity of the container 2 (85). If comprised in this way, the correction amount of tilting angular velocity can be calculated
- the pouring method according to the thirteenth aspect of the present invention includes, for example, a step of tilting the container 2 and pouring the mold 100 as shown in FIGS. 1 and 6; a step of detecting the weight of the molten metal in the container 2 (87); step (84) of detecting the hot water level of the pouring cup 110 of the casting mold 100 receiving hot water from the container 2; and tilting the container 2 using the detected weight and the detected hot water level. And (86) controlling the tilt angle.
- hot water level is kept constant, there is no spillage, overflow or sink at the end of pouring, it does not drain and fill, and a necessary and sufficient pouring flow rate is ensured, and pouring is performed with an appropriate pouring time.
- a pouring device for hot water can be provided.
- the container 2 is tilted and poured into the mold 100.
- the container 2 is moved in the horizontal direction, further moved up and down, and the tilting axis for tilting the container 2 is an arc centering on the molten metal dropping start point of the pouring port 6 of the container 2 or a virtual point O set in the vicinity thereof. It moves up, and the pouring position from the container 2 to the mold 100 is kept constant. If comprised in this way, since the tilting axis of a container moves on a circular arc centering on a virtual point, the pouring position from a container to a mold can be maintained accurately, and appropriate flow rate control is performed. Can do.
- the pouring method according to the fifteenth aspect of the present invention includes a flow rate pattern (96) applicable to the mold 100 in the pouring method according to the thirteenth or fourteenth aspect, for example, as shown in FIGS.
- the flow pattern includes data of tilt angular velocity and casting weight for tilting the container 2 over time; based on the tilt angular speed for tilting the container 2 (85), the tilt angle of the container 2 is controlled. (86). If comprised in this way, it can pour with an appropriate pouring flow rate from the start of pouring to completion.
- the pouring method according to the sixteenth aspect of the present invention is detected as cast weight data of the flow rate pattern (96) in the pouring method according to the fifteenth aspect, for example, as shown in FIGS.
- the weight difference (82) from the molten metal weight (87) in the container 2 and the molten metal level difference (84) between the detected molten metal level (83) and the predetermined molten metal level (94) are used. Then, the correction amount of the tilting angular velocity of the container 2 is obtained (85) and controlled (86).
- the pouring apparatus and pouring method of the present invention there is no spillage, overflow or sink at the end of pouring while keeping the hot water level constant in the process from the initial filling of the pouring process to the hot water cutting. It is possible to pour in an appropriate pouring time by securing a necessary and sufficient casting flow rate without being put in and out.
- FIG. 1 is a front view of the pouring device, and shows the pouring from the ladle to the mold.
- FIG. 2 is a side view of the pouring device, showing the ladle being lowered.
- FIG. 3 is a plan view of the pouring device.
- 4A and 4B are diagrams illustrating a pouring cup, where FIG. 4A is a rectangular pouring cup in a plan view, FIG. 4B is a circular pouring cup in a plan view, and FIG. 4C is a mold and a pouring cup. .
- FIGS. 5A and 5B are diagrams illustrating a ladle, where FIG. 5A is a plan view, and FIG. 5B is a side view, which also illustrates a movement center point.
- FIG. 5A is a plan view
- FIG. 5B is a side view, which also illustrates a movement center point.
- FIG. 6 is a diagram illustrating the configuration of the control unit.
- FIG. 7 is a diagram for explaining the relationship between the elapsed time and the casting flow rate.
- FIG. 8 is a front view of another pouring device, and shows the pouring from the ladle to the mold.
- FIG. 1 is a front view of a pouring device 1 for pouring the mold 100 from the ladle 2
- FIG. 2 is a side view
- FIG. 3 is a plan view.
- the pouring device 1 includes a traveling cart 10 that travels on the rail R, a front / rear moving mechanism 20 that is provided in the traveling cart 10 and moves in a direction orthogonal to the traveling direction of the traveling cart 10, and the front / rear moving mechanism 20.
- An elevating mechanism 30 that elevates and lowers the ladle 2 and a tilting mechanism 40 that is provided in the elevating mechanism 30 and tilts the ladle 2 are provided.
- the load cell 50 as a weight detection part which detects the weight of the molten metal in the ladle 2 is provided.
- a frame 64 erected from the traveling carriage 10 and a camera arm 62 that extends horizontally from the frame 64 and supports the camera 60 at a position suitable for imaging the pouring cup 110 of the mold 100.
- a camera 60 as a hot water level detection unit for detecting a hot water level in the pouring cup 110 of the casting mold 100 that receives hot water from the ladle 2.
- the control part 70 which controls the driving
- the rail R is laid along a mold line L through which the molds 100 are sent out in a row. Therefore, the traveling carriage 10 travels along the mold line L. Since the traveling carriage 10 may have a known structure, detailed description thereof is omitted.
- the traveling carriage 10 may have a known structure, detailed description thereof is omitted.
- the mold line L is moved by one frame of the mold, the empty mold 100 is placed in front of the pouring device 1, and pouring is performed again. It is.
- the pouring apparatus 1 moves on the rail R while pouring from the pouring apparatus 1 to the mold 100. Then, the mold 100 may move on the mold line L in the same direction and at the same speed.
- Time is not wasted when the mold line L moves by a distance corresponding to one frame of the mold.
- the pouring device 1 returns on the rail R by a distance corresponding to one frame of the mold in order to pour the next mold 100.
- the distance moved together with the mold line L may be returned collectively.
- the back-and-forth moving mechanism 20 is a device that moves on the traveling carriage 10 in a direction perpendicular to the traveling direction of the traveling carriage 10, that is, in a direction approaching or leaving the mold 100 or the mold line L.
- a rail may be laid on the traveling carriage 10 to travel on the rail, or may be a carriage that moves on a roller conveyor, or other structures.
- the elevating mechanism 30 is an apparatus for elevating the ladle 2 provided on the forward / backward moving mechanism 20.
- a support column 32 erected on the front-rear moving mechanism 20 and an elevating body 34 that surrounds the periphery of the support column 32 and moves up and down along the support column 32 are provided.
- the elevating body 34 is lifted and lowered by suspending the elevating body 34 with a chain (not shown) and winding the chain with an elevating drive unit 36, for example, a motor, installed at the upper end of the column 32.
- an elevating drive unit 36 for example, a motor
- the elevating mechanism 30 may be a pantograph type elevating mechanism (not shown), and the structure for elevating is not limited.
- the tilting mechanism 40 is a device that is supported by the lifting device 30 and moves up and down, tilts the ladle 2 and pours the ladle 2 into the mold 100.
- a tilting shaft 44 of the tilting mechanism 40 is supported by the elevating body 34 so as to be tiltable about a horizontal axis.
- a ladle base 46 for placing the ladle 2 is supported at one end of the tilt shaft 44.
- the ladle base 46 is horizontally extended from the side plate 47 and the bottom side of the side plate 47 so that the tilt shaft 44 and the center of gravity of the ladle 2 are close to each other, and the ladle 2 is mounted thereon.
- a bottom plate 48 to be placed.
- the other end of the tilt shaft 44 is connected to a tilt drive unit 42 that tilts the tilt shaft.
- the tilt drive unit 42 is, for example, a motor with a deceleration function.
- the tilt shaft 44, that is, the ladle base 46 may be tilted by hydraulic pressure, and the power for
- the load cell 50 detects the weight of the molten metal in the ladle 2.
- the load cell 50 may be installed at a position where the weight of the front-rear moving mechanism 20 is measured.
- the weights of the molten metal in the ladle 2 are detected by subtracting the weights of the back-and-forth movement mechanism 20, the lifting device 30, the tilting mechanism 40 and the ladle 2 from the weight measured by the load cell 50.
- the load cell 50 may be installed at a position where the weight of the traveling carriage 10, the lifting device 30, the tilting mechanism 40, or the ladle 2 is measured.
- the camera 60 images the hot water surface of the pouring cup 110 in order to detect the hot water surface level of the pouring cup 110 of the casting mold 100 received from the pouring device 1.
- the camera 60 is supported by a camera arm 62 extending substantially horizontally from the upper part of the frame 64 erected on the traveling carriage 10, and the camera 60 is disposed at a position suitable for imaging the hot water surface of the pouring cup 110. . It is preferable that the position and orientation of the camera 60 can be adjusted by the camera arm 62 in accordance with the positional relationship between the traveling carriage 10 and the pouring cup 110 of the mold 100. Without installing the frame 64, the camera arm 62 may extend from the control unit 70, and the camera 60 may be supported in other configurations.
- the pouring cup 110 is tapered.
- the pouring cup 110 refers to a first flow path in the vertical direction that is provided in the mold 100 and receives the molten metal to be poured into the mold 100.
- the hot water level can be easily detected from the area of the hot water imaged by the camera 60.
- the cross-sectional shape of the pouring cup 110 is arbitrary, and may be rectangular as shown in FIG. 4A, circular as shown in FIG. 4B, or other shapes. However, a shape that can accurately guide the level of the molten metal from the change due to the taper of the area of the molten metal is preferable.
- the position of the pouring cup 110 in the mold 100 is not necessarily the center shown in FIG. 3, but may be a biased position as shown in FIG. Therefore, it is preferable that the position and orientation of the camera 60 can be adjusted.
- the camera 60 that images the hot water surface of the pouring cup 110 is preferably an image sensor such as a CCD or CMOS.
- the hot water level detection unit 60 the hot water level may be detected based on the distance from the hot water level detection unit 60 instead of the hot water surface area using an infrared sensor or a laser sensor.
- the control unit 70 controls the operation of the pouring device 1. That is, the travel of the traveling carriage 10, the movement of the back-and-forth moving mechanism 20, the lifting and lowering of the lifting mechanism 30, the tilting of the tilting mechanism 40, the detection of the weight of the molten metal in the ladle 2 from the weight measured by the load cell 50, and the image taken by the camera 60. The level of the hot water is detected from the hot water surface. Details of the control of the control unit will be described later.
- the control unit 70 is generally placed on the traveling carriage 10, but may be placed at another position, or may be placed directly on a site along the rail R.
- the pouring device 1 receives a ladle 2 for storing molten metal from a molten metal conveying system (not shown) in the foundry. An alloy material and an inoculant are added to the molten metal depending on the application. Normally, the elevating device 30 is lowered, the ladle table 46 is moved to the molten metal transport system side by the back-and-forth moving mechanism 20, and the ladle 2 conveyed by the ladle conveyor (not shown) is placed on the ladle table 46. Put. The ladle 2 may be placed on the ladle base 46 with a crane or the like.
- the pouring device 1 on which the ladle 2 is placed moves to a predetermined position where the running cart 10 pours the mold 100. Subsequently, the ladle 2 is moved to a position suitable for pouring by the back-and-forth moving mechanism 20 and the elevating mechanism 30. Next, the tilting mechanism 40 tilts the ladle 2 and the pouring from the ladle 2 to the mold 100 is started.
- the ladle 2 tilts around the tilting axis 44, that is, rotates and tilts.
- the position where the molten metal flows out of the ladle 2 moves according to the tilting angle.
- the outflow position moves, the position at which the molten metal is poured into the mold 100 changes. Therefore, it is preferable to keep the position at which the molten metal is poured into the mold 100 by moving the ladle 2 back and forth and up and down by the back and forth moving mechanism 20 and the elevating mechanism 30.
- Fig. 5 shows an example of the ladle 2.
- the ladle 2 includes a ladle body 4 that is a container for storing molten metal, and a pouring port 6 that is a flow path for pouring the molten metal from the ladle 2. Therefore, when the ladle 2 is tilted, the molten metal flows out from the tip of the pouring port 6. Therefore, a virtual movement center point O is set in the vicinity of the molten metal dropping start point of the pouring port 6 or close thereto. Then, the ladle 2 is moved back and forth and up and down by the back-and-forth moving mechanism 20 and the elevating mechanism 30, and the tilting shaft 44 is moved to the center point O as shown in FIG.
- the tilt angle T of the ladle is controlled in order to keep the pouring flow rate appropriate from the start to the end of pouring.
- pouring is performed according to a pouring pattern determined in advance based on a pouring process of a skilled worker. By using the pouring pattern in this way, it is possible to easily ensure a substantially appropriate casting flow rate.
- By detecting the weight of the molten metal in the mold 100 it is possible to pour molten metal at a casting flow rate close to a predetermined flow rate pattern more accurately than the control based on the tilt angle T of the mold 100 alone.
- the hot water level in the pouring cup 110 is kept constant. This can prevent the occurrence of overflow and lack of pouring.
- the control unit 70 includes a central control device 72, a shaft drive device amplifier 74, an image processing arithmetic device 76, and a load cell amplifier 78.
- the shaft drive device amplifier 74 is a device that amplifies operation command signals from an axial speed command / position command calculation means 86 (to be described later) of the central control device 72 to the back-and-forth movement mechanism 20, the lifting mechanism 30, and the tilting mechanism 40.
- the direction and speed of moving the ladle 2 in the apparatus are instructed, and the instructed signal or data on the direction and speed of moving the ladle 2 measured by each apparatus is output to the central controller 72.
- the image processing arithmetic device 76 is a device that performs image processing on data acquired by the camera 60, processes input data from the camera 60, and outputs the processed data to the central control device 72.
- the load cell amplifier 78 is a device that amplifies the voltage output from the load cell 50 and outputs the detected weight of the load cell 50 to the central controller 72.
- the central controller 72 is divided into a calculation area 80 and a storage area 90.
- the calculation area 80 has means for calculating, and the storage area 90 has means for storing data.
- the means is hardware such as a circuit or an element, or a combination of hardware and software.
- the calculation area 80 includes a shaft current position / speed calculation means 81, a casting weight correction calculation means 82, a gate area calculation means 83, a molten metal surface level correction calculation means 84, an operation tilt angular velocity calculation means 85, an axis speed command / position command.
- the calculation means 86 and the molten metal weight calculation means 87 in a ladle are provided.
- the storage area 90 includes calculation data storage means 91, time lapse parameter storage means 92, parameter storage means 93, hot water surface level reference value storage means 94, ladle tilt angle correction function storage means 95, flow rate pattern storage means 96, and A ladle tare weight storage means 97 is provided.
- the calculation data storage means 91 is used for temporary storage of calculation data in the calculation area 80.
- the time lapse parameter storage unit 92 counts time lapse as a timer. That is, the elapsed time tp of pouring from the ladle 2 to the mold 100 is counted. Further, the time after the molten metal is received in the ladle 2 is counted, or the time elapsed after the addition of the alloying agent or the inoculant to the molten metal is counted. In particular, the time after the addition of the alloying agent or the inoculant is important for the determination of fading (the effect of the alloying agent or the inoculant is diminished if the result of difficulty in shaping after the addition).
- the parameter storage means 93 stores parameters relating to the shape of the mold 100 and parameters relating to the shape of the ladle 2. Data is stored in the casting weight correction calculation means 82, the molten metal surface level correction calculation means 84, and the operation tilt angular velocity calculation means 85. Is output.
- the hot water level reference value storage means 94 stores the reference value of the hot water level in the pouring cup 110.
- the reference value of the molten metal level varies depending on the mold 100 and also depending on the properties of the molten metal.
- the data of the molten metal level reference value is output to the molten metal level correction calculating means 84.
- the ladle tilt angle correction function storage means 95 stores a tilt angle correction function f (T) representing the relationship between the tilt angle T and the casting weight for each ladle type, and the operation tilt angular velocity calculation is performed on the data. It outputs to the means 85.
- the flow rate pattern storage means 96 stores a flow rate pattern for each type of mold and molten metal.
- the flow rate pattern stores, for example, the casting weight for each elapsed time (that is, the molten metal weight in the ladle 2) and the tilting angular velocity of the ladle.
- the data is output to the casting weight correction calculation means 82 and the operation tilt angular velocity calculation means 85.
- the ladle tare weight storage means 97 stores weight data of devices and equipment other than the molten metal included in the weight detected by the load cell 50, such as the ladle 2, the back and forth movement mechanism 20, the elevating mechanism 30, the tilting mechanism 40, and the like. It outputs to the molten metal weight calculation means 87 in a pan.
- the shaft current position / speed calculating means 81 the movement data of the ladle 2 in each device measured by the back-and-forth moving mechanism 20, the elevating mechanism 30, and the tilting mechanism 40, or the shaft speed command / position command calculating means 86 described later.
- a device that calculates the position and movement speed of the shaft in each device based on the operation commands to the back-and-forth movement mechanism 20, the elevating mechanism 30, and the tilting mechanism 40.
- the calculated value that is, the position of the ladle 2 at that time And the tilt angle are output to the operation tilt angular velocity calculating means 85.
- the casting weight correction calculation means 82 calculates the difference between the molten metal weight in the ladle 2 detected from the molten metal weight calculation means 87 in the ladle described later and the molten metal weight in the flow rate pattern from the flow rate pattern storage means 96. Based on parameters such as the shape of the ladle 2 from the parameter storage means 93, a correction amount of the casting weight from the ladle 2 to the mold 100 is calculated and output to the operation tilt angular velocity calculation means 85.
- the sprue area calculating means 83 calculates the spout area based on the image data from the image processing arithmetic device 76 and outputs it to the pouring surface level correction calculating means 84.
- the hot water surface level correction calculation means 84 calculates the hot water surface level based on the pouring gate area and the shape parameter of the pouring cup 110 from the parameter storage means 93, and calculates the reference value from the hot water surface level reference value storage means 94. Based on the difference, a correction value for the molten metal level is calculated. The result is output to the operation tilt angular velocity calculating means 85.
- the operation tilt angular velocity calculation means 85 includes the current position and inclination angle of the ladle 2 from the current position / speed calculation means 81 of the shaft, the amount of correction of the casting weight from the casting weight correction calculation means 82, and the surface level.
- the angular velocity at which the ladle 2 is tilted is calculated from the correction value of the molten metal surface level from the correction calculation means 84 and is output to the shaft speed command / position command calculation means 86.
- parameters such as the shape of the ladle 2 from the parameter storage means 93, the tilt angle correction function f (T) from the ladle tilt angle correction function storage means 95, and the flow rate pattern memory are stored.
- the tilt angular velocity is used as a flow pattern that fits the mold 100 from the means 96.
- the calculation of the tilt angle correction function f (T) and the angular velocity for tilting the ladle 2 will be described later.
- the shaft speed command / position command calculating means 86 calculates an operation command to the front / rear moving mechanism 20, the elevating mechanism 30, and the tilting mechanism 40 based on the angular speed at which the ladle 2 is tilted from the operation tilt angular speed calculating means 85. This is output to each device via the drive device amplifier 74 and also to the current position / speed calculation means 81 of the shaft.
- the molten metal weight calculating means 87 in the ladle includes the detected weight of the load cell 50 from the load cell amplifier 78 and the weight of the ladle 2 from the ladle tare weight storage means 97, the back-and-forth moving mechanism 20, the lifting mechanism 30, the tilting mechanism 40, and the like. Based on the data, the molten metal weight in the ladle is calculated and output to the cast weight correction calculating means 82.
- FIG. 7 is a diagram for explaining the flow rate pattern in relation to the elapsed time and the casting flow rate, and is shown in a graph with the elapsed time on the horizontal axis and the casting flow rate on the vertical axis.
- the solid line represents the casting flow rate from the ladle 2 to the mold 100
- the broken line represents the casting flow rate based on the flow rate pattern.
- the flow rate is short enough, for example, about 2 seconds, so as not to spill from the pouring cup. Increase the temperature and pour hot water.
- the tilt angle T of the ladle 2 at this time is determined based on the flow rate pattern. That is, from the tilt angular velocity data V Tobj (tp) at the predetermined elapsed time tp stored in the flow rate pattern storage unit 96 by the operation tilt angular velocity calculating unit 85, the command tilt angular velocity V Tp at the time tp suitable for the ladle 2 is ( 1) Calculate by the equation.
- V Tp f (T) ⁇ V Tobj (tp) (1)
- T Tilt angle of ladle movement center point O
- the shaft speed command / position command calculating means 86 calculates the amount of movement of each of the back-and-forth moving mechanism 20, the lifting mechanism 30, and the tilting mechanism 40. Output. As each of the devices 20, 30, 40 is moved in accordance with an instruction from the shaft speed command / position command calculating means 86, the ladle 2 is tilted by the tilting angular velocity by the tilting mechanism 40, and the tilting shaft 44 sets the movement center point O. Move on the arc around the center.
- control unit 70 performs feedforward control using the commanded tilt angular velocity V Tp which is a value obtained by multiplying the tilt angular velocity V Tobj (tp) of the flow rate pattern by the tilt angular velocity correction coefficient f (T).
- the plan part is filled with molten metal, and the molten metal begins to fill the product part.
- the ladle 2 is tilted based on the flow rate pattern. Up to this point, the control is the same as the initial filling control.
- the load cell 50 detects the weight of the apparatus including the ladle 2, and the molten metal weight calculating means 87 in the ladle continues to measure the molten metal weight in the ladle.
- the molten metal weight in the ladle 2 is detected by the load cell 50 including the calculation of the molten metal weight in the ladle 2 by the molten metal weight calculating means 87.
- the casting weight correction calculating means 82 calculates the difference between the detected molten metal weight in the ladle 2 and the molten metal weight in the flow rate pattern, and outputs the casting weight correction amount to the operation tilt angular velocity calculating means 85. .
- the tilting angular velocity calculating means 85 calculates the correction amount V Tw of ladle tilting angular velocity equation (2).
- the calculation in ⁇ is performed by the cast weight correction calculation means 82.
- V Tw cg ⁇ ⁇ g obj (tp) ⁇ g (tp) ⁇ (2)
- cg casting weight correction coefficient for deriving the tilting angular velocity of the ladle from the correction amount of the casting weight
- g obj (tp) casting weight at time tp in the flow rate pattern
- g (tp) detected at time tp Molten metal weight in mold
- Correction amount V Tw of ladle tilting angular velocity is output to the shaft speed command and position command calculating means 86, the axial velocity command and position command calculating means 86, the anteroposterior moving mechanism 20, the elevating mechanism 30, each movement of the tilt mechanism 40
- the amount correction value is output, and the tilt angle T of the ladle 2 is corrected. That is, the control unit 70 performs feedback control using the molten metal weight in the ladle 2 detected by the load cell 50.
- the hot water level of the pouring cup 110 of the mold 100 is continuously detected by the camera 60.
- Data taken by the camera 60 is converted into image data by the image processing arithmetic device 76, and the gate area calculation means 83 calculates the gate area.
- the molten metal level correction calculating means 84 calculates the molten metal level based on the gate area and the parameters from the parameter storage means 93.
- the molten metal level data detected by the camera 60 is calculated through the image processing arithmetic device 76 and the molten metal level correction calculating means 84. Including the calculation of the molten metal level in this way.
- the hot water surface level correction calculation means 84 calculates a correction value of the hot water surface level based on the difference between the calculated hot water surface level and the reference value from the hot water surface level reference value storage means 94. From the correction amount of the operation the tilting angular velocity calculating means 85 in molten metal surface level, with the melt surface level correction coefficient cl from the parameter storage unit 93, calculates the correction amount V Ts of ladle tilting angular velocity by equation (3). Note that the calculation in ⁇ in the expression (3) is performed by the molten metal level correction calculation means 84.
- V Ts cl ⁇ ⁇ s obj ⁇ s ⁇ (3)
- cl hot water surface level correction coefficient for deriving the tilting angular velocity of the ladle from the correction amount of the hot water surface level s obj : the reference value of the hot water surface level s: the hot water surface level detected by the camera
- the correction amount V Ts of the ladle tilting angular velocity is output to the shaft speed command / position command calculating means 86, and the shaft speed command / position command calculating means 86 moves each of the back-and-forth moving mechanism 20, the lifting mechanism 30, and the tilting mechanism 40.
- the amount correction value is output, and the tilt angle T of the ladle 2 is corrected. That is, the control unit 70 performs feedback control using the hot water level of the pouring cup 110 of the casting mold 100 detected by the camera 60.
- the timing for hot water cutting is determined based on the molten metal weight in the ladle 2 detected by the load cell 50. Then, the tilt of the ladle is returned to zero based on the tilt angular velocity data of the hot water cutting in the flow rate pattern. Normally, the ladle is returned at the maximum inclination angular velocity. In this case, it is not necessary to move the ladle 2 back and forth or up and down so that only the tilting mechanism 40 operates and the tilting shaft 44 moves on the arc around the movement center point O.
- the tilt angle T of the ladle 2 is controlled to adjust the pouring flow rate from the ladle 2 to the mold 100, and the weight of the molten metal in the ladle 2 detected by the load cell 50 and the camera 60 are detected.
- control unit 70 has been described as performing a specific calculation by a specific unit.
- control unit 70 may be configured to perform a calculation by other units, and the configuration of the control unit 70 is not limited.
- control unit 70 measures the time after the molten metal is received into the ladle 2 or the time after the addition of the alloy material or the inoculum, the control of the movement of the pouring device 1, and the abnormality of the received voltage.
- Other controls such as detection, detection for other safe driving and generation of an alarm may be performed.
- FIG. 8 is a front view of a pouring device 101 having a mechanism different from that of the pouring device 1.
- the traveling cart 10 is provided with the back-and-forth movement mechanism 20 in the same manner as the pouring device 1.
- a first tilting mechanism 130 is provided in the front-rear moving mechanism 20, and a second tilting mechanism 140 is provided in the first tilting mechanism 130.
- the support 131 and the first tilt drive unit 132 are fixed to the front-rear moving mechanism 20.
- a first tilting shaft 136 is rotatably supported at the top of the support column 131.
- a first tilting frame 134 is fixed to the first tilting shaft 136.
- a first sector gear 138 is fixed to the first tilt frame 134 and meshes with the first pinion 139 of the first tilt drive unit 132. That is, when the first pinion 139 is rotated by the first tilt driving unit 132, the first sector gear 138 and the first tilt frame 134 are tilted around the first tilt shaft 136.
- the support plate 141 is fixedly supported on the first tilting shaft 136 of the first tilting mechanism 130. That is, the support plate 141 tilts together with the first tilting shaft 136.
- the second tilting shaft 146 is supported so as to be tiltable at a position near the pouring gate 6 of the ladle 2 of the support plate 141.
- a second tilting frame 144 is fixed to the second tilting shaft 146.
- a second sector gear 148 is fixed to the end of the second tilt frame 144 opposite to the second tilt shaft 146 and meshes with the second pinion 149 of the second tilt drive unit 142.
- the second tilt driving unit 142 when the second pinion 149 is rotated by the second tilt driving unit 142, the second sector gear 148 and the second tilt frame 144 are tilted around the second tilt shaft 146.
- the second tilt drive unit 142 is supported by the first tilt frame 134.
- the ladle 2 is supported by the second tilting mechanism 140.
- the support plate 141 tilts in the same manner, and the second tilt shaft 146 moves so as to change the position in the vertical direction.
- the second tilt mechanism 140 tilts around the second tilt shaft 146. Therefore, the first tilting mechanism 130 has a function of moving the ladle 2 to the vertical position.
- a frame 164 is provided in the forward / backward movement mechanism 20, and the camera arm 162 extends in the horizontal direction from the frame 164 to support the camera 60.
- the frame 164 may be provided on the support 131.
- the load cell 50 is disposed between the traveling carriage 10 and the longitudinal movement mechanism 20.
- the load cell 50 may be arranged at other positions as long as the weight of the ladle 2 can be detected.
- the control unit 70 is installed in the same manner as the pouring device 1.
- the traveling carriage 10 can move to a predetermined position along the mold line L. Then, the back and forth moving mechanism 20 can approach and separate from the mold 100. Further, the first tilt mechanism 130 tilts around the first tilt axis 136, and the second tilt mechanism 140 tilts around the second tilt axis 146. Therefore, it moves with the back-and-forth moving mechanism 20 and tilts around the first tilting shaft 136 and the second tilting shaft 146, thereby pouring the molten metal from the ladle 2 while keeping the position where the molten metal is poured into the mold 100 constant. be able to.
- the second tilting shaft 140 can be used as the movement center point O of the pouring device 1. Further, it is possible to pour while detecting the molten metal level in the ladle 2 with the load cell 50 while detecting the level of the molten metal in the pouring cup 110 with the camera 60.
- the position of the camera 60 may be adjusted by the camera arm 162 in accordance with the positional relationship between the pouring device 101 and the pouring cup 110.
- the frame 164 may be configured to move according to the tilt of the first tilt mechanism 130.
- the container 2 of the present invention may be a furnace such as a melting furnace.
- the molten metal should be poured directly from the melting furnace into the mold without being replaced with a ladle.
- the pouring position may be kept constant by raising and lowering the mold 100 without raising and lowering the melting furnace, that is, the container 2. That is, the pouring device 1 does not include the lifting mechanism 30, and a lifting mechanism (not shown) for lifting the mold 100 may be provided separately.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Casting Support Devices, Ladles, And Melt Control Thereby (AREA)
Abstract
Description
出願人は、記載された実施の形態のいずれをも公衆に献上する意図はなく、開示された改変、代替案のうち、特許請求の範囲内に文言上含まれないかもしれないものも、均等論下での発明の一部とする。
本明細書あるいは請求の範囲の記載において、名詞及び同様な指示語の使用は、特に指示されない限り、または文脈によって明瞭に否定されない限り、単数および複数の両方を含むものと解釈すべきである。本明細書中で提供されたいずれの例示または例示的な用語(例えば、「等」)の使用も、単に本発明を説明し易くするという意図であるに過ぎず、特に請求の範囲に記載しない限り本発明の範囲に制限を加えるものではない。
VTp=f(T)・VTobj(tp) (1)
ここで、f(T):傾動角速度補正係数、
T:取鍋の移動中心点Oの傾動角度
VTw=cg・{gobj(tp)-g(tp)} (2)
ここで、cg:鋳込重量の補正量から取鍋の傾動角速度を導く鋳込重量補正係数
gobj(tp):流量パターンにおける時間tpの鋳込重量
g(tp):時間tpにおける検知された鋳型内の溶湯重量
VTs=cl・{sobj-s} (3)
ここで、cl:湯面レベルの補正量から取鍋の傾動角速度を導く湯面レベル補正係数
sobj:湯面レベルの基準値
s:カメラで検知された湯面レベル
1 注湯装置
2 取鍋(容器)
4 取鍋本体
6 注湯口
10 走行台車
20 前後移動機構
30 昇降機構
32 支柱
34 昇降本体
36 昇降駆動部
40 傾動機構
42 傾動駆動部
44 傾動軸
46 取鍋台
47 側板
48 底板
50 ロードセル(重量検知部)
60 カメラ(湯面検知部)
62 カメラ用アーム
64 フレーム
70 制御部
72 中央処理装置
74 軸駆動装置アンプ
76 画像処理演算装置
78 ロードセルアンプ
80 演算領域
81 軸の現在位置・速度演算手段
82 鋳込重量補正演算手段
83 湯口面積演算手段
84 湯面レベル補正演算手段
85 操作傾動角速度演算手段
86 軸速度指令・位置指令演算手段
87 取鍋内の溶湯重量演算手段
90 記憶領域
91 演算データ記憶手段
92 時間経過パラメータ記憶手段
93 パラメータ記憶手段
94 湯面レベル基準値記憶手段
95 取鍋傾動角度補正関数記憶手段
96 流量パターン記憶手段
97 取鍋風袋重量記憶手段
100 鋳型
110 注湯カップ
112 注湯カップのテーパー
130 第1傾動機構
131 支柱
132 第1傾動駆動部
134 第1傾動フレーム
136 第1傾動軸
138 第1セクタギア
139 第1ピニオン
140 第2傾動機構
141 支持プレート
142 第2傾動駆動部
144 第2傾動フレーム
146 第2傾動軸
148 第2セクタギア
149 第2ピニオン
162 カメラ用アーム
164 フレーム
L 鋳型ライン
O 移動中心点(仮想点)
R レール
T 傾動角度
Claims (16)
- 列状に送り出される鋳型に容器から注湯を行う注湯装置であって、
前記列状に送り出される鋳型に沿って走行する走行台車と;
前記走行台車に設けられ、前記走行台車の走行方向と直交する方向に前記容器を移動する前後移動機構と;
前記前後移動機構に設けられ、前記容器を傾動する傾動機構と;
前記容器内の溶湯の重量を検知する重量検知部と;
前記走行台車に設けられ、前記容器から受湯する鋳型の注湯カップにおける湯面レベルを検知する湯面検知部と;
前記湯面検知部で検知された前記湯面レベルと前記重量検知部で検知された前記溶湯の重量とを用いて前記容器の傾動角度を制御する制御部とを備える;
注湯装置。 - 前記湯面検知部はイメージセンサである;
請求項1の注湯装置。 - 前記注湯カップにテーパーが設けられ、前記湯面検知部は前記湯面の面積に基づき湯面レベルを検知する;
請求項2の注湯装置。 - 前記容器は、炉から溶湯を受け取るとともに鋳型に注湯を行う取鍋であり;
前記取鍋を昇降する昇降機構が、前記前後移動機構に設けられ;
前記傾動機構は、前記昇降機構に設けられる;
請求項1ないし3のいずれか1項の注湯装置。 - 前記前後移動機構と前記昇降機構と前記傾動機構は、前記傾動機構が前記容器を傾動する傾動軸が前記容器の注湯口の溶湯落下開始点またはこれに近接して設定された仮想点を中心として円弧上を移動するように連動し、前記容器から前記鋳型への注湯位置を一定に維持する;
請求項4の注湯装置。 - 前記制御部は、前記鋳型に適合する流量パターンを記憶し、該流量パターンは時間毎の前記容器を傾動させるための傾動角速度と鋳込重量とのデータを含み;
前記制御部は、前記傾動角速度に基づき、前記容器の傾動角度を制御する;
請求項1ないし5のいずれか1項の注湯装置。 - 前記制御部は、前記流量パターンの前記傾動角速度を前記容器の形状に適合させるための補正関数をさらに記憶し、前記傾動角速度に前記補正関数を乗じた値を用いる;
請求項6の注湯装置。 - 前記制御部は、前記傾動角速度に前記補正関数を乗じた前記値を用いてフィードフォワード制御をし、前記湯面検知部で検知された前記湯面レベルと前記重量検知部で検知された前記溶湯の重量とを用いてフィードバック制御をする;
請求項7の注湯装置。 - 前記制御部は、前記流量パターンの鋳込重量のデータと、前記重量検知部で検知された容器内の溶湯の重量との重量差を用いて、前記容器の傾動角速度の補正量を求めて制御する;
請求項1ないし8のいずれか1項の注湯装置。 - 前記制御部は、前記重量差から前記容器の傾動角速度の補正量を算定するための鋳込重量補正係数を記憶し、前記重量差に前記鋳込重量補正係数を乗じて前記容器の傾動角速度の補正量を求める;
請求項9の注湯装置。 - 前記制御部は、前記湯面検知部で検知された前記湯面レベルが所定の湯面レベルとなるように前記容器の傾動角速度の補正量を求めて制御する;
請求項1ないし10のいずれか1項の注湯装置。 - 前記制御部は、前記湯面検知部で検知された前記湯面レベルと前記所定の湯面レベルのレベル差から前記容器の傾動角速度の補正量を算定するための湯面レベル補正係数を記憶し、前記レベル差に前記湯面レベル補正係数を乗じて前記容器の傾動角速度の補正量を求める;
請求項11の注湯装置。 - 容器を傾動して鋳型に注湯する工程と;
前記容器内の溶湯の重量を検知する工程と;
前記容器から受湯する鋳型の注湯カップの湯面レベルを検知する工程と;
前記検知した重量と、前記検知した湯面レベルとを用いて、前記容器を傾動する傾動角度を制御する工程とを備える:
注湯方法。 - 前記容器を傾動して鋳型に注湯する工程では、前記容器を水平方向に移動し、さらに昇降して、前記容器を傾動する傾動軸が前記容器の注湯口の溶湯落下開始点またはこれに近接して設定された仮想点を中心として円弧上を移動し、前記容器から前記鋳型への注湯位置を一定に維持する;
請求項13の注湯方法。 - 前記鋳型に適用可能な流量パターンを用い、該流量パターンは時間毎の前記容器を傾動させるための傾動角速度と鋳込重量とのデータを含み;
前記容器を傾動させるための傾動角速度に基づき、前記容器の傾動角度を制御する;
請求項13または14の注湯方法。 - 前記流量パターンの鋳込重量のデータと前記検知された容器内の溶湯の重量との重量差、ならびに、前記検知された前記湯面レベルと所定の湯面レベルとの湯面レベル差を用いて、前記容器の傾動角速度の補正量を求めて制御する;
請求項15の注湯方法。
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US15/553,039 US10537937B2 (en) | 2015-03-06 | 2015-03-06 | Pouring machine and method |
KR1020177024989A KR20170125040A (ko) | 2015-03-06 | 2015-03-06 | 주탕 장치 및 주탕 방법 |
EP15884481.1A EP3266540B1 (en) | 2015-03-06 | 2015-03-06 | Pouring machine and method |
PCT/JP2015/056615 WO2016142983A1 (ja) | 2015-03-06 | 2015-03-06 | 注湯装置および注湯方法 |
JP2015553951A JP5957152B1 (ja) | 2015-03-06 | 2015-03-06 | 注湯装置および注湯方法 |
CN201580001068.4A CN106132595B (zh) | 2015-03-06 | 2015-03-06 | 浇铸装置以及浇铸方法 |
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Also Published As
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EP3266540B1 (en) | 2020-05-13 |
EP3266540A4 (en) | 2018-08-08 |
JP5957152B1 (ja) | 2016-07-27 |
JPWO2016142983A1 (ja) | 2017-04-27 |
CN106132595B (zh) | 2019-08-23 |
EP3266540A1 (en) | 2018-01-10 |
US20180029116A1 (en) | 2018-02-01 |
KR20170125040A (ko) | 2017-11-13 |
US10537937B2 (en) | 2020-01-21 |
CN106132595A (zh) | 2016-11-16 |
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