WO2014174977A1 - 注湯制御方法及びコンピュータを注湯制御手段として機能させるためのプログラムを記憶した記憶媒体 - Google Patents
注湯制御方法及びコンピュータを注湯制御手段として機能させるためのプログラムを記憶した記憶媒体 Download PDFInfo
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- WO2014174977A1 WO2014174977A1 PCT/JP2014/058802 JP2014058802W WO2014174977A1 WO 2014174977 A1 WO2014174977 A1 WO 2014174977A1 JP 2014058802 W JP2014058802 W JP 2014058802W WO 2014174977 A1 WO2014174977 A1 WO 2014174977A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D37/00—Controlling or regulating the pouring of molten metal from a casting melt-holding vessel
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D39/00—Equipment for supplying molten metal in rations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D41/00—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like
- B22D41/06—Equipment for tilting
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D19/00—Arrangements of controlling devices
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D3/00—Charging; Discharging; Manipulation of charge
- F27D3/14—Charging or discharging liquid or molten material
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D19/00—Arrangements of controlling devices
- F27D2019/0028—Regulation
Definitions
- the present invention relates to a pouring control method in a ladle tilting type automatic pouring apparatus for pouring a mold by tilting a ladle holding molten metal, and a memory storing a program for causing a computer to function as pouring control means. It relates to the medium.
- the pouring flow rate (outflow weight from the ladle per unit time) data when the pouring operator pours water is stored and automatic pouring is performed.
- a method of adjusting the ladle tilting angular velocity so that the flow rate of pouring water by the machine is equivalent to the pouring flow rate by the operator (Patent Document 1), and the relationship between the ladle tilting angle and the pouring flow rate through a prior test pouring experiment.
- a method for correcting so as to obtain a desired pouring flow rate pattern Patent Document 2
- a method for performing feedback control so that the liquid level at the pouring gate in the mold is constant Patent Document 3
- Patent Documents 4 and 5 a model-based pouring control system that is a pouring control system based on the model. did. Since this control system has a clear relationship between the physical parameters of the pouring process and the control parameters, it is possible to construct a control system with only a few pouring experiments even in automatic pouring equipment with different ladle shapes and pouring liquids. It becomes.
- Japanese Patent No. 4565240 Japanese Patent No. 3537012 Japanese Patent No. 4282066 Japanese Patent No. 4328826 Japanese Patent No. 4396280
- the parameter value may change due to changes in the pouring temperature caused by changes in the pouring temperature, slag adhesion, etc., but the changes from the pouring experiment are not supported. There was a risk that accuracy would be reduced.
- the present invention shortens the identification work of parameters that require a lot of work time, and also updates the parameters of the pouring model according to the pouring state in order to perform high-precision pouring. It aims at providing the pouring control method and storage medium in a pan tilting type automatic pouring apparatus.
- the ladle is used from the input of control parameters.
- a pouring control method for controlling pouring based on a mathematical model of a pouring process up to pouring, wherein the weight of liquid flowing out from the ladle, the tilt angle of the ladle, and the tilt of the ladle measured during pouring Based on the command signal that controls the flow rate, the flow rate coefficient, the liquid density, and the tapping start angle that is the tilt angle of the ladle when the tapping is started from the ladle is identified by the optimization method.
- a technical means is used that includes a step and a step of updating the identified control parameter.
- the mathematical model is obtained by the optimization method. It is possible to identify and update the flow coefficient, liquid density, and hot water start angle, which are control parameters within the system, shortening the identification work that requires a lot of work time, and adjusting the control parameters according to the pouring state Since the value can be updated and control corresponding to a change in the pouring state can be performed, pouring accuracy can be improved.
- the flow coefficient, liquid density, and tapping start angle are identified by optimizing an evaluation function expressed by the following equation: The technical means is used.
- c id identified flow coefficient
- ⁇ sid identified hot water start angle
- ⁇ id identified liquid density
- T pouring operation time for pouring into one mold
- W Lex ladle tilting
- W Lsim Outflow weight when simulating with mathematical model using ladle tilt angle
- c sim Flow coefficient used during simulation
- ⁇ ssim Tapping start angle used during simulation
- ⁇ sim liquid density used during simulation
- C avg average value of flow coefficient up to the previous time
- ⁇ avg average value of liquid density up to the previous time
- w 1 pouring A weighting factor for controlling the fluctuation of the flow coefficient for each
- w 2 a weighting coefficient for controlling the fluctuation of the liquid density for each pouring.
- the flow coefficient, the liquid density, and the tapping start angle can be identified by optimizing the evaluation function represented by the above equation.
- this evaluation function includes a weighting coefficient that adjusts the influence of the flow coefficient and the liquid density, more accurate parameter identification is possible, and pouring accuracy can be improved.
- the flow coefficient and the liquid density are identified and updated each time one pouring is completed.
- the tapping start angle uses a technical means that, after continuous pouring by the ladle, an approximate function of the identified tapping start angle and the corresponding liquid weight in the ladle is calculated and updated. .
- the flow coefficient and the liquid density are identified and updated every time when one pouring is completed, and are reflected in the next pouring control. It can be performed.
- the hot water start angle is updated after an approximate function with the corresponding liquid weight in the ladle is calculated and updated after the continuous pouring by the ladle, so a highly accurate calibration curve can be created. More accurate pouring can be performed.
- the parameter convergence is fast and the calculation load can be reduced, so that the parameter update time can be shortened, which is preferable. It is.
- a recording medium storing a program for functioning as a pouring control means for controlling pouring based on a model, the weight of liquid flowing out from the ladle measured during pouring, the ladle tilt angle, and the ladle Based on the command signal that controls the tilt of the ladle, the flow rate coefficient, the liquid density, and the tapping start angle, which is the tilt angle of the ladle when the tapping is started from the ladle, are optimized by the optimization method.
- a computer-readable recording medium characterized by storing a program for executing the process of identifying and the process of updating the identified control parameter Use of surgical means.
- the pouring control method of the present invention is also applied to a pouring control program that enables the control method to be executed by a computer, and a storage medium that stores the program so as to be readable by the computer. Is done.
- the ladle tilting type automatic pouring device 1 (hereinafter referred to as the automatic pouring device 1) includes a ladle 10 in which the molten metal is held, and a tilt that rotates around the axis about the ⁇ axis of the ladle 10; Servo motors 11, 12, and 13 are provided that enable back-and-forth movement in the Y-axis direction and vertical movement in the Z-axis direction.
- Each of the servo motors 11, 12, 13 is provided with a rotary encoder so that the position and inclination angle of the ladle 10 can be measured and a control command signal is given by the computer 14.
- “computer” refers to a motion controller such as a personal computer, a microcomputer, a programmable logic controller (PLC), and a digital signal processor (DSP).
- PLC programmable logic controller
- DSP digital signal processor
- the load cell is installed at the lower end of the rigid structure including the ladle 10 or the lower end of the automatic pouring device 1 in order to measure the weight of the ladle 10 including the liquid.
- the automatic pouring device 1 controls the servo motors 11, 12, and 13 to convey the ladle 10 along a predetermined track, thereby discharging the molten metal from the pouring gate 10 a, and the pouring gate 20 a in the mold. More molten metal can be poured into the mold 20.
- FIG. 2 shows a configuration example of the model-based pouring control system. Here, a two-degree-of-freedom pouring control system in which feedforward control and feedback control are combined is shown.
- the computer 14 adjusts and outputs a command signal to the automatic pouring device 1 in order to realize the target pouring flow rate and the target pouring weight.
- the command signal is a speed command or a position command depending on the control mode of the servo motors 11, 12, and 13. Further, various forms such as a voltage and a pulse can be adopted as the command signal.
- the ladle tilt angle is measured by a rotary encoder, and the liquid weight in the ladle is measured by a load cell provided in the automatic pouring apparatus 1.
- the outflow weight of the liquid flowing out of the ladle 10 can be measured by the difference between the liquid weight in the ladle before pouring and the liquid weight in the ladle during pouring.
- the computer 14 outputs the measured ladle tilt angle and the liquid weight in the ladle, and the computer 14 controls the pouring operation based on these. 2 is removed, the feed-forward type pouring control system is obtained.
- the computer 14 identifies and updates the model parameters based on the command signal, the acquired ladle tilt angle and the liquid weight in the ladle. Obtains the liquid weight in the ladle, the ladle tilt angle, and the command signal detected by one pouring operation, and uses these data and the mathematical model of the pouring process to determine the flow rate that is a model parameter of the pouring process. By identifying the coefficient, the liquid density, and the pouring start angle, and updating the model parameters in the pouring control, command signals to the servo motors 11, 12, and 13 corresponding to the model parameters are generated by the pouring control system. .
- Step 1 for the pouring control, an initial model parameter, a function (calibration curve) of the pouring start angle that is the inclination angle of the ladle 10 when the pouring is started from the ladle 10 and the liquid weight in the ladle. It is given as a pouring control setting parameter.
- initial model data as initial model parameters are a ladle shape, a liquid density, and a flow coefficient.
- the ladle shape data gives numerical values used for ladle design, and the liquid density and flow coefficient give values that are considered to be reasonable through experiments and experience.
- the function of the tapping start angle and the weight of the liquid in the ladle is obtained by calculating the ladle filling volume of the liquid with respect to the ladle tilt angle from the ladle shape data, multiplying the volume by the density, and functionalizing. In this stage, it is assumed that the ladle 10 is supplied with hot water and is ready to start pouring operation.
- the pouring machine is controlled based on a mathematical model described later, and pouring from the ladle 10 to the mold 20 is executed.
- the optimization method described later is used. Then, the liquid density and the flow coefficient are identified as parameters to be updated.
- the identified pouring start angle and the liquid weight in the ladle measured before pouring are stored in the computer 14 as a set of data.
- step 5 the liquid density and the flow coefficient input as initial parameters for the pouring control and used for the pouring control are updated online with the liquid density and the flow coefficient identified in step 3.
- step 6 it is determined whether or not the molten metal is supplied to the ladle 10 after step 2.
- step 6: No the process proceeds to step 2 in order to continue pouring from the ladle 10 to the mold 20. Thereby, a liquid density and a flow coefficient will be updated for every pouring.
- step 6 When the molten metal is supplied to the ladle 10 (step 6: Yes), a series of pouring is completed, and the process proceeds to step 7.
- step 7 based on a plurality of sets of data obtained from the respective data strings of “identified tapping start angle and liquid weight in the ladle measured before pouring” acquired in step 4 for each pouring, The relation between the starting angle and the liquid weight in the ladle is expressed by an approximate function.
- step 8 the approximate function of the previously started tapping temperature and the liquid weight in the ladle is updated to the approximate function obtained in step 7.
- pouring control is performed using this approximate function.
- Equation (2) shows the case of the speed control mode.
- ⁇ [rad / s] is a ladle tilting angular velocity
- T m [s] represents a time constant of the motor system
- K m [m / s / V] represents a gain constant.
- Equations (3) and (4) The mathematical models from the ladle tilting angular velocity ⁇ to the pouring flow rate q c [m 3 / s] are shown in Equations (3) and (4).
- Equation (3) indicates the liquid level of the upper liquid from the tap
- a [m 2 ] is the surface area of the upper surface of the liquid in the ladle
- V s [m 3 ] Indicates the volume of the lower liquid from the outlet.
- ⁇ [rad] is the ladle tilt angle.
- the formula (3) is useful when the upper surface of the ladle liquid is higher than the lower surface of the tap and the ladle tilt angle ⁇ s [rad] when the ladle liquid begins to flow out is useful. This ladle tilting angle ⁇ s is called a tapping start angle.
- L f [m] in the equation (4) is the width of the tap at the depth h b [m] from the top surface of the liquid as shown in FIG. 5, g [m / s 2 ] is the gravitational acceleration, c Indicates a flow coefficient.
- the formula (4) is useful under the condition that the liquid height in the ladle is higher than the bottom surface of the tap.
- Equation (5) The relationship between the outflow weight W [kg] and the pouring flow rate q c [m 3 / s] is shown in Equation (5).
- ⁇ [kg / m 3 ] indicates the liquid density.
- the outflow weight W [kg] is measured by a load cell built in the automatic pouring device 1.
- the response delay of the load cell is expressed by a first-order delay system of equation (6).
- W L [kg] is an outflow weight measured by the load cell
- T L [s] indicates a time constant with respect to the load cell response.
- Equations (2) to (6) are mathematical models of the automatic pouring device 1, and the ladle tilt angle ⁇ [rad] is detected by the rotary encoder, and the outflow weight W L [kg] is detected by the load cell.
- a pouring control system is constructed.
- the desired pouring flow rate pattern q cref [m 3 / s] is given, the desired pouring shown in equation (7) is obtained from the inverse function of equation (4).
- the liquid height h ref [m] that realizes the flow rate pattern is obtained.
- the reference ladle tilt angle ⁇ ref [rad] is obtained by the equation (9) using the equation (2).
- ⁇ sref [rad] is a tapping start angle that is a ladle tilting angle when the liquid starts to flow out of the ladle.
- the ladle tilting angular velocity ⁇ ref [rad / s] obtained by the equation (8) is realized by the command signal u ref [V] derived from the inverse model of the motor model shown in the equation (2).
- the inverse model of the motor model is shown in equation (10).
- Ford forward pouring flow rate control is constructed using equations (7) to (10).
- the liquid height h ref [m] is required to be second-order differentiable.
- a two-degree-of-freedom pouring flow rate control based on flatness shown below is constructed.
- the feedback linearization mechanism shown in the equation (11) is constructed based on the equation (3) with the flat output F as the liquid height h.
- This is the control parameter to be adjusted.
- a desired pouring flow rate q cref is given, and a liquid height h ref that realizes the desired pouring flow rate is obtained from the equation (7).
- the two-degree-of-freedom pouring flow rate control shown in the equations (11) and (12) is performed.
- the expression (11) is useful when the ladle tilting angle ⁇ is equal to or greater than the pouring start angle ⁇ s , as in the feedforward pouring flow control.
- the two pouring flow control shown above is model-based pouring flow control based on a mathematical model of the pouring process.
- most of the model parameters are set from the shape of the ladle.
- the flow coefficient c depends on the liquid characteristics and the ladle surface characteristics, it is necessary to perform parameter identification by experiment.
- the tapping start angle ⁇ s can be obtained from the liquid volume from the liquid weight in the ladle before pouring and can be obtained from the liquid volume and ladle shape. The difference may occur.
- the liquid density ⁇ varies depending on the temperature and is easily affected by the pouring environment. Therefore, as shown in FIG. 2, a method for identifying the flow coefficient, the tapping start angle, and the liquid density is constructed based on the outflow liquid weight data, ladle tilt angle data, and command signal data obtained by automatic pouring.
- the parameter identification performed in step 7 is performed by minimizing the evaluation function shown in the equation (14).
- the downhill simplex method is applied as an optimization method to the evaluation function of the equation (14) to minimize.
- the downhill simplex method is preferable because the parameter convergence is fast and the calculation load can be reduced, so that the parameter update time can be shortened.
- optimization methods such as genetic algorithm and sequential quadratic programming can be employed.
- T [s] indicates the pouring operation time of the automatic pouring device 1 for pouring into one mold
- W Lex [kg] is from the ladle obtained by the load cell in which the automatic pouring device 1 is built.
- Outflow weight data, W Lsim [kg] is the outflow weight when simulating with the mathematical model of (2) to (6) using the command value to the motor and the ladle tilt angle measured from the rotary encoder It is.
- c sim , ⁇ ssim , and ⁇ sim respectively indicate a flow coefficient, a tapping start angle, and a liquid density used during the simulation.
- C avg and ⁇ avg are the average values of the flow coefficient and liquid density up to the previous time, and are shown in equations (15) and (16), respectively.
- N indicates the number of times of pouring to be averaged. If the flow coefficient and liquid density of the liquid to be poured are unchanged, N can be the maximum number of pouring, but in the case of high-temperature molten metal, the flow coefficient and liquid density vary depending on the temperature characteristics. , N number is adjusted, and identification data by past pouring is forgotten. Thereby, the precision of identification data can be improved.
- w 1 of the formula is a weighting coefficient for controlling the variation of the flow rate coefficient for each pouring
- w 2 are weighting factors for controlling the variation of the liquid density of each pouring.
- the identified hot water start angle ⁇ sid [rad] is a set with the liquid weight W b [kg] in the ladle before pouring measured by the load cell, and is stored in the computer 14.
- an automatic pouring machine performs a plurality of times of pouring with one hot water supply to the ladle.
- Data sequence of tapping start angle identified for each pouring ⁇ sid ( ⁇ sid (1), ⁇ sid (2), ... ⁇ sid (n)) and data sequence of liquid weight in the ladle before pouring
- W b (W b (1), W b (2),... W b (n)) as an approximate function
- the tapping start angle is calculated from the liquid weight in the ladle measured before pouring. Can be predicted.
- the approximation function linear approximation or polynomial approximation is used.
- the present invention is also applied to a pouring control program that enables the above-described control to be executed by a computer, and a storage medium that stores the program in a readable manner by the computer. That is, in the ladle tilting type automatic pouring apparatus 1 configured to control the operation of the ladle, the computer is poured based on a mathematical model of the pouring process from the input of the control parameters to the pouring by the ladle.
- a recording medium storing a program for functioning as a pouring control means for controlling the pouring, and a command for controlling the weight of the liquid flowing out from the ladle, the tilt angle of the ladle, and the tilt of the ladle measured during pouring Based on the signal, a process for identifying the flow coefficient, liquid density, and the control parameters in the mathematical model by the optimization method, and the tapping start angle that is the tilt angle of the ladle when tapping is started from the ladle, and the identification
- the present invention can be applied to a computer-readable recording medium characterized in that a program for executing the process for updating the control parameters is stored.
- a mathematical model is obtained by an optimization method. It is possible to identify and update the flow coefficient, liquid density, and hot water start angle, which are control parameters within the system, shortening the identification work that requires a lot of work time, and adjusting the control parameters according to the pouring state Since the value can be updated and control corresponding to a change in the pouring state can be performed, pouring accuracy can be improved.
- the ladle shape and the type of molten metal differ.
- the present invention is also applied to a pouring control program that enables the above control to be executed by a computer, and a storage medium that stores the program so as to be readable by the computer.
- Ladle shape Fan-shaped ladle Target liquid: Water target outflow weight: 1.55kg Target pouring flow rate (steady state): 5 ⁇ 10 ⁇ 4 m 3 / s Pouring control: Feed forward pouring flow control weighting factor w 1 : 3 Weight coefficient w 2 : 0.01
- FIGS. 6 and 7 are ladle tilt angles measured by a rotary encoder
- FIGS. 6 (B) and 7 (B) are outflow weights measured by a load cell.
- the solid line is the experimental result, and the broken line shows the simulation result by the mathematical model of the pouring process.
- the initial parameters used for pouring control are a flow coefficient of 0.98, a liquid density of 1 ⁇ 10 3 [kg / m 3 ], and a tapping start angle of 21. 70 ⁇ ⁇ / 180 [rad].
- the flow coefficient was 0.98
- the liquid density was 1 ⁇ 10 3 [kg / m 3 ]
- the tapping start angle was 20.20 ⁇ ⁇ / 180 [rad]. became.
- the difference in flow rate coefficient and liquid density was small, but the tapping start angle was greatly different.
- the flow coefficient used for the pouring control is 0.99
- the liquid density is 1 ⁇ 10 3 [kg / m 3. Since the weight of the liquid in the ladle was 5.58 kg, 30.86 ⁇ ⁇ / 180 [rad] was used as an estimated value for the tapping start angle.
- the flow coefficient used for pouring control is 0.99
- the liquid density is 1 ⁇ 10 3 [kg / m 3 ]
- the flow coefficient, liquid density, and pouring start angle used for pouring control are almost the same as the parameter identification results, and the parameters that were in the pouring state were used for pouring control. The results were consistent and it was confirmed that the hot water was poured with high accuracy.
- FIG. 8 shows the relationship between the liquid weight in the ladle before pouring and the tapping start angle.
- the broken line shows the relationship between the liquid weight in the ladle derived from the ladle shape drawing and the tapping start angle, and the black circle mark ⁇ ⁇ '' indicates the tapping start angle identified and the liquid weight in the ladle before pouring,
- the solid line shows a linear approximation of the identification result.
- the relationship between the linearly approximated liquid weight in the ladle and the tapping start angle is shown in equation (17).
- the pouring start angle is predicted using the relationship between the pouring start angle linearly approximated and the liquid weight in the ladle before pouring. From FIG. 8, it was confirmed that the hot water start angle derived from the ladle shape drawing and the hot water start angle by parameter identification were significantly different. This is considered to be caused by the modeling error and the secular change of the ladle shape caused by simplifying the shape when deriving the tapping start angle from the ladle shape drawing.
- the pouring control method it was possible to grasp the relationship between the exact pouring start angle and the liquid weight in the ladle before pouring, and to use it for pouring control.
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Abstract
Description
しかし、これらの注湯制御方法は、制御パラメータを決定するために、数多くのテスト注湯実験を必要とする。特に、制御パラメータと注湯プロセスに関する物理パラメータ(取鍋形状、流量係数、液体密度など)の関係が不明確なため、取鍋形状や注湯液体が異なった注湯工程に対しては、同様のテスト注湯実験を必要としている。また、テスト注湯実験と注湯環境が変化した際、たとえば、溶湯温度の低下などによる注湯液体の特性変動やスラグ付着による取鍋形状変動が生じた場合に、注湯精度が低下することが問題となっている。
また、流体力学に基づく注湯プロセスの数理モデルを導出し、そのモデルに基づいた注湯制御システムであるモデルベースド注湯制御システムを採用しているため、取鍋形状や溶湯の種類が異なる取鍋傾動式自動注湯装置でもパラメータを共有することにより、短時間での立ち上げや注湯プロセス解析が可能となる。
但し、cid:同定された流量係数、θsid:同定された出湯開始角度、ρid:同定された液体密度、T:一つの鋳型に注湯する注湯動作時間、WLex:取鍋傾動式自動注湯装置から取得される取鍋からの流出重量データ、WLsim:取鍋傾動角度を用いて数理モデルでシミュレーションした際の流出重量、csim:シミュレーション時に用いられた流量係数、θssim:シミュレーション時に用いられた出湯開始角度、ρsim:シミュレーション時に用いられた液体密度、Cavg:前回までの流量係数の平均値、ρavg:前回までの液体密度の平均値、w1:注湯毎の流量係数の変動を制御するための重み係数、w2:注湯毎の液体密度の変動を制御するための重み係数である。
また、本発明は以下の詳細な説明により更に完全に理解できるであろう。しかしながら、詳細な説明および特定の実施例は、本発明の望ましい実施の形態であり、説明の目的のためにのみ記載されているものである。この詳細な説明から、種々の変更、改変が、当業者にとって明らかだからである。
出願人は、記載された実施の形態のいずれをも公衆に献上する意図はなく、開示された改変、代替案のうち、特許請求の範囲内に文言上含まれないかもしれないものも、均等論下での発明の一部とする。
本明細書あるいは請求の範囲の記載において、名詞及び同様な指示語の使用は、特に指示されない限り、または文脈によって明瞭に否定されない限り、単数および複数の両方を含むものと解釈すべきである。本明細書中で提供されたいずれの例示または例示的な用語(例えば、「等」)の使用も、単に本発明を説明し易くするという意図であるに過ぎず、特に請求の範囲に記載しない限り本発明の範囲に制限を加えるものではない。
本発明の注湯制御方法によれば、制御パラメータの入力から前記取鍋による注湯までの注湯プロセスの数理モデルに基づいて注湯を制御する注湯制御方法において、最適化手法により数理モデル内の制御パラメータである流量係数、液体密度及び出湯開始角度を同定し、更新することができるため、多くの作業時間を必要とする同定作業を短縮するとともに、制御パラメータを注湯状態に応じた値に更新し、注湯状態の変化に対応した制御を行うことができるので、注湯精度を向上させることができる。
また、流体力学に基づく注湯プロセスの数理モデルを導出し、そのモデルに基づいた注湯制御システムであるモデルベースド注湯制御システムを採用しているため、取鍋形状や溶湯の種類が異なる取鍋傾動式自動注湯装置でもパラメータを共有することにより、短時間での立ち上げや注湯プロセス解析が可能となる。
また、本発明は、上記制御をコンピュータによって実行可能とする注湯制御プログラム、このプログラムをコンピュータによって読み取り可能に記憶した記憶媒体にも適用される。
対象液体:水
目標流出重量:1.55kg
目標注湯流量(定常時):5×10-4m3/s
注湯制御:フィードフォワード型注湯流量制御
重み係数w1:3
重み係数w2:0.01
図7に示すパラメータが同定及び更新された後の注湯制御を行った4回目の注湯では、注湯制御に用いる流量係数を0.99、液体密度を1×103[kg/m3]、とし、取鍋内液体重量が5.58kgであったことから、出湯開始角度は30.86×π/180[rad]が推定値として用いられた。4回目の注湯実験の後のパラメータ同定では、注湯制御に用いる流量係数は0.99、液体密度は1×103[kg/m3]、出湯開始角度は30.90×π/180[rad]であった。注湯制御に用いられた流量係数、液体密度、出湯開始角度は、パラメータ同定結果とほぼ同じ値であり、注湯状態にあったパラメータが注湯制御に用いられたことから、実験とシミュレーションの結果が一致しており、高精度に注湯されたことが確認できた。
より、正確な出湯開始角度と注湯前取鍋内液体重量との関係を把握し、注湯制御に用いることができた。
10…取鍋
10a…出湯口
11、12、13…サーボモータ
14…コンピュータ
20…鋳型
20a…鋳型内湯口
Claims (7)
- 溶湯を保持した取鍋を傾動させて前記溶湯を鋳型に注湯する取鍋傾動式自動注湯装置において制御パラメータの入力から前記取鍋による注湯までの注湯プロセスの数理モデルに基づいて注湯を制御する注湯制御方法であって、
注湯時に計測される前記取鍋から流出する液体重量、取鍋傾動角度及び取鍋の傾動を制御する指令信号に基づいて、最適化手法により数理モデル内の前記制御パラメータである流量係数、液体密度及び取鍋から出湯が開始されるときの取鍋の傾斜角である出湯開始角度を同定する工程と、
前記制御パラメータを前記同定された制御パラメータに更新する工程と、
を備えたことを特徴とする注湯制御方法。 - 前記流量係数、液体密度及び出湯開始角度は、下式で表わされる評価関数を最適化することにより同定されることを特徴とする請求項1に記載の注湯制御方法。
但し、cid:同定された流量係数、θsid:同定された出湯開始角度、ρid:同定された液体密度、T:一つの鋳型に注湯する注湯動作時間、WLex:取鍋傾動式自動注湯装置から取得される取鍋からの流出重量データ、WLsim:取鍋傾動角度を用いて数理モデルでシミュレーションした際の流出重量、csim:シミュレーション時に用いられた流量係数、θssim:シミュレーション時に用いられた出湯開始角度、ρsim:シミュレーション時に用いられた液体密度、Cavg:前回までの流量係数の平均値、ρavg:前回までの液体密度の平均値、w1:注湯毎の流量係数の変動を制御するための重み係数、w2:注湯毎の液体密度の変動を制御するための重み係数である。 - 前記流量係数及び液体密度は、一回の注湯が完了する毎に同定されて更新され、
前記出湯開始角度は、前記取鍋による連続した注湯が終了後に、同定された前記出湯開始角度と対応する取鍋内液体重量との近似関数が算出されて更新されることを特徴とする請求項1または請求項2に記載の注湯制御方法。 - 前記最適化手法は、滑降シンプレックス法であることを特徴とする請求項1に記載の注湯制御方法。
- 前記最適化手法は、滑降シンプレックス法であることを特徴とする請求項2に記載の注湯制御方法。
- 前記最適化手法は、滑降シンプレックス法であることを特徴とする請求項3に記載の注湯制御方法。
- コンピュータを、溶湯を保持した取鍋を傾動させて前記溶湯を鋳型に注湯する取鍋傾動式自動注湯装置において制御パラメータの入力から前記取鍋による注湯までの注湯プロセスの数理モデルに基づいて注湯を制御する注湯制御手段として機能させるためのプログラムを記憶した記録媒体であって、
注湯時に計測される前記取鍋から流出する液体重量、取鍋傾動角度及び取鍋の傾動を制御する指令信号に基づいて、最適化手法により数理モデル内の前記制御パラメータである流量係数、液体密度及び取鍋から出湯が開始されるときの取鍋の傾斜角である出湯開始角度を同定する処理と、
前記制御パラメータを前記同定された制御パラメータに更新する処理と、
を実行するためのプログラムが記憶されたことを特徴とするコンピュータ読み取り可能な記録媒体。
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