CN111069526A - Energy-saving consumption-reducing automatic resin quantifying method and system - Google Patents
Energy-saving consumption-reducing automatic resin quantifying method and system Download PDFInfo
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- CN111069526A CN111069526A CN201911237593.2A CN201911237593A CN111069526A CN 111069526 A CN111069526 A CN 111069526A CN 201911237593 A CN201911237593 A CN 201911237593A CN 111069526 A CN111069526 A CN 111069526A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C5/00—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose
- B22C5/04—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose by grinding, blending, mixing, kneading, or stirring
- B22C5/0409—Blending, mixing, kneading or stirring; Methods therefor
- B22C5/0472—Parts; Accessories; Controlling; Feeding; Discharging; Proportioning
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
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Abstract
The invention provides an energy-saving consumption-reducing automatic resin quantification method and system, and the bending strength of resin sand for casting large-scale wind power ductile iron parts is summarized from production practice to be not less than 2.0 MPa; the method has the advantages that the range of the acidity value of the curing agent is changed along with the change of seasons, but the strength of the resin sand is changed along with the increase of the acidity of the curing agent, so that the high-acidity curing agent can adopt lower resin addition amount and meet the strength requirement, the original resin feeding system is improved, a resin frequency converter is incorporated into an A + B curing agent automatic control device, the resin addition amount is adjusted according to different curing agent gears, and a resin quantitative automatic system is implemented to save the resin usage amount; through measurement and calculation, the system and the method can realize that the annual average resin addition amount is reduced by 5-10%; calculated according to the capacity of 10 ten thousand tons (sand-iron ratio 6), the resin can be saved by about 200 tons every year.
Description
Technical Field
The invention belongs to the field of metallurgy, particularly belongs to the field of metallurgical resin sand mold preparation, and particularly relates to a resin quantification method and a resin quantification system in the resin sand mold preparation process.
Background
The molding sand is a key factor in casting production and is generally formed by proportionally mixing raw sand, a binder and auxiliary additives. At present, about 30-50% of casting waste is associated with the quality of the molding sand. The molding sand can be classified into clay sand, sodium silicate sand, cement sand, resin sand and the like according to the used binder. Among them, resin sand is widely used for the production of cast steel, cast iron, and cast nonferrous alloy castings because of its excellent properties such as high strength, small dimensional variation, good collapsibility, and low energy consumption.
The sand-iron ratio of a large casting generally reaches more than 5, and the dosage of the molding sand is one of key factors for forming the cost of the casting. The resin sand is mainly determined by the addition amount of resin, and although the addition amount of resin in the resin sand is only about 1%, the resin cost in the resin sand accounts for 80% or more of the total cost because the resin is expensive. In the production of wind power nodular iron castings, the mainstream molding sand is self-hardening furan resin sand at present, which is a molding method that raw sand (or reclaimed sand) takes synthetic furan resin as a binder and is self-hardened at room temperature under the action of a corresponding curing agent. The curing agent used in large wind power foundries is typically an organic acid such as a sulfonic acid based curing agent. The sulfonic acid curing agents are divided into single type and combined type according to the production requirements and the use mode.
The resin sand process requires that the usable time must be longer than the sand mold casting time. The pot life refers to the time interval from the time when the curing reaction starts to the time when the resin adhesion force decreases to a certain value, and the sample preparation time in which only 70% of the final strength remains is generally referred to as the pot life of the resin sand. The mold-release time refers to the time during which the resin sand fills the mold. The weight of the wind-power casting varies from dozens of kilograms to hundreds of tons, and correspondingly, the time for casting the sand mold varies from dozens of seconds to dozens of minutes. This requires that the usable time of the resin sand can be flexibly adjusted between several minutes and several tens of minutes depending on the specific casting type.
The main factors influencing the usable time of the resin sand are the temperature (sand temperature) and the acidity of the curing agent. The temperature can be regularly changed in a larger range along with seasons, but the temperature is generally constant and can not be obviously changed when a certain production is carried out; therefore, adjusting the acidity of the curing agent by using the a + B combination type curing agent is currently the most important and convenient method for adjusting the usable time. Wherein A is a high-acid curing agent with total acidity of 30-34%, B is a low-acid curing agent with total acidity of 6-9%, and the adding proportion of the A-type curing agent and the B-type curing agent is adjusted by an A + B curing agent automatic control instrument, so that the overall acidity of the curing agent is adjusted. The A + B curing agent automatic control instrument is generally 4 to 5 gears, and the 1 gear is a high acidity gear, so that the acidity value is reduced in sequence. The site production can select proper gear according to the size of the casting core.
The existing A + B curing agent automatic control instrument and a resin control system are mutually independent, the curing agent automatic control instrument adjusts the acidity of the curing agent through gears, and the adding amount of the resin is constant. In order to ensure that the strength of the sand mold after being cured under the constantly changing acidity of the curing agent can meet the technical requirement of not less than 2MPa, a safety margin is usually selected to meet the strength requirement under all the acidity conditions of the curing agent when the addition amount of the resin is determined. This in turn leads to additional resin consumption and increased costs, and makes the actual usable time and final strength of the resin sand difficult to predict, resulting in a reduction in production efficiency.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides an energy-saving consumption-reducing automatic resin quantifying method and system.
Specifically, the invention provides an energy-saving and consumption-reducing automatic resin quantifying system, which comprises a touch screen, a PLC (programmable logic controller) control unit, two curing agent pumps, two curing agent pump frequency converters, a resin pump frequency converter, a temperature collector, a curing agent gear regulator and a sand mixer; the temperature collector is electrically connected with the PLC control unit and is used for collecting sand temperature and feeding back a sand temperature signal to the PLC control unit; the curing agent gear regulator is electrically connected with the PLC control unit and is used for regulating the curing agent gear, changing the adding proportion of the A-type curing agent and the B-type curing agent and further controlling the integral acidity value of the A + B-type combined curing agent; the curing agent gear regulator feeds back a current curing agent gear signal to the PLC control unit; the touch screen is electrically connected with the PLC and is used for inputting formula data, calibration data and manual data to the PLC control unit or processing system alarm; the PLC control unit is also electrically connected with a curing agent A frequency converter, a curing agent B frequency converter and a resin frequency converter respectively; the curing agent A frequency converter and the curing agent B frequency converter are respectively electrically connected with a curing agent pump; the resin frequency converter is electrically connected with a resin pump; and the two curing agent pumps and the resin pump are connected with the sand mixer through pipelines.
The curing agent pump and the resin pump respectively adjust the flow of corresponding materials according to signals of frequency converters electrically connected with the curing agent pump and the resin pump; and the frequency converter signals are sent to the corresponding frequency converters by the PLC.
The invention also provides a method for realizing automatic resin quantification according to the system, which comprises the following steps:
1. formula data are stored in a PLC control unit in advance, and the formula data are shown in the table 1 (determined through a temperature change experiment) of the invention and comprise sand temperature, a curing agent gear, curing agent acidity, resin addition and corresponding strength;
2. determining the usable time of the resin sand according to the weight of the sand mold to be prepared;
3. the PLC control unit receives the sand temperature signal collected by the temperature collector and displays the sand temperature signal on the touch screen;
4. determining the acidity value of the A + B type curing agent according to the available time determined in the step 2 and the temperature signal determined in the step 3, and further determining the gear of the curing agent;
5. inputting the curing agent gear determined in the step 4 through a touch screen, and automatically matching the pre-stored formula data by the PLC to obtain the lowest resin addition amount of which the strength value is not less than 2MPa under the current sand temperature and the curing agent gear;
6. the PLC control unit respectively sends signals to a curing agent pump frequency converter A, a curing agent pump frequency converter B and a resin frequency converter according to the curing agent gear determined in the step 5 and the automatically matched resin adding amount;
7. and each frequency converter controls the operation of the curing agent pump and the resin pump according to the received signals, and supplies materials to the sand mixer.
Compared with the prior art, the invention can at least obtain the following beneficial effects: the bending strength of the resin sand for casting the large-scale wind power ductile iron piece is concluded to be not less than 2.0MPa from production practice; the method is characterized in that the range of the acidity value of a curing agent is changed along with the change of seasons, but the strength of resin sand is changed along with the increase of the acidity of the curing agent, so that the curing agent with high acidity can adopt lower resin addition amount and meet the strength requirement, and the method is found out that the original resin feeding system is improved, a resin frequency converter and an automatic control device of A + B curing agent are combined, the resin addition amount is adjusted according to the difference of the gears of the curing agent, and a resin quantitative automatic system is implemented so as to save the resin usage amount; through measurement and calculation, the system and the method can realize that the annual average resin addition amount is reduced by 5-10%. Calculated according to the capacity of 10 ten thousand tons (sand-iron ratio 6), the resin can be saved by about 200 tons every year.
Drawings
FIG. 1 is a schematic diagram of a conventional resin and curing agent control system;
FIG. 2 is a schematic diagram of an automated resin dosing system of the present invention.
Detailed Description
Example 1
As shown in fig. 2, an automatic resin quantifying system is provided, which comprises a touch screen, a PLC control unit, two curing agent pumps, two curing agent pump frequency converters, a resin pump frequency converter, a temperature collector, a curing agent gear adjuster, and a sand mixer; the temperature regulator is electrically connected with the PLC control unit and is used for collecting sand temperature and feeding back a sand temperature signal to the PLC control unit; the curing agent gear regulator is electrically connected with the PLC control unit and is used for regulating the curing agent gear, changing the adding proportion of the A-type curing agent and the B-type curing agent and further controlling the integral acidity value of the A + B-type combined curing agent; the curing agent gear regulator feeds back a current curing agent gear signal to the PLC control unit; the touch screen is electrically connected with the PLC and is used for inputting formula data, calibration data and manual data to the PLC control unit or processing system alarm; the PLC control unit is also electrically connected with a curing agent A frequency converter, a curing agent B frequency converter and a resin frequency converter respectively; the curing agent A frequency converter and the curing agent B frequency converter are respectively electrically connected with a curing agent pump; the resin frequency converter is electrically connected with a resin pump; and the two curing agent pumps and the resin pump are connected with the sand mixer through pipelines.
The curing agent pump and the resin pump respectively adjust the flow of corresponding materials according to signals of frequency converters electrically connected with the curing agent pump and the resin pump; and the frequency converter signals are sent to the corresponding frequency converters by the PLC.
Example 2
A method for realizing automatic resin quantification according to the system in the embodiment 1 is provided, and the method comprises the following specific steps:
1. formula data are stored in a PLC control unit in advance, and are shown in a table 1 of the invention;
2. the weight of the sand mold prepared by the embodiment is 2t, and the service life of the resin sand is not less than 30 min;
3. the temperature of the sand collected by the temperature collector is 23 ℃, and the PLC control unit receives the temperature signal and displays the temperature signal on the touch screen;
4. determining the acidity value of the A + B type curing agent to be 15 according to the available time determined in the step 2 and the temperature signal determined in the step 3, and further determining the gear of the curing agent to be 3;
5. inputting the curing agent gear determined in the step 4 through a touch screen, automatically matching the pre-stored formula data by the PLC, and obtaining that the lowest resin addition amount meeting the strength value not less than 2MPa is 0.8% under the current sand temperature and the curing agent gear;
6. the PLC control unit respectively sends signals to a curing agent pump frequency converter A, a curing agent pump frequency converter B and a resin frequency converter according to the curing agent gear determined in the step 5 and the automatically matched resin adding amount;
7. and each frequency converter controls the operation of the curing agent pump and the resin pump according to the received signals, and supplies materials to the sand mixer.
TABLE 1
Comparative example 1
A 2t weight sand mold was prepared using the system shown in fig. 1. Because the system is not related to the relationship between the resin addition and the curing agent gear, in order to ensure the strength of the prepared sand mold, the resin addition is 0.85 percent according to the industry convention.
The addition of the resin in the comparative example 1 is 0.05 percent higher than that of the resin in the example 2, and the practical resin in the example 2 is 16kg, and the practical resin in the comparative example 1 is 17kg according to the weight of the sand mold of 2 t; compared with the comparative example 1, the resin can be saved by 1kg in the example 2, which accounts for 6.25 percent of the actual resin amount in the example 2.
Referring to the data in table 1, in the case of spring and autumn, 3 rd grade curing agent, the strength of the sand mold is 2.3MPa, which is higher than the strength requirement of 2MPa, but the addition amount is not the optimal amount, with the resin addition amount of 0.85% adopted in comparative example 1. And after the resin adding amount is related to the curing agent gear in the embodiment 2, the resin adding amount can be further reduced on the premise of meeting the requirement of the sand mold strength, and the sand mold cost is reduced.
Claims (2)
1. An energy-saving consumption-reducing automatic resin quantifying system comprises a touch screen, a PLC control unit, two curing agent pumps, two curing agent pump frequency converters, a resin pump frequency converter, a temperature collector, a curing agent gear regulator and a sand mixer; the temperature collector is electrically connected with the PLC control unit and is used for collecting sand temperature and feeding back a sand temperature signal to the PLC control unit; the curing agent gear regulator is electrically connected with the PLC control unit and is used for regulating the curing agent gear, changing the adding proportion of the A-type curing agent and the B-type curing agent and further controlling the integral acidity value of the A + B-type combined curing agent; the curing agent gear regulator feeds back a current curing agent gear signal to the PLC control unit; the touch screen is electrically connected with the PLC and is used for inputting formula data, calibration data and manual data to the PLC control unit or processing system alarm; the PLC control unit is also electrically connected with a curing agent A frequency converter, a curing agent B frequency converter and a resin frequency converter respectively; the curing agent A frequency converter and the curing agent B frequency converter are respectively electrically connected with a curing agent pump; the resin frequency converter is electrically connected with a resin pump; the two curing agent pumps and the resin pump are both connected with the sand mixer through pipelines; the curing agent pump and the resin pump respectively adjust the flow of corresponding materials according to signals of frequency converters electrically connected with the curing agent pump and the resin pump; and the frequency converter signals are sent to the corresponding frequency converters by the PLC.
2. A method for realizing automatic resin quantification according to the system of claim 1 comprises the following specific steps:
① pre-storing formula data in the PLC control unit, wherein the formula data comprises sand temperature, curing agent gear, curing agent acidity, resin addition amount and corresponding strength;
② determining the usable time of the resin sand according to the weight of the sand mold to be prepared;
③ the PLC control unit receives the sand temperature signal collected by the temperature collector and displays the signal on the touch screen;
④ determining the acidity value of A + B type curing agent according to the usable time determined in step ② and the temperature signal determined in step 3, and further determining the gear of the curing agent;
⑤, inputting the curing agent gear determined in the step ④ through a touch screen, and automatically matching the PLC with pre-stored formula data to obtain the lowest resin addition amount with the strength value not less than 2MPa under the current sand temperature and the curing agent gear;
⑥ PLC control unit respectively sends signals to the frequency converter A of the curing agent pump, the frequency converter B of the curing agent pump and the frequency converter of the resin according to the curing agent gear determined in step ⑤ and the automatically matched resin adding amount;
⑦ each frequency converter controls the operation of the curing agent pump and the resin pump according to the received signals to supply materials to the sand mixer.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201911237593.2A CN111069526A (en) | 2019-12-05 | 2019-12-05 | Energy-saving consumption-reducing automatic resin quantifying method and system |
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| CN201911237593.2A CN111069526A (en) | 2019-12-05 | 2019-12-05 | Energy-saving consumption-reducing automatic resin quantifying method and system |
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| CN111069526A true CN111069526A (en) | 2020-04-28 |
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| CN201911237593.2A Pending CN111069526A (en) | 2019-12-05 | 2019-12-05 | Energy-saving consumption-reducing automatic resin quantifying method and system |
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Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1413982A (en) * | 1972-01-19 | 1975-11-12 | Staple R V M | Foam producing apparatus |
| CN101081427A (en) * | 2006-06-01 | 2007-12-05 | 沈阳迅天科技有限公司 | Intelligent type sand mulling control method |
| CN201259637Y (en) * | 2007-12-29 | 2009-06-17 | 济南圣泉集团股份有限公司 | Caking agent-curing agent mixture ratio control instrument for casting |
| CN202015811U (en) * | 2011-01-27 | 2011-10-26 | 天津市铸诚铸造辅料有限公司 | Intelligent resin bonded sand control instrument |
| CN104858360A (en) * | 2015-04-19 | 2015-08-26 | 奉化市宇创产品设计有限公司 | Liquid and material matching technology of resin sand mixer |
| CN106311971A (en) * | 2015-06-30 | 2017-01-11 | 共享装备有限公司 | Liquid material control system of sand mixer |
| CN110193585A (en) * | 2019-04-25 | 2019-09-03 | 青岛双星智能铸造装备有限公司 | A kind of stepless adjustable control system of sand mixer mulling and its control method |
-
2019
- 2019-12-05 CN CN201911237593.2A patent/CN111069526A/en active Pending
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1413982A (en) * | 1972-01-19 | 1975-11-12 | Staple R V M | Foam producing apparatus |
| CN101081427A (en) * | 2006-06-01 | 2007-12-05 | 沈阳迅天科技有限公司 | Intelligent type sand mulling control method |
| CN201259637Y (en) * | 2007-12-29 | 2009-06-17 | 济南圣泉集团股份有限公司 | Caking agent-curing agent mixture ratio control instrument for casting |
| CN202015811U (en) * | 2011-01-27 | 2011-10-26 | 天津市铸诚铸造辅料有限公司 | Intelligent resin bonded sand control instrument |
| CN104858360A (en) * | 2015-04-19 | 2015-08-26 | 奉化市宇创产品设计有限公司 | Liquid and material matching technology of resin sand mixer |
| CN106311971A (en) * | 2015-06-30 | 2017-01-11 | 共享装备有限公司 | Liquid material control system of sand mixer |
| CN110193585A (en) * | 2019-04-25 | 2019-09-03 | 青岛双星智能铸造装备有限公司 | A kind of stepless adjustable control system of sand mixer mulling and its control method |
Non-Patent Citations (1)
| Title |
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| 林勃等: "《砂型铸造工艺学》", 31 October 1992, 北京：机械工业出版社 * |
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