CN212077136U - Intelligent pilot test platform for aluminum-based material preparation - Google Patents
Intelligent pilot test platform for aluminum-based material preparation Download PDFInfo
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- CN212077136U CN212077136U CN201921870750.9U CN201921870750U CN212077136U CN 212077136 U CN212077136 U CN 212077136U CN 201921870750 U CN201921870750 U CN 201921870750U CN 212077136 U CN212077136 U CN 212077136U
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Abstract
The utility model discloses an intelligent pilot test platform for preparing aluminum-based materials, which comprises an intelligent control system of the whole machine, wherein the intelligent control system is composed of a PLC and a WinCC upper computer, and the intelligent control system is in communication connection with a medium-frequency melting device, an electromagnetic stirring and heat preservation device, a hydraulic mold opening device, a multifunctional degassing device and an ultrasonic metal melt processing device; the electromagnetic stirring and heat preservation device is arranged at the lower part of the intermediate frequency melting device; the metal mould is arranged at the lower part of the electromagnetic stirring and heat preservation device; the multifunctional degassing device is arranged above the intermediate frequency melting device and the electromagnetic stirring and heat preservation device; a video monitoring system is arranged above the intermediate frequency melting device; and the video monitoring system is in communication connection with a WinCC upper computer control system. The intelligent aluminum-based material preparation pilot test platform can complete various tests on aluminum substrates; and the independent control of each functional module and the combined control of the whole platform can be realized.
Description
Technical Field
The utility model relates to a pilot scale platform, concretely relates to aluminium-based material of intelligence preparation pilot scale platform belongs to metal material experiment platform technical field.
Background
Aluminum is the second largest metallic material next to steel; due to the characteristics of excellent structure and function, the improvement and improvement of the performance of the aluminum and the aluminum alloy material are combined, the application range of the aluminum alloy material is continuously expanded, along with the development of science and technology, more and more industrial aluminum profiles such as 'aluminum replaces steel', 'aluminum saves wood', 'aluminum saves copper' and the like are widely researched and developed, and in the prior art, the high-performance aluminum-based material is applied to the industries such as aerospace, rail transit, automobile light weight, electronic information, household appliances and the like; however, the experiments on the aluminum-based materials involve various aspects, and no good experimental platform exists in the prior art.
SUMMERY OF THE UTILITY MODEL
In order to solve the problems, the utility model provides an intelligent pilot test platform for preparing aluminum base materials, which can complete various tests on the aluminum base materials; and the independent control of each functional module and the combined control of the whole platform can be realized.
The utility model discloses an intelligence aluminum-based material preparation pilot test platform, including the intelligent control system of complete machine, the intelligent control system comprises PLC and WinCC host computer, the communication connection of intelligent control system has intermediate frequency melting device, electromagnetic stirring and heat preservation device, hydraulic pressure die sinking device, multi-functional degasser and ultrasonic wave metal melt processing apparatus; the electromagnetic stirring and heat preservation device is arranged at the lower part of the intermediate frequency melting device; a metal mold is arranged on the hydraulic mold opening device; the metal mould is arranged at the lower part of the electromagnetic stirring and heat preservation device; the multifunctional degassing device is arranged above the intermediate frequency melting device and the electromagnetic stirring and heat preservation device; a video monitoring system is arranged above the intermediate frequency melting device; the video monitoring system is in communication connection with a WinCC upper computer control system; the medium-frequency melting device can complete the melting and heating of metal materials such as steel, stainless steel, copper, aluminum, gold, silver and the like, and is controlled in a WinCC control system remote communication mode, the medium-frequency melting device is controlled in a 4-20mA or 0-5V control heating mode, and is kept at 720-730 ℃; the function of a multiple alarm protection device is arranged; the aluminum liquid can be automatically/manually tipped to be poured into a lower furnace, and the degassing work of the intermediate frequency smelting device and the electromagnetic stirring and heat preservation device needs to be completed; after degassing and stirring, detecting the degassing efficiency of the aluminum liquid, wherein the degassing rate is more than or equal to 65%; the inspection method comprises the steps of respectively vacuumizing a hydrogen measuring instrument for the aluminum liquid before degassing and the aluminum liquid after degassing, and calculating the degassing rate according to the area of the section hole of the sample; after degassing and stirring, extracting an aluminum liquid sample, and solidifying the aluminum liquid sample in a vacuum state, wherein the pinhole degree of the section of the sample is more than grade 1; the electromagnetic stirring and heat preservation device comprises a furnace body and a feeding device arranged on the furnace body; an input voltmeter, an input current indication module, an emergency stop module and the like; the device is divided into an electromagnetic stirring part and a heat preservation control part; the touch screen displays indication interfaces such as working frequency, working current, fault alarm, stirring mode and the like; the stirring state can change the output current of work by adjusting the working frequency and the working strength, thereby achieving the purpose of changing the stirring strength; the stirring can be divided into a continuous mode and a timing mode, and the 2 modes have 3 stirring modes of positive stirring, reverse stirring and positive and negative stirring; in the stirring state, the stirring time, the forward stirring time and the reverse stirring time can be set; the temperature control meter can be used for carrying out more than 7-segment program control, the programming and operation of the temperature rising and reducing slope of the size can be set very flexibly, and programmable/operable commands such as jumping (circulation), running, pausing, stopping and the like are provided; the heat preservation control part has excellent control characteristics of no overshoot and no undershoot in a PID (proportion integration differentiation) regulation mode; four power-off/power-on event processing modes are set; the device has a curve fitting function and can obtain a smooth curve control effect; a light-weight densely-installed single-phase thyristor regulator is adopted; the internal short-circuit wire can be switched into a phase control mode and a zero control mode (wherein the zero control mode is variable-period zero-crossing triggering); the heat-preservation control part has the functions of over-temperature alarm of the radiator; the system is provided with a WinCC monitoring system; the ultrasonic metal melt processing device is an additional module, the existing production device and process flow are not changed, and the installation and the operation are convenient; the special energy-saving casting material can refine metal grains and homogenize alloy components, remarkably improve the strength and fatigue resistance of the casting material, and improve the comprehensive performance of the material, and mainly comprises a special power supply, a special energy converter, a special amplitude transformer, a special tool head and the like; it is simple and convenient to install: the standard flange plates are installed in a butt joint mode, and the existing production device and the existing process flow do not need to be changed; the metal mold and hydraulic mold opening device of the platform comprises a non-calibration device for casting the aluminum alloy metal mold, and the device mainly comprises: the device comprises a metal mold (with a top rod mechanism and a water cooling channel), a hydraulic mold opening machine (comprising an automatic material ejecting mechanism and a hydraulic pump station) and an operation platform; the metal mold 2 sleeve (the sizes of the molded products are phi 150x500 and phi 100x500 respectively) adopts a bottom injection and side injection mode, and is provided with an ejection structure and a cooling water channel; the hydraulic mold opening machine adopts button type electric mold opening and closing, and can automatically eject a mechanism, and the system pressure of a hydraulic pump station is 25 Mpa; because the intermediate frequency melting device, the electromagnetic stirring and heat preservation device, the hydraulic mold opening device, the multifunctional degassing device and the ultrasonic metal melt processing device are all assembled by the existing modules to form an experimental platform, the specific structure of each module is not detailed herein.
The utility model discloses an aluminium base material of intelligence preparation pilot scale platform experimentation as follows:
1. preparation of the experiment:
1) raw material preparation: adding the prepared aluminum ingot and aluminum block into a crucible of the intermediate frequency furnace; coating a release agent on the die opener;
2) preparation work before power-on: before starting the system, all power supplies are powered on;
2. after the control system is started, firstly, the whole set of equipment carries out fault self-checking work;
3. after the self-checking is finished, after a system starting button is pressed, a control system and a cooling system of the system are electrified;
4. the real-time temperature of a crucible of the intermediate frequency melting device is uploaded to a PLC control system, and then the PLC control system adjusts the real-time power control temperature of the intermediate frequency power supply in a mode of outputting 4-20mA or 0-5V through PID operation; meanwhile, the temperature is uploaded to a PLC control system by the electromagnetic stirring heat preservation device, and then the PLC adjusts the real-time power control temperature of the medium-frequency power supply in a mode of outputting 4-20mA or 0-5V through PID operation;
5. after the intermediate frequency smelting temperature reaches 720-730 ℃, preserving the heat for 30 minutes (the time can be revised by a WinCC system); after the temperature of the electromagnetic stirring heat preservation device reaches 720-;
6. observing the state of the aluminum liquid through video monitoring, and controlling a degassing device to automatically reach the designated position of the intermediate frequency furnace and the height of the crucible to carry out degassing operation for about 3-5 minutes by a PLC system after the heat preservation time is up (the time can be revised by a WinCC system);
7. after the degassing is finished, the PLC remote control multifunctional degassing device automatically returns to a standby state, and the temperature is maintained at 720-730 ℃ for 30 minutes (the time can be revised by a WinCC system);
8. when the heat preservation time is reached again and the temperature of the electromagnetic stirring heat preservation device is also within the specified range, the PLC sends a furnace tipping and turning instruction to the intermediate frequency smelting device, after the intermediate frequency smelting device receives the instruction, the PLC starts tipping and turning the aluminum liquid, and the aluminum liquid realizes the fixed-point water pouring operation of the electromagnetic stirring heat preservation device through the filtering device; the intermediate frequency smelting device can selectively enter a heat preservation standby state or a PID automatic cooling shutdown state according to the situation;
9. after the electromagnetic stirring heat preservation device is subjected to aluminum, the device is kept still for 5-10 minutes (the time can be revised by a WinCC system), the PLC sends out an electromagnetic stirring starting signal to the device and sends out a signal of 4-20mA to the feeding device, and the stirring intensity and the feeding speed are controlled by the WinCC. (when the temperature of the electromagnetic stirring heat-insulating device is also within a prescribed range);
10. after the feeding is finished, refining and stirring are continued for 30-60 minutes (the time can be revised by a WinCC system); the PLC automatically controls the metal mold and the hydraulic mold opening device to be in a state of waiting for aluminum receiving and heat preservation of 200 ℃ and 300 ℃ (the time can be revised by the WinCC system) 30-60 minutes before casting (the time can be revised by the WinCC system);
11. after the refining is stopped, the mixture is kept still for 1-2 minutes (the time can be revised by a WinCC system). The PLC generates an instruction to the ultrasonic metal melt processing device and then carries out degassing operation. After finishing, automatically returning for standby;
12. after the degassing is finished, the preparation of the metal mold and the hydraulic mold opening device is finished, the PLC sends a tipping and water pouring instruction, and the electromagnetic stirring heat preservation device starts casting operation. After the water is poured, the electromagnetic stirring heat-preserving device can be selected to enter a heat-preserving standby state or a PID automatic cooling shutdown state according to the situation;
13. after the casting operation is finished, the casting mold is cooled for 10-20 minutes (the time can be revised by a WinCC system), and the PLC sends out a mold opening instruction. And ejecting the aluminum bar after the die opener obtains the instruction. The metal mould and the hydraulic mould opening device can be selected to enter a heat preservation standby state or a PID automatic cooling shutdown state according to the situation;
14. and (5) taking out the aluminum bar, and finishing the experiment.
Further, an aluminum liquid filtering device is arranged at a discharge port of the intermediate frequency melting device.
Compared with the prior art, the intelligent aluminum-based material preparation pilot test platform can complete metal smelting process experiments, metal material degassing and purifying experiments, metal material electromagnetic composite experiments, metal material ultrasonic treatment experiments and metal die-casting forming experiments; the PLC control system is used for remotely transmitting a medium-frequency melting device, a multifunctional degassing device, an electromagnetic stirring and heat-insulating device, an ultrasonic metal melt processing device, a metal mold and a hydraulic mold opening device which are mainly equipped with the medium-frequency melting device to a WinCC monitoring system for operation and control, so that the production and preparation process is intelligentized; each functional module uploads a digital quantity signal, an analog quantity signal, an alarm signal and image data to a Siemens PLC control system, and then processes and identifies the signals to realize the function of automatic control; meanwhile, the independent control function of each component department is reserved.
Drawings
Fig. 1 is a schematic view of the overall structure of the present invention.
Detailed Description
Example 1:
the intelligent pilot test platform for preparing the aluminum-based material shown in the figure 1 comprises an intelligent control system 1 controlled by the whole machine, wherein the intelligent control system is composed of a PLC and a WinCC upper computer, and is in communication connection with a medium-frequency melting device 2, an electromagnetic stirring and heat preservation device 3, a hydraulic mold opening device 4, a multifunctional degassing device 5 and an ultrasonic metal melt processing device 6; the electromagnetic stirring and heat preservation device 3 is arranged at the lower part of the intermediate frequency melting device 2; a metal mold 9 is arranged on the hydraulic mold opening device 4; the metal mould is arranged at the lower part of the electromagnetic stirring and heat preservation device 3; the multifunctional degassing device 5 is arranged above the intermediate frequency melting device 2 and the electromagnetic stirring and heat preservation device 3; a video monitoring system 7 is arranged above the intermediate frequency melting device 2; the video monitoring system 7 is in communication connection with the PLC control system 1; the intermediate frequency melting device 2 can complete the melting and heating of metal materials such as steel, stainless steel, copper, aluminum, gold, silver and the like, the intermediate frequency melting device 2 is controlled in a PLC control system remote communication mode, the intermediate frequency melting device 2 is in a 4-20mA or 0-5V control heating mode, and the temperature is kept at 720-730 ℃; the function of a multiple alarm protection device is arranged; the aluminum liquid can be automatically/manually tipped to be poured into a lower furnace, and the degassing work of the intermediate frequency smelting device and the electromagnetic stirring and heat preservation device 3 needs to be completed; after degassing and stirring, detecting the degassing efficiency of the aluminum liquid, wherein the degassing rate is more than or equal to 65%; the inspection method comprises the steps of respectively vacuumizing a hydrogen measuring instrument for the aluminum liquid before degassing and the aluminum liquid after degassing, and calculating the degassing rate according to the area of the section hole of the sample; after degassing and stirring, extracting an aluminum liquid sample, and solidifying the aluminum liquid sample in a vacuum state, wherein the pinhole degree of the section of the sample is more than grade 1; the electromagnetic stirring and heat preservation device 3 comprises a furnace body and a feeding device arranged on the furnace body; an input voltmeter, an input current indication module, an emergency stop module and the like; the device is divided into an electromagnetic stirring part and a heat preservation control part; the touch screen displays indication interfaces such as working frequency, working current, fault alarm, stirring mode and the like; the stirring state can change the output current of work by adjusting the working frequency and the working strength, thereby achieving the purpose of changing the stirring strength; the stirring can be divided into a continuous mode and a timing mode, and the 2 modes have 3 stirring modes of positive stirring, reverse stirring and positive and negative stirring; in the stirring state, the stirring time, the forward stirring time and the reverse stirring time can be set; the temperature control meter can be used for carrying out more than 7-segment program control, the programming and operation of the temperature rising and reducing slope of the size can be set very flexibly, and programmable/operable commands such as jumping (circulation), running, pausing, stopping and the like are provided; the heat preservation control part has excellent control characteristics of no overshoot and no undershoot in a PID (proportion integration differentiation) regulation mode; four power-off/power-on event processing modes are set; the device has a curve fitting function and can obtain a smooth curve control effect; a light-weight densely-installed single-phase thyristor regulator is adopted; the internal short-circuit wire can be switched into a phase control mode and a zero control mode (wherein the zero control mode is variable-period zero-crossing triggering); the heat-preservation control part has the functions of over-temperature alarm of the radiator; the system is provided with a WinCC monitoring system; the ultrasonic metal melt processing device 6 is an additional module, the existing production device and process flow are not changed, and the installation and the operation are convenient; the special energy-saving casting material can refine metal grains and homogenize alloy components, remarkably improve the strength and fatigue resistance of the casting material, and improve the comprehensive performance of the material, and mainly comprises a special power supply, a special energy converter, a special amplitude transformer, a special tool head and the like; it is simple and convenient to install: the standard flange plates are installed in a butt joint mode, and the existing production device and the existing process flow do not need to be changed; the metal mold and hydraulic mold opening device 4 of the platform comprises a non-calibration device for casting the metal mold for smelting the aluminum alloy, and the device mainly comprises: the device comprises a metal mold (with a top rod mechanism and a water cooling channel), a hydraulic mold opening machine (comprising an automatic material ejecting mechanism and a hydraulic pump station) and an operation platform; the metal mold 2 sleeve (the sizes of the molded products are phi 150x500 and phi 100x500 respectively) adopts a bottom injection and side injection mode, and is provided with an ejection structure and a cooling water channel; the hydraulic mold opening machine adopts button type electric mold opening and closing, and can automatically eject a mechanism, and the system pressure of a hydraulic pump station is 25 Mpa; because the intermediate frequency melting device 2, the electromagnetic stirring and heat preservation device 3, the hydraulic mould opening device 4, the multifunctional degassing device 5 and the ultrasonic metal melt processing device 6 are all assembled by the existing modules to form an experimental platform, the specific structure of each module is not detailed herein.
The utility model discloses an aluminium base material of intelligence preparation pilot scale platform experimentation as follows:
1. preparation of the experiment:
1) raw material preparation: adding the prepared aluminum ingot and aluminum block into a crucible of the intermediate frequency furnace; coating a release agent on the die opener;
2) preparation work before power-on: before starting the system, all power supplies are powered on;
2. after the control system is started, firstly, the whole set of equipment carries out fault self-checking work;
3. after the self-checking is finished, after a system starting button is pressed, a control system and a cooling system of the system are electrified;
4. the crucible real-time temperature of the intermediate frequency melting device 2 is uploaded to a PLC control system, and then the PLC control system adjusts the real-time power control temperature of the intermediate frequency power supply in a mode of outputting 4-20mA or 0-5V through PID operation; meanwhile, the temperature is uploaded to a PLC control system by the electromagnetic stirring heat preservation device, and then the PLC adjusts the real-time power control temperature of the medium-frequency power supply in a mode of outputting 4-20mA or 0-5V through PID operation;
5. after the intermediate frequency smelting temperature reaches 720-730 ℃, preserving the heat for 30 minutes (the time can be revised by a WinCC upper computer control system); after the temperature of the electromagnetic stirring heat preservation device reaches 720-730 ℃, heat preservation is carried out for 120 minutes (the time can be revised by a WinCC upper computer control system) or infinitely;
6. observing the state of the aluminum liquid through video monitoring, and controlling a degassing device to automatically reach the designated position of the intermediate frequency furnace and the height of the crucible to carry out degassing operation for about 3-5 minutes by a PLC system after the heat preservation time is up (the time can be revised by a WinCC upper computer control system);
7. after the degassing is finished, the PLC remote control multifunctional degassing device 5 automatically returns to enter a standby state, and the temperature is maintained at 720-730 ℃ for 30 minutes (the time and the temperature can be revised through a WinCC upper computer control system);
8. when the heat preservation time is reached again and the temperature of the electromagnetic stirring heat preservation device is also within the specified range, the PLC sends a furnace tipping and turning instruction to the intermediate frequency smelting device, after the intermediate frequency smelting device receives the instruction, the PLC starts tipping and turning the aluminum liquid, and the aluminum liquid realizes the fixed-point water pouring operation of the electromagnetic stirring heat preservation device through the filtering device; the intermediate frequency smelting device can selectively enter a heat preservation standby state or a PID automatic cooling shutdown state according to the situation;
9. after the electromagnetic stirring heat preservation device is subjected to aluminum, the device is kept still for 5-10 minutes (the time can be revised through a WinCC upper computer control system), the PLC sends out an electromagnetic stirring starting signal to the device and sends out a signal of 4-20mA to the feeding device, and the stirring intensity and the feeding speed are controlled through the WinCC upper computer. (when the temperature of the electromagnetic stirring heat-insulating device is also within a prescribed range);
10. after the feeding is finished, refining and stirring are continued for 30-60 minutes (the time can be revised by a WinCC upper computer control system); the PLC automatically controls the metal mold and the hydraulic mold opening device 4 to be in a state of waiting for aluminum receiving and heat preservation of 200 ℃ and 300 ℃ (the temperature can be revised through the WinCC upper computer control system) 30-60 minutes before casting (the time can be revised through the WinCC upper computer control system);
11. and (3) standing for 1-2 minutes after refining is stopped (the time can be revised by a WinCC upper computer control system). The PLC gives an instruction to the ultrasonic molten metal processing apparatus 6 and then performs degassing operation. After finishing, automatically returning for standby;
12. after the degassing is finished, the preparation of the metal mold and the hydraulic mold opening device 4 is finished, the PLC sends a tipping and water pouring instruction, and the electromagnetic stirring heat preservation device starts casting operation. After the water is poured, the electromagnetic stirring heat-preserving device can be selected to enter a heat-preserving standby state or a PID automatic cooling shutdown state according to the situation;
13. after the casting operation is finished, the casting mold is cooled for 10-20 minutes (the time can be revised by a WinCC upper computer control system), and the PLC sends a mold opening instruction. And ejecting the aluminum bar after the die opener obtains the instruction. The metal mould and hydraulic mould opening device 4 can be selected to enter a heat preservation standby state or a PID automatic cooling shutdown state according to the situation;
14. and (5) taking out the aluminum bar, and finishing the experiment.
Wherein, the discharge port of the intermediate frequency melting device 2 is provided with an aluminum liquid filtering device 8.
The above-mentioned embodiment is only the preferred embodiment of the present invention, so all the equivalent changes or modifications made by the structure, features and principles of the present invention are included in the claims of the present invention.
Claims (2)
1. An intelligent pilot test platform for preparing aluminum-based materials is characterized in that: the intelligent control system comprises a PLC and a WinCC upper computer, and is in communication connection with a medium-frequency melting device, an electromagnetic stirring and heat preservation device, a hydraulic mold opening device, a multifunctional degassing device and an ultrasonic metal melt processing device; the electromagnetic stirring and heat preservation device is arranged at the lower part of the intermediate frequency melting device; a metal mold is arranged on the hydraulic mold opening device; the metal mould is arranged at the lower part of the electromagnetic stirring and heat preservation device; the multifunctional degassing device is arranged above the intermediate frequency melting device and the electromagnetic stirring and heat preservation device; a video monitoring system is arranged above the intermediate frequency melting device; and the video monitoring system is in communication connection with a WinCC upper computer control system.
2. The smart aluminum-based material preparation pilot platform of claim 1, wherein: and an aluminum liquid filtering device is arranged at a discharge port of the intermediate frequency melting device.
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| CN201921870750.9U CN212077136U (en) | 2019-11-01 | 2019-11-01 | Intelligent pilot test platform for aluminum-based material preparation |
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| CN201921870750.9U CN212077136U (en) | 2019-11-01 | 2019-11-01 | Intelligent pilot test platform for aluminum-based material preparation |
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