EP0659504A2 - Method for repositioning of a casting system for a form- and transportsystem which presses balers - Google Patents

Method for repositioning of a casting system for a form- and transportsystem which presses balers Download PDF

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Publication number
EP0659504A2
EP0659504A2 EP94118953A EP94118953A EP0659504A2 EP 0659504 A2 EP0659504 A2 EP 0659504A2 EP 94118953 A EP94118953 A EP 94118953A EP 94118953 A EP94118953 A EP 94118953A EP 0659504 A2 EP0659504 A2 EP 0659504A2
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EP
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Prior art keywords
casting
deviation
casting system
liquid metal
measuring zone
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Granted
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EP94118953A
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German (de)
French (fr)
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EP0659504A3 (en
EP0659504B1 (en
Inventor
Ralf Dr. Sesing
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ABB Patent GmbH
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ABB Patent GmbH
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D37/00Controlling or regulating the pouring of molten metal from a casting melt-holding vessel

Definitions

  • the invention relates to a method for repositioning a casting system in a baling molding and conveying system according to the preamble of claim 1.
  • Such a method for repositioning a casting system in a baling molding and conveying system is known from DE 42 02 020 A1.
  • a bottom hole of the casting system is arranged above a casting funnel of the casting mold located on a conveyor system.
  • the position of the bottom hole above the pouring funnel is checked and the positional deviations are recorded as soon as a shaping and conveying process of a shaped bale has ended and the shaped bale is at rest.
  • a change in position takes place only after the casting process has ended and during the next molding and conveying process of a mold bale.
  • EP 02 65 206 B1 discloses an apparatus and a method for regulating the casting of molten metal into individual casting molds, image-area information being generated during previously determined sampling intervals for a casting process.
  • Regulating means for adjusting the flow of the molten metal respond to difference values between captured image area information and reference area values.
  • Each regulating value is a function of the difference value for its assigned sampling interval and a regulating preset value for this sampling interval based on preselected casting parameters from at least one previous pouring process.
  • EP 02 69 591 B1 discloses a method for controlling the casting of a molten metal into casting molds, in which the upper side of the casting molds is scanned during their progressive movement to the casting station in order to determine the casting funnels. The remaining distance of the respective mold to the casting station is determined. On the basis of the determination of the remaining distance to be covered by the respective casting mold, the casting kettle is moved into a position exactly above the end position of this casting mold in the casting station.
  • the invention has for its object a method for repositioning a casting system in a baling molding and conveying system of the type mentioned specify in which the measuring device used for the mold level control can be used with a video camera.
  • the advantages that can be achieved with the invention are, in particular, that the method requires no additional equipment in addition to the mold level control.
  • Repositioning during a model series advantageously and easily compensates for bale thickness tolerances when a predetermined tolerance range with regard to the difference between the casting system position and the casting funnel position is exceeded.
  • baling molding and conveying systems In the case of baling molding and conveying systems (generally referred to as boxless molding systems), the position of the casting device required for the casting is the sum of all bale thicknesses between the molding system and the casting funnel of the casting mold in the casting position.
  • the thickness of the individual bales varies absolutely by a few millimeters, depending on the nature of the molding sand, etc.
  • the position of the hopper of the mold bale must be determined relative to the position of the pouring system. This measurement takes place during casting. Then the deviation of the real casting position from the desired casting position has to be determined. Finally, the position of the casting system is changed if necessary according to the result of the above step. This happens after the casting has taken place.
  • FIG. 1 shows a system for positioning a casting system in a baling molding and conveying system.
  • the shaped bales 1 are transported to a casting system 4 via a conveyor system 3.
  • a stopper control 5b serves to actuate the stopper, i.e. For the controlled opening and closing of the bottom hole and thus for the metered pouring of the liquid metal.
  • a video camera 6, which is connected to the casting system, is used to control the level of the mold and to determine the position of the pouring funnels in relation to the casting system.
  • the signals from the video camera 6 arrive at an image evaluation 7, which optically processes the entire video image (see number 12 according to FIG. 2) during the casting process and determines the current liquid metal height in the casting funnel from the visible liquid metal surface (see B according to FIG. 2) and the stop control 5b feeds.
  • image evaluation 7 optically processes the entire video image (see number 12 according to FIG. 2) during the casting process and determines the current liquid metal height in the casting funnel from the visible liquid metal surface (see B according to FIG. 2) and the stop control 5b feeds.
  • the pouring jet which can be seen in the video image see number 15 according to FIG. 2 is masked out in order to avoid falsification of the measured values. In this way, the casting performance of the casting system is automatically adjusted to the swallowing capacity of the mold.
  • a measuring zone (see number 16 according to FIG. 2) is defined such that e.g. in the case of a casting system correctly positioned above the casting funnel, the visible surface of the bale within the measuring zone (see C according to FIG. 2) corresponds to the visible liquid metal surface in the casting funnel within the measuring zone (see D according to FIG. 2). If a subsequent measurement shows a deviation from the originally defined area ratio between the visible surface of the bale in the measuring zone and the visible liquid metal surface in the measuring zone, this deviation is a measure of the deviation between the position of the bottom hole of the casting system and the position of the casting funnel of the casting mold.
  • the result of this area measurement described above is fed to a control system consisting of a histogram evaluation 8 for the measuring zone, an area evaluation 9, a measurement value weighting 10 and a position calculation 11 for the coordinate specification to the positioning system 5a.
  • the validity of the measurement is checked via the distribution of the liquid metal surface in the x-direction and the distribution of the shaped bale surface in the x-direction in order to rule out incorrect measurements caused by metal sprayed onto the shaped bale surface or by slag on the liquid metal surface.
  • the area ratio between the visible surface of the bale in the measuring zone and the visible liquid metal surface in the measuring zone is used to determine the deviation of the current actual pouring position of the pouring system from the position of the pouring funnel.
  • the positioning of the casting system is not exclusively based on the individual, current measurement, but rather using the measurement value weighting 10, both the current measurement and several previous measurements with the same or different weightings are used (whereby the current measurement is appropriately taken into account with a higher weight than previous measurements). In this way e.g. a moving average over the position deviation is formed and it is prevented that the casting system is constantly moved. The casting system is not repositioned until the difference between the casting system position and the casting funnel position exceeds a specified tolerance limit.
  • the position calculation 11 has, for example, correlations determined off-line between the area relationships and the coordinates for the repositioning.
  • the repositioning it is also possible for the repositioning to be carried out exclusively on-line in the sense of a "self-learning system" by specifying a fixed distance (or a fixed time for the operation of the casting system drives) for the method of the casting system and in the subsequent ones The effects of these specifications are evaluated, ie it is checked whether the deviation between the casting system position and the casting funnel position has decreased to the desired extent. Depending on the result of these evaluations, the specified distances (or the specified time) may be corrected.
  • the direction for repositioning the casting system can be determined in a simple manner from which of the surfaces has increased within the measuring zone. If, for example, the liquid metal surface has increased in relation to the surface of the bale, repositioning against the transport direction (x direction) of the conveyor system 3 is necessary. If the shape of the bale surface has increased in relation to the liquid metal surface (as shown in FIG. 3), repositioning in the transport direction x of the conveyor system is necessary. These repositionings apply to a video camera seen in the transport direction x.
  • FIG. 2 shows a video image used for the level control and repositioning of the casting system.
  • the pouring funnel edge 14 of the pouring funnel of a casting mold can be seen on the video image 12 of the screen 13.
  • the visible surface of the bale is labeled A.
  • the liquid metal height in the casting funnel is determined from the visible liquid metal surface B (and the known dimensions of the pouring funnel), the pouring jet 15 indicated by dashed lines being hidden.
  • the measuring zone 16 is defined, for example, in such a way that when the pouring funnel position is correct below the bottom hole of the casting system, the visible mold bale surface C within the measuring zone is equal to the visible liquid metal surface D within the measuring zone.
  • the pouring jet 15 is of course not blanked out, as can also be seen below in FIG. 5.
  • the direction of transport of the conveyor system is designated x.
  • FIG 3 a video image is shown in which the position of the pouring hopper is changed, i.e. the pouring funnel edge 14 and the visible liquid metal surface B have "migrated" upward within the video image 12. This change does not cause a measurement error to determine the liquid metal height in the casting funnel.
  • the visible liquid metal surface D within the measuring zone 16 is significantly smaller than the visible bale surface C within the measuring zone. From the ratio of D to C, the deviation between the casting system position and the casting funnel position can be determined.
  • FIG. 4 shows a video image in which the liquid metal surface and the bale surface are contaminated.
  • slag 18 on the liquid metal surface D within the measuring zone This contamination falsifies the measurement result, since the metal splash 17 reduces the visible shape of the bale surface C and the slag 18 reduces the visible liquid metal surface D.
  • Such incorrect measurements are recognized by means of the histogram evaluation 8.
  • FIG. 5 shows a video image in which the pouring funnel is not yet filled with liquid metal.
  • the pouring funnel rim 14, the pouring jet 15 and the measuring zone 16 can be seen. Correct measurement of the bale surface C and liquid metal surface D within the measuring zone is advantageously ensured even when the pouring funnel is not yet filled, since the pouring jet 15 is located in the center of the image with respect to the y coordinate (transverse direction to the transport direction x) and its width b is greater than the width a the measuring zone 16.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
  • Casting Devices For Molds (AREA)

Abstract

The invention proposes a method for repositioning the casting system in a moulding and conveying system, the deviation between the position of the bottom hole of a casting system and the position of the gate of a casting mould being determined and, after a pouring operation has been carried out, the position at the casting system being altered in accordance with this deviation if the said deviation exceeds a tolerance value. The deviation between the position of the casting system and that of the gate is determined during casting by a procedure in which a measuring zone (16) is defined in such a way in a video image (12) used to determine the liquid metal level in the gate for the purpose of controlling the said level that, if the casting system is correctly positioned above a gate, the ratio of the visible surface area (C) of the mould within the measuring zone to the visible surface area (D) of the liquid metal within the measuring zone corresponds to a specifiable factor. Deviations in the area ratios from the specifiable factor which are detected in renewed measurements are used as a measure of the deviation between the position of the casting system and the position of the gate. <IMAGE>

Description

Die Erfindung bezieht sich auf ein Verfahren zur Nachpositionierung eines Gießsystems bei einem ballenpressenden Form- und Fördersystem gemäß dem Oberbegriff des Anspruchs 1.The invention relates to a method for repositioning a casting system in a baling molding and conveying system according to the preamble of claim 1.

Ein solches Verfahren zur Nachpositionierung eines Gießsystems bei einem ballenpressenden Form- und Fördersystem ist aus der DE 42 02 020 A1 bekannt. Dort ist zum dosierten Abgießen von Flüssigmetall ein Bodenloch des Gießsystems über einem Gießtrichter der auf einem Fördersystem befindlichen Gußform angeordnet. Die Position des Bodenlochs über dem Gießtrichter wird überprüft und die Positionsabweichungen werden erfaßt, sobald ein Form- und Förderprozeß eines Formballens beendet ist und sich der Formballen in Ruhe befindet. Eine Positionsveränderung erfolgt erst nach beendetem Gießvorgang und während des nächsten Form- und Förderprozesses eines Formballens.Such a method for repositioning a casting system in a baling molding and conveying system is known from DE 42 02 020 A1. There, for the metered pouring of liquid metal, a bottom hole of the casting system is arranged above a casting funnel of the casting mold located on a conveyor system. The position of the bottom hole above the pouring funnel is checked and the positional deviations are recorded as soon as a shaping and conveying process of a shaped bale has ended and the shaped bale is at rest. A change in position takes place only after the casting process has ended and during the next molding and conveying process of a mold bale.

Aus der BBC-Druckschrift Nr. DIA 12 46 84D Gießspiegelregelung beim Guß von Formstücken" von G.W. Drees und P. Hildenbrand ist es bekannt, eine Videokamera zur Feststellung des Füllstandes im Gießtrichter heranzuziehen. Ein nachgeschaltetes optoelektronisches Meß- und Sensorsystem (Bildauswertung) digitalisiert das Videobild punktweise in Hell-Dunkel-Anteile. Der Gießstrahl vom Bodenloch des Gießsystems in den Trichter wird ausgeblendet. Die Flüssigmetallhöhe im Gießtrichter wird aus der Flüssigmetallfläche (Dunkel-Anteile) bestimmt.It is known from the BBC publication No. DIA 12 46 84D casting level control for the casting of shaped pieces "by GW Drees and P. Hildenbrand, a video camera for detection of the level in the pouring funnel. A downstream optoelectronic measuring and sensor system (image evaluation) digitizes the video image point-by-point in light-dark portions. The pouring jet from the bottom hole of the pouring system into the funnel is hidden. The liquid metal height in the casting funnel is determined from the liquid metal surface (dark parts).

Aus der EP 02 65 206 B1 sind eine Vorrichtung und ein Verfahren zum Regulieren des Gießens von geschmolzenem Metall in einzelne Gießformen bekannt, wobei Bild-Flächen-Informationen während vorher bestimmter Abtast-Intervalle für einen Gießvorgang erzeugt werden. Reguliermittel zur Einstellung des Fließens der Metallschmelze sprechen auf Differenzwerte zwischen erfaßten Bild-Flächen-Informationen und Bezugs-Flächen-Werten an. Dabei ist jeder Regulierwert eine Funktion des Differenzwertes für sein zugeordnetes Abtast-Intervall und eines Regulier-Voreinstellungs-Wertes für dieses Abtast-Intervall basierend auf vorgewählten Gießparametern von wenigstens einem vorangegangenen Gießvorgang.EP 02 65 206 B1 discloses an apparatus and a method for regulating the casting of molten metal into individual casting molds, image-area information being generated during previously determined sampling intervals for a casting process. Regulating means for adjusting the flow of the molten metal respond to difference values between captured image area information and reference area values. Each regulating value is a function of the difference value for its assigned sampling interval and a regulating preset value for this sampling interval based on preselected casting parameters from at least one previous pouring process.

Aus der EP 02 69 591 B1 ist ein Verfahren zur Steuerung des Gießens einer Metallschmelze in Gußformen bekannt, bei dem ein Abtasten der Oberseite der Gußformen während deren fortschreitenden Bewegung zur Gießstation erfolgt, um die Gießtrichter zu ermitteln. Der Restweg der jeweiligen Gußform bis zur Gießstation wird bestimmt. Der Gießkessel wird aufgrund der Bestimmung des von der jeweiligen Gußform noch zurückzulegenden Restweges in eine Stellung genau über der Endposition dieser Gußform in der Gießstation bewegt.EP 02 69 591 B1 discloses a method for controlling the casting of a molten metal into casting molds, in which the upper side of the casting molds is scanned during their progressive movement to the casting station in order to determine the casting funnels. The remaining distance of the respective mold to the casting station is determined. On the basis of the determination of the remaining distance to be covered by the respective casting mold, the casting kettle is moved into a position exactly above the end position of this casting mold in the casting station.

Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren zur Nachpositionierung eines Gießsystems bei einem ballenpressenden Form- und Fördersystem der eingangs genannten Art anzugeben, bei dem die zur Gießspiegelregelung verwendete Meßeinrichtung mit Videokamera verwendet werden kann.The invention has for its object a method for repositioning a casting system in a baling molding and conveying system of the type mentioned specify in which the measuring device used for the mold level control can be used with a video camera.

Diese Aufgabe wird in Verbindung mit den Merkmalen des Oberbegriffes erfindungsgernäß durch die im Kennzeichen des Anspruchs 1 angegebenen Merkmale gelöst.This object is achieved in connection with the features of the preamble according to the invention by the features specified in the characterizing part of claim 1.

Die mit der Erfindung erzielbaren Vorteile bestehen insbesondere darin, daß das Verfahren keinen weiteren Geräte-Mehraufwand zusätzlich zur Gießspiegelregelung erfordert. Die Videokamera und die Bildauswertung für das Videobild werden vorteilhaft sowohl zur Bestimmung der Flüssigmetallhöhe im Gießtrichter (= Gießspiegel-Isthöhe) für die Gießspiegelregelung als auch zur Ermittlung von Abweichungen zwischen der Position des Bodenlochs des Gießsystems und der Position des Gießtrichters der Gußform herangezogen. Durch das Nachpositionieren während einer Modellreihe werden Ballendickentoleranzen vorteilhaft und einfach ausgeglichen, wenn ein vorgegebener Toleranzbereich hinsichtlich der Differenz zwischen der Gießsystem-Position und der Gießtrichter-Position überschritten ist.The advantages that can be achieved with the invention are, in particular, that the method requires no additional equipment in addition to the mold level control. The video camera and the image evaluation for the video image are advantageously used both to determine the liquid metal height in the pouring funnel (= actual mold level) for the mold level control and to determine deviations between the position of the bottom hole of the casting system and the position of the pouring funnel of the mold. Repositioning during a model series advantageously and easily compensates for bale thickness tolerances when a predetermined tolerance range with regard to the difference between the casting system position and the casting funnel position is exceeded.

Vorteilhafte Ausgestaltungen der Erfindung sind in den Unteransprüchen gekennzeichnet.Advantageous embodiments of the invention are characterized in the subclaims.

Die Erfindung wird nachstehend anhand der in der Zeichnung dargestellten Ausführungsbeispiele erläutert. Es zeigen:

Figur 1
eine Anlage zur Positionierung eines Gießsystems bei einem ballenpressenden Form- und Fördersystem,
Figur 2
ein zur Gießspiegelregelung und Nachpositionierung des Gießsystems herangezogenes Videobild,
Figur 3
ein Videobild, bei dem die Lage des Gießtrichters verändert ist,
Figur 4
ein Videobild, bei dem die Flüssigmetalloberfläche und die Ballenoberfläche verschmutzt sind,
Figur 5
ein Videobild, bei dem der Gußtrichter noch nicht gefüllt ist.
The invention is explained below with reference to the embodiments shown in the drawing. Show it:
Figure 1
a system for positioning a casting system in a baling molding and conveying system,
Figure 2
a video image used for the mold level control and repositioning of the casting system,
Figure 3
a video image in which the position of the pouring hopper is changed,
Figure 4
a video image in which the liquid metal surface and the bale surface are dirty,
Figure 5
a video image in which the casting funnel is not yet filled.

Bei ballenpressenden Form- und Fördersystemen (im allgemeinen als kastenlose Formanlagen bezeichnet) ergibt sich die zum Gießen notwendige Position der Gießeinrichtung als Summe aller Ballendicken zwischen Formanlage und dem Gießtrichter der in Gießposition befindlichen Gußform. Die Dicke der einzelnen Ballen variiert abhängig von der Beschaffenheit des Formsandes usw. absolut um wenige Millimeter. Somit ergibt sich bei einer Serie gleicher Modelle von Zeit zu Zeit die Notwendigkeit, das Gießsystem neu zu positionieren, wenn die Gießtrichterposition nicht mehr mit der Position der Gießeinrichtung übereinstimmt.In the case of baling molding and conveying systems (generally referred to as boxless molding systems), the position of the casting device required for the casting is the sum of all bale thicknesses between the molding system and the casting funnel of the casting mold in the casting position. The thickness of the individual bales varies absolutely by a few millimeters, depending on the nature of the molding sand, etc. Thus, with a series of identical models, there is a need from time to time to reposition the pouring system when the position of the pouring hopper no longer matches the position of the pouring device.

Schließt man den Fall eines Modellwechsels aus, bei dem sich die Gießpositon von Abguß zu Abguß um die Dickendifferenz der Ballen des alten und des neuen Modells verschiebt, kann man davon ausgehen, daß bei korrekt positionierter Gießeinrichtung die nächsten Gießformen ohne Korrektur der Gießposition gegossen werden können. Es reicht daher aus, das Gießsystem lediglich dann neu zu positionieren, wenn die Abweichung zwischen Gießtrichterposition und Gießsystemposition ein bestimmtes festgelegtes Toleranzband verläßt.If one excludes the case of a model change in which the pouring position shifts from casting to casting by the thickness difference of the bales of the old and the new model, it can be assumed that the next casting molds can be cast without correcting the casting position if the casting device is correctly positioned . It is therefore sufficient to reposition the casting system only when the deviation between the casting funnel position and the casting system position leaves a certain defined tolerance band.

Zur Bestimmung der Gießposition ist die Position des Gießtrichters des Formballens relativ zur Gießsystemposition zu bestimmen. Diese Messung erfolgt beim Gießen. Anschließend ist die Abweichung der realen Gießposition von der gewünschten Gießposition zu ermitteln. Abschließend erfolgt gegebenenfalls die Positionsveränderung des Gießsystems entsprechend dem Ergebnis des vorstehenden Verfahrensschrittes. Dies geschieht nach erfolgtem Abguß.To determine the pouring position, the position of the hopper of the mold bale must be determined relative to the position of the pouring system. This measurement takes place during casting. Then the deviation of the real casting position from the desired casting position has to be determined. Finally, the position of the casting system is changed if necessary according to the result of the above step. This happens after the casting has taken place.

In Figur 1 ist eine Anlage zur Positionierung eines Gießsystems bei einem ballenpressenden Form- und Fördersystem dargestellt. Es sind mehrere, mittels eines kastenlosen, ballenpressenden Formsystems hergestellte Formballen 1 zu erkennen, die Gußformen mit Gießtrichtern bilden. Die Formballen 1 werden über ein Fördersystem 3 zu einem Gießsystem 4 transportiert. Das Gießsystem 4 weist einen Flüssigmetallspeicher mit Bodenloch und Stopfen zum Verschließen des Bodenlochs auf und kann mittels eines Positioniersystems 5a in x- und y-Richtung verschoben werden, d.h. in Transportrichtung des Fördersystems 3 (= x-Richtung) und quer hierzu (= y-Richtung). Eine Stopfenregelung 5b dient zur Betätigung des Stopfens, d.h. zum geregelten Öffnen und Schließen des Bodenlochs und damit zum dosierten Abgießen des Flüssigmetalls. Zur Gießspiegelregelung und zur Bestimmung der Position der Gießtrichter in Relation zum Gießsystem dient eine mit dem Gießsystem verbundene Videokamera 6. Beim Verfahren des Gießsystems wird die Videokamera 6 in gleicher Weise verfahren.1 shows a system for positioning a casting system in a baling molding and conveying system. There are several shaped bales 1 produced by means of a boxless, baling molding system, which form casting molds with casting funnels. The shaped bales 1 are transported to a casting system 4 via a conveyor system 3. The casting system 4 has a liquid metal reservoir with a bottom hole and plug for closing the bottom hole and can be displaced in the x and y direction by means of a positioning system 5a, i.e. in the transport direction of the conveyor system 3 (= x direction) and transversely to it (= y direction). A stopper control 5b serves to actuate the stopper, i.e. For the controlled opening and closing of the bottom hole and thus for the metered pouring of the liquid metal. A video camera 6, which is connected to the casting system, is used to control the level of the mold and to determine the position of the pouring funnels in relation to the casting system.

Die Signale der Videokamera 6 gelangen zu einer Bildauswertung 7, die während des Gießvorganges das gesamte Videobild (siehe Ziffer 12 gemäß Figur 2) optisch aufbereitet und aus der sichtbaren Flüssigmetalloberfläche (siehe B gemäß Figur 2) die aktuelle Flüssigmetallhöhe im Gießtrichter bestimmt und der Stopfregelung 5b zuführt. Zur Ermittlung der aktuellen Flüssigmetallhöhe im Gießtrichter wird der im Videobild erkennbare Gießstrahl (siehe Ziffer 15 gemäß Figur 2) ausgeblendet, um Meßwertverfälschungen zu vermeiden. Auf diese Weise wird die Gießleistung des Gießsystems automatisch dem Schluckvermögen der Gußform angepaßt.The signals from the video camera 6 arrive at an image evaluation 7, which optically processes the entire video image (see number 12 according to FIG. 2) during the casting process and determines the current liquid metal height in the casting funnel from the visible liquid metal surface (see B according to FIG. 2) and the stop control 5b feeds. To determine the current liquid metal height in the pouring funnel, the pouring jet which can be seen in the video image (see number 15 according to FIG. 2) is masked out in order to avoid falsification of the measured values. In this way, the casting performance of the casting system is automatically adjusted to the swallowing capacity of the mold.

Innerhalb des von der Videokamera 6 erfaßten Videobildes ist eine Meßzone (siehe Ziffer 16 gemäß Figur 2) derart definiert, daß z.B. bei einem korrekt über dem Gießtrichter positionierten Gießsystem die sichtbare Formballenoberfläche innerhalb der Meßzone (siehe C gemäß Figur 2) der sichtbaren Flüssigmetalloberfläche im Gießtrichter innerhalb der Meßzone (siehe D gemäß Figur 2) entspricht. Stellt man bei einer nachfolgenden Messung eine Abweichung vom ursprünglich definierten Flächenverhältnis zwischen sichtbarer Formballenoberfläche in der Meßzone und sichtbarer Flüssigmetalloberfläche in der Meßzone fest, so ist diese Abweichung ein Maß für die Abweichung zwischen der Position des Bodenlochs des Gießsystems und der Position des Gießtrichters der Gußform. Das Ergebnis dieser vorstehend beschriebenen Flächenmessung wird einem Kontrollsystem, bestehend aus einer Histogrammauswertung 8 für die Meßzone, einer Flächenbewertung 9, einer Meßwertgewichtung 10 und einer Positionsberechnung 11 für die Koordinatenvorgabe an das Positioniersystem 5a zugeführt.Within the video image captured by the video camera 6, a measuring zone (see number 16 according to FIG. 2) is defined such that e.g. in the case of a casting system correctly positioned above the casting funnel, the visible surface of the bale within the measuring zone (see C according to FIG. 2) corresponds to the visible liquid metal surface in the casting funnel within the measuring zone (see D according to FIG. 2). If a subsequent measurement shows a deviation from the originally defined area ratio between the visible surface of the bale in the measuring zone and the visible liquid metal surface in the measuring zone, this deviation is a measure of the deviation between the position of the bottom hole of the casting system and the position of the casting funnel of the casting mold. The result of this area measurement described above is fed to a control system consisting of a histogram evaluation 8 for the measuring zone, an area evaluation 9, a measurement value weighting 10 and a position calculation 11 for the coordinate specification to the positioning system 5a.

In der Histogrammauswertung 8 wird über die Verteilung der Flüssigmetalloberfläche in x-Richtung und die Verteilung der Formballenoberfläche in x-Richtung die Gültigkeit der Messung überprüft, um durch auf die Formballenoberfläche gespritztes Metall oder durch Schlacke auf der Flüssigmetalloberfläche verursachte fehlerhafte Messungen auszuschließen.In the histogram evaluation 8, the validity of the measurement is checked via the distribution of the liquid metal surface in the x-direction and the distribution of the shaped bale surface in the x-direction in order to rule out incorrect measurements caused by metal sprayed onto the shaped bale surface or by slag on the liquid metal surface.

Bei fehlerfreier Messung wird mittels einer Flächenbewertung 9 aus dem Flächenverhältnis zwischen sichtbarer Formballenoberfläche in der Meßzone und sichtbarer Flüssigmetalloberfläche in der Meßzone die Abweichung der aktuellen Ist-Gießposition des Gießsystems von der Position des Gießtrichters ermittelt.If the measurement is error-free, the area ratio between the visible surface of the bale in the measuring zone and the visible liquid metal surface in the measuring zone is used to determine the deviation of the current actual pouring position of the pouring system from the position of the pouring funnel.

Um etwa auftretende Meßungenauigkeiten zu eliminieren, wird für die Positionierung des Gießsystems nicht ausschließlich die einzelne, gerade aktuelle Messung herangezogen, sondern es werden unter Einsatz der Meßwert-Gewichtung 10 sowohl die aktuelle Messung als auch mehrere zurückliegende Messungen mit gleicher oder unterschiedlicher Gewichtung herangezogen (wobei die aktuelle Messung zweckmäßig mit höherem Gewicht berücksichtigt wird als zurückliegende Messungen). Auf diese Art und Weise wird z.B. ein gleitender Mittelwert über die Positionsabweichung gebildet und es wird verhindert, daß das Gießsystem ständig verfahren wird. Erst wenn die Differenz zwischen Gießsystemposition und Gießtrichterposition eine festgelegte Toleranzgrenze überschreitet, wird das Gießsystem nachpositioniert.In order to eliminate any measurement inaccuracies that may occur, the positioning of the casting system is not exclusively based on the individual, current measurement, but rather using the measurement value weighting 10, both the current measurement and several previous measurements with the same or different weightings are used (whereby the current measurement is appropriately taken into account with a higher weight than previous measurements). In this way e.g. a moving average over the position deviation is formed and it is prevented that the casting system is constantly moved. The casting system is not repositioned until the difference between the casting system position and the casting funnel position exceeds a specified tolerance limit.

Entsprechend der so ermittelten Abweichung werden von der Positionsberechnung 11 entsprechende Koordinatensignale berechnet und an das Positionierungssystem 5a des Gießsystems 4 gegeben. Der Positionsberechnung 11 liegen hierzu beispielsweise off-line ermittelte Zusammenhänge zwischen den Flächenverhältnissen und den Koordinaten für die Nachpositionierung vor. Ferner ist es auch möglich, daß die Nachpositionierung ausschließlich on-line im Sinne eines "selbstlernenden Systems" erfolgt, indem für das Verfahren des Gießsystems eine festgelegte Wegstrecke (oder eine festgelegte Zeit für den Betrieb der Gießsystem-Antriebe) vorgegeben wird und in den nachfolgenden Meßintervallen die Wirkungen dieser Vorgaben ausgewertet werden, d.h. es wird überprüft, ob sich die Abweichung zwischen Gießsystemposition und Gießtrichterposition im gewünschten Umfang verringert hat. In Abhängigkeit des Ergebnisses dieser Auswertungen erfolgt gegebenenfalls eine Korrektur der festgelegten Wegstrecken( oder der festgelegten Zeit).Corresponding to the deviation determined in this way, corresponding coordinate signals are calculated by the position calculation 11 and sent to the positioning system 5a of the casting system 4. For this purpose, the position calculation 11 has, for example, correlations determined off-line between the area relationships and the coordinates for the repositioning. Furthermore, it is also possible for the repositioning to be carried out exclusively on-line in the sense of a "self-learning system" by specifying a fixed distance (or a fixed time for the operation of the casting system drives) for the method of the casting system and in the subsequent ones The effects of these specifications are evaluated, ie it is checked whether the deviation between the casting system position and the casting funnel position has decreased to the desired extent. Depending on the result of these evaluations, the specified distances (or the specified time) may be corrected.

Die Richtung zur Nachpositionierung des Gießsystems läßt sich in einfacher Weie daraus ermitteln, welche der Flächen innerhalb der Meßzone sich vergrößert hat. Hat sich z.B. die Flüssigmetalloberfläche in Relation zur Formballenoberfläche vergrößert, ist eine Nachpositionierung entgegen der Transportrichtung (x-Richtung) des Fördersystems 3 notwendig. Hat sich die Formballenoberfläche in Relation zur Flüssigmetalloberfläche vergrößert (wie in Figur 3 gezeigt), ist eine Nachpositionierung in der Transportrichtung x des Fördersystems notwendig. Diese Nachpositionierungen gelten für eine in Transportrichtung x sehene Videokamera.The direction for repositioning the casting system can be determined in a simple manner from which of the surfaces has increased within the measuring zone. If, for example, the liquid metal surface has increased in relation to the surface of the bale, repositioning against the transport direction (x direction) of the conveyor system 3 is necessary. If the shape of the bale surface has increased in relation to the liquid metal surface (as shown in FIG. 3), repositioning in the transport direction x of the conveyor system is necessary. These repositionings apply to a video camera seen in the transport direction x.

Vorstehend wird beispielhaft stets von einem Verhältnis bzw. Faktor Formballenoberfläche C/Flüssigmetalloberfläche D innerhalb der Meßzone 16 von 1 (d.h. C=D) ausgegangen (bei korrekt positioniertem Gießsystem). Es sind selbstverständlich auch andere Faktoren vorgebbar.In the above, a ratio or factor of the shape of the bale surface C / liquid metal surface D within the measuring zone 16 of 1 (i.e. C = D) is always assumed (with the casting system correctly positioned). Of course, other factors can also be specified.

In Figur 2 ist ein zur Gießspiegelregelung und Nachpositionierung des Gießsystems herangezogenes Videobild dargestellt. Auf dem Videobild 12 des Bildschirms 13 ist der Gießtrichterrand 14 des Gießtrichters einer Gußform zu erkennen. Die sichtbare Formballenoberfläche ist mit A bezeichnet. Aus der sichtbaren Flüssigmetalloberfläche B (und den bekannten Abmessungen des Gießtrichters) wird die Flüssigmetallhöhe im Gießtrichter ermittelt, wobei der gestrichelt angedeutete Gießstrahl 15 ausgeblendet wird. Die Meßzone 16 ist z.B. derart definiert, daß bei korrekter Gießtrichterposition unterhalb des Bodenlochs des Gießsystems die sichtbare Formballenoberfläche C innerhalb der Meßzone gleich der sichtbaren Flüssigmetalloberfläche D innerhalb der Meßzone ist. Zur Ermittlung der Abweichung zwischen Gießsystemposition und Gießtrichterposition wird der Gießstrahl 15 selbstverständlich nicht ausgeblendet, wie nachfolgend noch unter Figur 5 ersichtlich ist. Die Transportrichtung des Fördersystems ist mit x bezeichnet.FIG. 2 shows a video image used for the level control and repositioning of the casting system. The pouring funnel edge 14 of the pouring funnel of a casting mold can be seen on the video image 12 of the screen 13. The visible surface of the bale is labeled A. The liquid metal height in the casting funnel is determined from the visible liquid metal surface B (and the known dimensions of the pouring funnel), the pouring jet 15 indicated by dashed lines being hidden. The measuring zone 16 is defined, for example, in such a way that when the pouring funnel position is correct below the bottom hole of the casting system, the visible mold bale surface C within the measuring zone is equal to the visible liquid metal surface D within the measuring zone. To determine the deviation between the casting system position and the pouring funnel position, the pouring jet 15 is of course not blanked out, as can also be seen below in FIG. 5. The direction of transport of the conveyor system is designated x.

In Figur 3 ist ein Videobild dargestellt, bei dem die Lage des Gießtrichters verändert ist, d.h. der Gießtrichterrand 14 und die sichtbare Flüssigmetalloberfläche B sind innerhalb des Videobildes 12 nach oben "gewandert". Für die Ermittlung der Flüssigmetallhöhe im Gießtrichter verursacht diese Änderung keinen Meßfehler. Wie jedoch zu erkennen ist, ist die sichtbare Flüssigmetalloberfläche D innerhalb der Meßzone 16 wesentlich kleiner als die sichtbare Formballenoberfläche C innerhalb der Meßzone. Aus dem Verhältnis von D zu C läßt sich die Abweichung zwischen Gießsystemposition und Gießtrichterposition ermitteln.In Figure 3 a video image is shown in which the position of the pouring hopper is changed, i.e. the pouring funnel edge 14 and the visible liquid metal surface B have "migrated" upward within the video image 12. This change does not cause a measurement error to determine the liquid metal height in the casting funnel. However, as can be seen, the visible liquid metal surface D within the measuring zone 16 is significantly smaller than the visible bale surface C within the measuring zone. From the ratio of D to C, the deviation between the casting system position and the casting funnel position can be determined.

In Figur 4 ist ein Videobild dargestellt, bei dem die Flüssigmetalloberfläche und die Ballenoberfläche verschmutzt sind. Wie zu erkennen ist, befindet sich ein Metallspritzer 17 auf der Formballenoberfläche C innerhalb der Meßzone 16. Ferner befindet sich Schlacke 18 auf der Flüssigmetalloberfläche D innerhalb der Meßzone. Diese Verschmutzungen verfälschen das Meßergebnis, denn der Metallspritzer 17 verkleinert die sichtbare Formballenoberfläche C und die Schlacke 18 verkleinert die sichtbare Flüssigmetalloberfläche D. Mittels der Histogrammauswertung 8 werden derartige falsche Messungen erkannt.FIG. 4 shows a video image in which the liquid metal surface and the bale surface are contaminated. As can be seen, there is a metal spatter 17 on the bale surface C within the measuring zone 16. Furthermore, there is slag 18 on the liquid metal surface D within the measuring zone. This contamination falsifies the measurement result, since the metal splash 17 reduces the visible shape of the bale surface C and the slag 18 reduces the visible liquid metal surface D. Such incorrect measurements are recognized by means of the histogram evaluation 8.

In Figur 5 ist ein Videobild dargestellt, bei dem der Gießtrichter noch nicht mit Flüssigmetall gefüllt ist. Es sind der Gießtrichterrand 14, der Gießstrahl 15 und die Meßzone 16 zu erkennen. Vorteilhaft wird auch bei noch nicht gefülltem Gießtrichter eine einwandfreie Messung von Formballenoberfläche C und Flüssigmetalloberfläche D innerhalb der Meßzone gewährleistet, da sich der Gießstrahl 15 bezüglich der y-Koordinate (Querrichtung zur Transportrichtung x) in Bildmitte befindet und seine Breite b größer als die Breite a der Meßzone 16 ist.FIG. 5 shows a video image in which the pouring funnel is not yet filled with liquid metal. The pouring funnel rim 14, the pouring jet 15 and the measuring zone 16 can be seen. Correct measurement of the bale surface C and liquid metal surface D within the measuring zone is advantageously ensured even when the pouring funnel is not yet filled, since the pouring jet 15 is located in the center of the image with respect to the y coordinate (transverse direction to the transport direction x) and its width b is greater than the width a the measuring zone 16.

Claims (5)

Verfahren zur Nachpositionierung eines Gießsystems bei einem ballenpressenden Form- und Fördersystem, wobei die Abweichung zwischen der Position des Bodenlochs eines Gießsystems und der Position des Gießtrichters einer Gußform ermittelt wird und nach erfolgtem Abguß die Position des Gießsystems entsprechend dieser Abweichung verändert wird, wenn die Abweichung einen Toleranzwert überschreitet, dadurch gekennzeichnet, daß die Abweichung zwischen Gießsystemposition und Gießtrichterposition während des Gießens bestimmt wird, indem in einem zur Ermittlung der Flüssigmetallhöhe im Gießtrichter für eine Gießspiegelregelung dienenden Videobild (12) eine Meßzone (16) derart definiert wird, daß bei einem korrekt über einem Gießtrichter positionierten Gießsystem das Flächenverhältnis zwischen der sichtbaren Formballenoberfläche (C) innerhalb der Meßzone und der sichtbaren Flüssigmetalloberfläche (D) innerhalb der Meßzone einem vorgebbaren Faktor entspricht und indem bei erneuten Messungen festgestellte Abweichungen der Flächenverhältnisse vom vorgebbaren Faktor als Maß für die Abweichung zwischen Gießsystemposition und Gießtrichterposition herangezogen werden.Method for repositioning a casting system in a baling molding and conveying system, wherein the deviation between the position of the bottom hole of a casting system and the position of the pouring funnel of a casting mold is determined and after casting has taken place, the position of the casting system is changed in accordance with this deviation if the deviation is one Tolerance value is exceeded, characterized in that the deviation between the casting system position and the casting funnel position during the casting is determined by defining a measuring zone (16) in a video image (12) used to determine the liquid metal height in the casting funnel for a mold level control in such a way that in the case of a correctly over a casting system positioned casting system the area ratio between the visible mold bale surface (C) within the measuring zone and the visible liquid metal surface (D) within the measuring zone corresponds to a predetermined factor and inde m Any deviations in the area ratios from the predeterminable factor that are found during renewed measurements can be used as a measure of the deviation between the casting system position and the pouring funnel position. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß die Verteilung der Formballenoberfläche (C) und/oder der Flüssigmetalloberfläche (D) innerhalb der Meßzone (16) überprüft wird, um eventuelle Verunreinigungen der Formballenoberfläche und/oder der Flüssigmetalloberfläche zu ermitteln.A method according to claim 1, characterized in that the distribution of the bale surface (C) and / or the liquid metal surface (D) within the measuring zone (16) is checked in order to determine possible contamination of the bale surface and / or the liquid metal surface. Verfahren nach Anspruch 1 und/oder 2, dadurch gekennzeichnet, daß die Koordinaten für die Nachpositionierung mittels off-line bestimmter Zusammenhänge zwischen Abweichungen des Flächenverhältnisses zwischen Formballenoberfläche (C) und Flüssigmetalloberfläche (D) innerhalb der Meßzone (16) und Abweichung zwischen Gießsystemposition und Gießtrichterposition bestimmt werden.Method according to Claim 1 and / or 2, characterized in that the coordinates for the repositioning by means of off-line specific relationships between deviations in the area ratio between the surface of the bale (C) and the liquid metal surface (D) within the measuring zone (16) and deviation between the casting system position and the casting funnel position be determined. Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, daß zur Ermittlung der Abweichung zwischen Gießsystemposition und Gießtrichterposition mehrere einzelne Messungen mit gleicher oder unterschiedlicher Gewichtung herangezogen werden.Method according to one of claims 1 to 3, characterized in that several individual measurements with the same or different weightings are used to determine the deviation between the casting system position and the casting funnel position. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, daß die Breite (a) der Meßzone (16) schmaler als die Breite (b) des Gießstrahles (15) ist.Method according to one of claims 1 to 4, characterized in that the width (a) of the measuring zone (16) is narrower than the width (b) of the pouring jet (15).
EP94118953A 1993-12-07 1994-12-01 Method for repositioning of a casting system for a form- and transportsystem which presses balers Expired - Lifetime EP0659504B1 (en)

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DE4341593 1993-12-07
DE4341593A DE4341593A1 (en) 1993-12-07 1993-12-07 Process for repositioning a casting system in a baling form and conveyor system

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EP0747152A1 (en) * 1995-06-07 1996-12-11 Inductotherm Corp. Video positioning system for a pouring vessel
CN113770340A (en) * 2021-08-26 2021-12-10 山东创新金属科技有限公司 Automatic control system for aluminum alloy casting

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Publication number Priority date Publication date Assignee Title
EP0747152A1 (en) * 1995-06-07 1996-12-11 Inductotherm Corp. Video positioning system for a pouring vessel
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CN113770340A (en) * 2021-08-26 2021-12-10 山东创新金属科技有限公司 Automatic control system for aluminum alloy casting

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ES2130337T3 (en) 1999-07-01
DE59407694D1 (en) 1999-03-04
EP0659504A3 (en) 1996-12-18
DK0659504T3 (en) 1999-09-13
EP0659504B1 (en) 1999-01-20
DE4341593A1 (en) 1995-06-08

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