CN105499549B - A kind of copper anode plate automatic ration casting control system and control method - Google Patents
A kind of copper anode plate automatic ration casting control system and control method Download PDFInfo
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- 238000005266 casting Methods 0.000 title claims abstract description 143
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 title claims abstract description 76
- 229910052802 copper Inorganic materials 0.000 title claims abstract description 76
- 239000010949 copper Substances 0.000 title claims abstract description 76
- 238000000034 method Methods 0.000 title claims abstract description 24
- 238000005303 weighing Methods 0.000 claims abstract description 47
- 238000006243 chemical reaction Methods 0.000 claims abstract description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 5
- 230000003750 conditioning effect Effects 0.000 claims abstract description 4
- PTVDYARBVCBHSL-UHFFFAOYSA-N copper;hydrate Chemical compound O.[Cu] PTVDYARBVCBHSL-UHFFFAOYSA-N 0.000 claims description 28
- 230000001133 acceleration Effects 0.000 claims description 12
- 239000003921 oil Substances 0.000 claims description 10
- 230000007423 decrease Effects 0.000 claims description 7
- 239000007788 liquid Substances 0.000 claims description 7
- 238000004891 communication Methods 0.000 claims description 5
- 230000001143 conditioned effect Effects 0.000 claims description 3
- 230000003247 decreasing effect Effects 0.000 claims description 3
- 239000010727 cylinder oil Substances 0.000 claims description 2
- 238000012545 processing Methods 0.000 claims description 2
- 238000010187 selection method Methods 0.000 claims description 2
- 230000006870 function Effects 0.000 description 12
- 238000010586 diagram Methods 0.000 description 7
- 238000005516 engineering process Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 238000003723 Smelting Methods 0.000 description 4
- 230000008859 change Effects 0.000 description 4
- 230000000875 corresponding effect Effects 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- 238000009434 installation Methods 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 238000007670 refining Methods 0.000 description 3
- 238000013461 design Methods 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000005284 excitation Effects 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000013178 mathematical model Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
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- 230000004048 modification Effects 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 239000004065 semiconductor Substances 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D39/00—Equipment for supplying molten metal in rations
- B22D39/04—Equipment for supplying molten metal in rations having means for controlling the amount of molten metal by weight
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D25/00—Special casting characterised by the nature of the product
- B22D25/02—Special casting characterised by the nature of the product by its peculiarity of shape; of works of art
- B22D25/04—Casting metal electric battery plates or the like
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Abstract
本发明公开了一种铜阳极板自动定量浇铸控制系统及控制方法,包括PLC控制器,接近开关连接PLC控制器的输入端;称重传感器与称重模块连接,称重模块对称重信号进行信号调理和模数转换后发送给PLC控制器,称重模块的输出端还与调节浇铸包和中间包启动液压缸进油管进油量大小的电磁比例阀连接;PLC控制器通过变频器控制圆盘驱动电机的转动;PLC控制器与安装在中间包进油管道中的电磁换向阀连接;PLC控制器与触摸屏连接;PLC控制器根据称重传感器采集的浇铸包的重量计算出已浇铜水量并生成速度控制信号,作用于电磁比例阀,使浇铸速度跟随设定的轨迹。提高了浇铸效率及品质,使浇铸出的铜阳极板具备较高外形规范。
The invention discloses a copper anode plate automatic quantitative casting control system and a control method, comprising a PLC controller, a proximity switch connected to the input end of the PLC controller; a weighing sensor connected to a weighing module, and the weighing module sends a signal to the weighing signal After conditioning and analog-to-digital conversion, it is sent to the PLC controller. The output end of the weighing module is also connected to the electromagnetic proportional valve that adjusts the oil inlet pipe of the hydraulic cylinder for starting the casting ladle and the tundish; the PLC controller controls the disc through the frequency converter. The rotation of the drive motor; the PLC controller is connected to the electromagnetic reversing valve installed in the oil inlet pipeline of the tundish; the PLC controller is connected to the touch screen; the PLC controller calculates the amount of copper poured water according to the weight of the casting ladle collected by the load cell And generate a speed control signal to act on the electromagnetic proportional valve to make the casting speed follow the set track. The casting efficiency and quality are improved, and the cast copper anode plate has a higher shape specification.
Description
技术领域technical field
本发明涉及定量浇铸技术领域,尤其涉及一种铜阳极板自动定量浇铸控制系统及控制方法。The invention relates to the technical field of quantitative casting, in particular to an automatic quantitative casting control system and control method for copper anode plates.
背景技术Background technique
随着中国经济的快速发展,中国GDP总量达到全球第二位的同时,中国的精炼铜产量增速较高,铜市场消费稳定增长,国际铜研究组织(ICSG)公布数据显示,中国铜金属含量产量是世界主要增产区。在此环境背景下,铜价格稳中升高,刺激了国内大型铜冶炼企业加紧提高产能、淘汰落后的铜冶炼技术,引进先进的冶炼技术与设备,在未来市场竞争中争取主动地位。铜阳极板是粗冶炼铜电解精炼生产纯铜的原材料,要获得优质的电解纯铜,除了铜阳极板本身各种杂质含量不能太高外,铜阳极板还要有一定规范的外形,这要求每块阳极板的厚度一致,表面光滑,几何尺寸一致,以保证在阳极板电解精炼时,可以缩小同极间距,提高电流密度,降低短路率和残极率,同时便于实现联动作业,满足后序工艺的要求。阳极板浇铸机正是获取铜电解精炼原材料的浇铸设备,研究和开发高效、节能、自动化程度高的铜阳极板定量浇铸设备有着重要的意义。With the rapid development of China's economy, China's total GDP has reached the second place in the world. At the same time, China's refined copper production has a high growth rate, and the copper market consumption has grown steadily. According to data released by the International Copper Study Group (ICSG), China's copper metal Content production is the world's main production area. Against this background, copper prices have risen steadily, which has stimulated domestic large-scale copper smelting enterprises to increase production capacity, eliminate outdated copper smelting technology, introduce advanced smelting technology and equipment, and strive for an active position in future market competition. Copper anode plate is the raw material for rough smelting copper electrolytic refining to produce pure copper. In order to obtain high-quality electrolytic pure copper, in addition to the impurity content of the copper anode plate itself should not be too high, the copper anode plate must have a certain standard shape, which requires The thickness of each anode plate is consistent, the surface is smooth, and the geometric dimensions are consistent, so as to ensure that the distance between the same electrodes can be reduced during the electrolytic refining of the anode plate, the current density can be increased, the short circuit rate and the residual electrode rate can be reduced, and at the same time, it is convenient to realize the linkage operation and meet the requirements process requirements. The anode plate casting machine is the casting equipment for obtaining copper electrolytic refining raw materials. It is of great significance to research and develop high-efficiency, energy-saving and highly automated copper anode plate quantitative casting equipment.
目前,铜阳极板圆盘定量浇铸机在节约资源、降低劳动力成本、提高产能、改善产品品质等方面有很大的优点,但是自动定量浇铸控制技术还不是很成熟,仍面临浇铸过程重量精度控制较低、系统稳定性较差、浇铸效率低以及应对工况变化自适应、自调整能力较低等问题。At present, the copper anode disc quantitative casting machine has great advantages in saving resources, reducing labor costs, increasing production capacity, and improving product quality. However, the automatic quantitative casting control technology is not very mature, and it still faces the weight accuracy control of the casting process. Low, poor system stability, low casting efficiency, self-adaptive to changes in working conditions, and low self-adjustment capabilities.
发明内容Contents of the invention
本发明的目的就是为了解决上述问题,提供一种铜阳极板自动定量浇铸控制系统及控制方法,提高了浇铸效率及品质,使浇铸出的铜阳极板具备较高外形规范。The purpose of the present invention is to solve the above problems, to provide a copper anode plate automatic quantitative casting control system and control method, which improves the casting efficiency and quality, and makes the cast copper anode plate have a higher shape specification.
为了实现上述目的,本发明采用如下技术方案:In order to achieve the above object, the present invention adopts the following technical solutions:
一种铜阳极板自动定量浇铸控制系统,包括PLC控制器,安装在圆盘中间空腔的接近开关连接所述PLC控制器的输入端;An automatic quantitative casting control system for copper anode plates, including a PLC controller, a proximity switch installed in the middle cavity of the disc is connected to the input end of the PLC controller;
安装在浇铸包底座上的称重传感器与称重模块连接,称重模块对称重信号进行信号调理和模数转换后发送给PLC控制器,所述称重模块的输出端还与调节浇铸包和中间包启动液压缸进油管进油量大小的电磁比例阀连接;The weighing sensor installed on the base of the casting ladle is connected to the weighing module, and the weighing module performs signal conditioning and analog-to-digital conversion on the weighing signal and sends it to the PLC controller. The output end of the weighing module is also connected to the adjustment casting ladle and The tundish start hydraulic cylinder oil inlet pipe is connected to the electromagnetic proportional valve of the size of the oil inlet;
所述PLC控制器通过变频器控制圆盘驱动电机的转动;The PLC controller controls the rotation of the disc drive motor through a frequency converter;
所述PLC控制器与安装在中间包进油管道中的电磁换向阀连接;The PLC controller is connected with the electromagnetic reversing valve installed in the oil inlet pipeline of the tundish;
所述PLC控制器与触摸屏连接;The PLC controller is connected with the touch screen;
PLC控制器根据称重传感器采集的浇铸包的重量计算出已浇铜水量并生成速度控制信号,作用于电磁比例阀,使浇铸速度跟随设定的轨迹。The PLC controller calculates the amount of copper poured water based on the weight of the casting ladle collected by the load cell and generates a speed control signal, which acts on the electromagnetic proportional valve to make the casting speed follow the set track.
所述接近开关包括限位开关和停止接近开关。The proximity switch includes a limit switch and a stop proximity switch.
所述PLC控制器还与控制按钮连接。The PLC controller is also connected with the control buttons.
所述PLC控制器的输出端连接用于指示中间包回位到位、浇铸包回位到位及圆盘到位的指示灯。The output end of the PLC controller is connected with indicator lights for indicating the return of the tundish, the return of the casting ladle and the arrival of the disc.
所述触摸屏与PLC控制器通过RS485接口通讯连接,通过触摸屏能监控铜水浇铸的工作状态,也能够通过触摸屏修改设置PLC控制器的参数以调整铜水浇铸工作状态。The touch screen is connected to the PLC controller through the RS485 interface, and the working state of the copper water casting can be monitored through the touch screen, and the parameters of the PLC controller can be modified and set through the touch screen to adjust the working state of the copper water casting.
采用所述一种铜阳极板自动定量浇铸控制系统的控制方法,包括,The control method adopting the automatic quantitative casting control system of a kind of copper anode plate comprises,
熔融状态下的铜水经溜槽流入中间包之后,到达设定重量后PLC控制器通过控制电磁换向阀使高压油进入中间包液压缸中使中间包启动,铜水流入浇铸包内,浇铸包底座下的称重传感器将铜水重量压力值转换成电压信号传递到称重模块内,称重模块将电压信号进行调理、滤波及模数转换后传递到PLC控制器供调用处理;当浇铸包内的铜水重量达到设定值时,PLC控制器通过控制电磁换向阀切换电磁阀位置使中间包回落;After the copper water in the molten state flows into the tundish through the chute, after reaching the set weight, the PLC controller controls the electromagnetic reversing valve so that the high-pressure oil enters the tundish hydraulic cylinder to start the tundish, and the copper water flows into the casting ladle, and the casting ladle The weighing sensor under the base converts the weight and pressure value of copper water into a voltage signal and transmits it to the weighing module. The weighing module conditioned, filtered and converted the voltage signal to the PLC controller for calling and processing; When the weight of the copper water inside reaches the set value, the PLC controller switches the electromagnetic valve position by controlling the electromagnetic reversing valve to make the tundish fall back;
等待圆盘运行到位后,接近开关传递给PLC控制器信号,从而形成浇铸包浇铸条件,PLC控制器通过发送设定值电压给电磁比例阀来控制浇铸包的浇铸速度;After the disc is running in place, the proximity switch transmits the signal to the PLC controller to form the ladle casting conditions. The PLC controller controls the casting speed of the ladle by sending the set value voltage to the electromagnetic proportional valve;
阳极板浇铸时,中间包向浇铸包倾倒铜液,倾倒量由称重传感器检测,当达到设定值时,停止倾倒,待浇铸圆盘到位后,浇铸包开始倾倒铜液,同时PLC控制器根据称重传感器检测,对采集的称重信号进行分析,来控制浇铸包的浇铸速度,形成浇铸速度上的反馈调节,使得浇铸速度按照设定的轨迹变化。When casting the anode plate, the tundish pours copper liquid into the casting ladle, and the pouring amount is detected by the load cell. When the set value is reached, the pouring stops. After the casting disc is in place, the casting ladle starts pouring copper liquid, and the PLC controller According to the detection of the weighing sensor, the collected weighing signal is analyzed to control the casting speed of the casting ladle, forming a feedback adjustment on the casting speed, so that the casting speed changes according to the set trajectory.
得到确定时刻点t1浇铸速度的方法为,以t1时刻的重量值为起点,包括t1时刻的重量值,开始连续采集其后的多个时刻点的重量值,将采集到的多个时刻点的重量值运用最小二乘法计算出的值作为该时刻t1的速度值。The method of determining the casting speed at the time point t1 is as follows: starting from the weight value at the time point t1, including the weight value at the time point t1, starting to continuously collect the weight values at multiple time points thereafter, and combining the collected weight values at the time point The weight value calculated by the least square method is used as the speed value at this time t1.
浇铸速度的控制反应出来的是对输出电压的控制,所述设定的轨迹包括多个曲线段,所述曲线段有启动段、等待出铜段、加速段、均速段、减速段及收包段,各浇铸曲线之间通过状态量进行切换。The control of the casting speed reflects the control of the output voltage. The set trajectory includes a plurality of curve segments, and the curve segments include a start-up segment, a waiting segment for copper output, an acceleration segment, an average speed segment, a deceleration segment and a closing segment. For the package section, switch between each casting curve through the state quantity.
状态量的选取方式为:The selection method of state quantity is:
浇铸包在启动段进行并保持1-4秒后,即进入等待出铜段;After the casting ladle is carried out in the start-up section and kept for 1-4 seconds, it enters the waiting section for copper output;
等待出铜段、加速段、匀速段、减速段及收包段之间以设定重量与实际重量的比较结果来切换,当各段的实际重量大于或等于设定重量后,即进入到下一曲线段;Wait for the switch between the output section, acceleration section, constant speed section, deceleration section and package receiving section according to the comparison result between the set weight and the actual weight. When the actual weight of each section is greater than or equal to the set weight, it will enter the next step. a curved segment;
减速段与收包段之间的切换以收包点重量为切换标志。The switch between the deceleration section and the packet receiving section takes the weight of the packet receiving point as the switch symbol.
启动段电磁比例阀的控制电压先以恒定的增加速率增加,增加到设定的最大值后保持最大值不变,延时设定时间后达到等待出铜段;The control voltage of the electromagnetic proportional valve in the start-up section increases at a constant rate of increase first, and then keeps the maximum value unchanged after increasing to the set maximum value, and reaches the waiting copper output section after a delay of the set time;
等待出铜段电磁比例阀的控制电压以恒定速率递减,递减到设定值后到达出铜段;Wait for the control voltage of the electromagnetic proportional valve in the copper outlet section to decrease at a constant rate, and reach the copper outlet section after decreasing to the set value;
出铜段电磁比例阀的控制电压保持设定值不变,经过设定延时后到达加速段;The control voltage of the electromagnetic proportional valve in the copper outlet section keeps the set value unchanged, and reaches the acceleration section after the set delay;
加速段给电磁比例阀的电压值逐渐减小,模型公式为指数函数e^x+f,到达设定值后进入匀速段;The voltage value of the electromagnetic proportional valve in the acceleration section decreases gradually, and the model formula is an exponential function e^x+f, and enters the constant speed section after reaching the set value;
匀速段输出恒定电压给比例伺服阀,此时曲线模型公式为恒定值g,经过设定延时后到达减速段;The constant speed section outputs a constant voltage to the proportional servo valve. At this time, the curve model formula is a constant value g, and it reaches the deceleration section after a set delay;
减速段系统输出给电磁比例阀的电压越来越小,以便捕捉和确定浇铸包收包点,曲线模型公式为指数函数h^x+I,到达设定值后再以恒定速率增加,增加到设定之后达到收包段;The voltage output from the deceleration section system to the electromagnetic proportional valve is getting smaller and smaller in order to capture and determine the casting wrapping point. The formula of the curve model is an exponential function h^x+I. After reaching the set value, it increases at a constant rate until it reaches the set value. After setting, it reaches the packet receiving segment;
收包段输出给电磁比例阀的电压以恒定的速率迅速减小到0,使铜水尽量少的流出,减少浇铸误差。The voltage output from the receiving section to the electromagnetic proportional valve is rapidly reduced to 0 at a constant rate, so that the copper water flows out as little as possible and the casting error is reduced.
本发明的有益效果:Beneficial effects of the present invention:
自动化程度高,操作准确、响应速度快且稳定,加入反馈控制可使浇铸过程更加精确,提高了浇铸控制系统的柔性,通过PLC控制机构的运动,减少了电气元器件的使用,够使控制系统内部结构的设计简单,减少了设计的工作量,接线简单,维修容易,并极大提高系统的使用效果和产品的浇铸品质。High degree of automation, accurate operation, fast and stable response, the addition of feedback control can make the casting process more precise, improve the flexibility of the casting control system, and reduce the use of electrical components through the movement of the PLC control mechanism, enabling the control system The design of the internal structure is simple, which reduces the workload of the design, the wiring is simple, the maintenance is easy, and the use effect of the system and the casting quality of the product are greatly improved.
附图说明Description of drawings
图1为本发明一种铜阳极板自动定量浇铸控制系统结构示意图。Fig. 1 is a structural schematic diagram of an automatic quantitative casting control system for copper anode plates according to the present invention.
图2为本发明一种铜阳极板自动定量浇铸控制系统的主程序框图。Fig. 2 is a main program block diagram of a copper anode plate automatic quantitative casting control system of the present invention.
图3为本发明一种铜阳极板自动定量浇铸控制系统手动模式程序流程图。Fig. 3 is a manual mode program flow chart of the automatic quantitative casting control system for copper anode plates according to the present invention.
图4为本发明一种铜阳极板自动定量浇铸控制系统功能测试程序流程图。Fig. 4 is a flow chart of the functional test program of the automatic quantitative casting control system for copper anode plates according to the present invention.
图5为本发明一种铜阳极板自动定量浇铸控制系统自动模式程序流程图。Fig. 5 is a flow chart of an automatic mode program of an automatic quantitative casting control system for copper anode plates according to the present invention.
图6为本发明一种铜阳极板自动定量浇铸控制系统电磁比例阀反馈调节流程图。Fig. 6 is a flow chart of the electromagnetic proportional valve feedback adjustment of the copper anode plate automatic quantitative casting control system of the present invention.
图7为本发明一种铜阳极板自动定量浇铸控制系统速度反馈调节流程图。Fig. 7 is a flow chart of speed feedback adjustment of an automatic quantitative casting control system for copper anode plates according to the present invention.
图8为本发明一种铜阳极板自动定量浇铸控制系统重量反馈调节流程图。Fig. 8 is a flow chart of weight feedback adjustment of an automatic quantitative casting control system for copper anode plates according to the present invention.
图9为本发明一种铜阳极板自动定量浇铸控制系统6线制传感器接线图。Fig. 9 is a wiring diagram of a 6-wire sensor of an automatic quantitative casting control system for copper anode plates according to the present invention.
图10为本发明一种铜阳极板自动定量浇铸控制系统称重模块与计算机通讯接线图。Fig. 10 is a communication wiring diagram between a weighing module and a computer of a copper anode plate automatic quantitative casting control system of the present invention.
图11为本发明一种铜阳极板自动定量浇铸控制系统称重模块重量采集点示意图。Fig. 11 is a schematic diagram of a weighing module weight collection point of an automatic quantitative casting control system for copper anode plates according to the present invention.
图12为本发明一种铜阳极板自动定量浇铸控制系统浇铸曲线图。Fig. 12 is a casting curve diagram of an automatic quantitative casting control system for copper anode plates according to the present invention.
其中,1PLC控制器,2触摸屏,3称重模块,4称重传感器,5电磁比例阀,6输入单元,7接近开关,8控制按钮,9变频器,10电机,11输出单元,12电磁换向阀,13指示灯。Among them, 1 PLC controller, 2 touch screen, 3 weighing module, 4 weighing sensor, 5 electromagnetic proportional valve, 6 input unit, 7 proximity switch, 8 control button, 9 frequency converter, 10 motor, 11 output unit, 12 electromagnetic switch Directional valve, 13 pilot lights.
具体实施方式detailed description
下面结合附图与实施例对本发明作进一步说明。The present invention will be further described below in conjunction with the accompanying drawings and embodiments.
如图1所示,一种铜阳极板自动定量浇铸控制系统,包括PLC控制器1,安装在圆盘中间空腔的接近开关7通过输入单元6连接PLC控制器1的输入端;安装在浇铸包底座上的称重传感器4与称重模块3连接,称重模块3对称重信号进行信号调理和模数转换后发送给PLC控制器1,称重模块3的输出端还与调节浇铸包和中间包启动液压缸进油管进油量大小的电磁比例阀5连接;PLC控制器1通过变频器9控制圆盘驱动电机10的转动;PLC控制器1与安装在中间包进油管道中的电磁换向阀12连接;PLC控制器1与触摸屏2连接;PLC控制器1根据称重传感器4采集的浇铸包的重量计算出已浇铜水量并生成速度控制信号,作用于电磁比例阀5,使浇铸速度跟随设定的轨迹。As shown in Figure 1, a kind of copper anode plate automatic quantitative casting control system, comprises PLC controller 1, and the proximity switch 7 that is installed in the middle cavity of disc connects the input end of PLC controller 1 through input unit 6; The weighing sensor 4 on the base of the bag is connected with the weighing module 3, and the weighing module 3 performs signal conditioning and analog-to-digital conversion on the weighing signal and sends it to the PLC controller 1. The output terminal of the weighing module 3 is also connected with the adjustment casting bag and the The electromagnetic proportional valve 5 of the size of the oil inlet pipe for starting the hydraulic cylinder of the tundish is connected; the PLC controller 1 controls the rotation of the disc drive motor 10 through the frequency converter 9; the PLC controller 1 is connected with the electromagnetic valve installed in the oil inlet pipe of the tundish The reversing valve 12 is connected; the PLC controller 1 is connected with the touch screen 2; the PLC controller 1 calculates the amount of copper poured water according to the weight of the ladle collected by the load cell 4 and generates a speed control signal, which acts on the electromagnetic proportional valve 5, so that The casting speed follows the set trajectory.
接近开关7包括限位开关和停止接近开关。PLC控制器1还通过输入单元6与控制按钮8连接。PLC控制器1的输出端连接用于指示中间包回位到位、浇铸包回位到位及圆盘到位的指示灯13。触摸屏2与PLC控制器1通过RS485接口通讯连接,通过触摸屏2能监控铜水浇铸的工作状态,也能够通过触摸屏2修改设置PLC控制器1的参数以调整铜水浇铸工作状态。Proximity switch 7 comprises limit switch and stop proximity switch. The PLC controller 1 is also connected to a control button 8 via an input unit 6 . The output end of the PLC controller 1 is connected to an indicator light 13 for indicating that the tundish is in place, the casting ladle is in place and the disc is in place. The touch screen 2 is connected to the PLC controller 1 through the RS485 interface. The working state of the copper water casting can be monitored through the touch screen 2, and the parameters of the PLC controller 1 can also be modified and set through the touch screen 2 to adjust the working state of the copper water casting.
在本实施例中,PLC控制器1通过输出单元11连接电磁换向阀12和指示灯13。In this embodiment, the PLC controller 1 is connected to the electromagnetic reversing valve 12 and the indicator light 13 through the output unit 11 .
PLC控制器1安装在操作柜内部,选用的是SIEMENS S7-300,西门子300系列PLC模块化结构,具备高速指令运算速度,体积小、CPU运行速度快、存储器宽裕、软元件范围丰富,可插装扩展模块进行扩充输入、输出以及通讯。The PLC controller 1 is installed inside the operation cabinet, and SIEMENS S7-300 is selected. Siemens 300 series PLC has a modular structure, which has high-speed instruction operation speed, small size, fast CPU operation speed, ample memory, rich range of soft components, and pluggable Install expansion modules to expand input, output and communication.
触摸屏2内嵌安装在操作柜面板上,与PLC控制器1通讯连接,其中,触摸屏2与PLC控制器1的通讯方式为:接口类型RS232,通讯线接线方式是屏(母头)6、9、5——PLC(公头)3、2、9,4和5短接;同时通过组态软件编程监控圆盘浇铸机的工作状态,也可以由触摸屏2设置PLC控制器1调整圆盘浇铸机的工作参数。触摸屏2选用的是昆仑通态TPC1061Ti型嵌入式一体化触摸屏2,通过MCGS组态软件编译人机界面。The touch screen 2 is embedded and installed on the panel of the operation cabinet, and communicates with the PLC controller 1. The communication method between the touch screen 2 and the PLC controller 1 is: interface type RS232, and the connection mode of the communication line is screen (female) 6, 9 , 5——PLC (male) 3, 2, 9, 4 and 5 are short-circuited; at the same time, the working status of the disc casting machine can be monitored through configuration software programming, and the PLC controller 1 can be set on the touch screen 2 to adjust the disc casting machine operating parameters. The touch screen 2 is Kunlun Tongtai TPC1061Ti embedded integrated touch screen 2, and the man-machine interface is compiled through MCGS configuration software.
称重模块3,选用的是SIMATIC S7-300的一个功能块SIWAREX FTA,可以直接集成到S7-300底板总线上。80毫米的称重模块3的安装,电缆敷设要求极低,因为采用了DIN导轨组件和搭锁技术。标准40针前连接器用来连接称重传感器4,RS485串行接口、模拟输出和数字输入输出,9脚Sub-D插头用来连接PC(RS232)。SIWAREX FTA在SIMATIC中,意味着可保证将称重技术完全集成到自动化系统中。The weighing module 3 is selected as a function block SIWAREX FTA of SIMATIC S7-300, which can be directly integrated into the S7-300 backplane bus. The installation of the 80mm weigh module 3 requires minimal cabling due to the DIN rail assembly and snap-on technology. The standard 40-pin front connector is used to connect the load cell 4, RS485 serial interface, analog output and digital input and output, and the 9-pin Sub-D plug is used to connect to the PC (RS232). SIWAREX FTA in SIMATIC means a guaranteed full integration of weighing technology into the automation system.
称重传感器4,采用压式传感器,在称重传感器4的弹性体受到来自浇铸包重力方向的力时,弹性体发生相应的微量变形,此时粘贴在弹性体上的电阻应变片的各桥路电阻产生相应的阻值变化。由惠斯顿电桥原理,此时电阻应变片两端加上恒定的激励电压,则浇铸包重量的变化就会体现在应变片两端的电压差上,由此即可检测出其受力大小从而测得浇铸包的重量。The load cell 4 adopts a pressure sensor. When the elastic body of the load cell 4 is subjected to the force from the direction of gravity of the casting ladle, the elastic body undergoes a corresponding slight deformation. At this time, the bridges of the resistance strain gauges pasted on the elastic body The circuit resistance produces a corresponding change in resistance value. According to the principle of Wheatstone bridge, when a constant excitation voltage is applied to both ends of the resistance strain gauge, the change of the weight of the casting ladle will be reflected in the voltage difference between the two ends of the strain gauge, so that the force can be detected The weight of the casting ladle is thus measured.
电磁比例阀5,阀内比例电磁铁输入电压信号产生相应的动作,使工作阀阀芯产生位移,阀口尺寸发生改变,并以此完成与输入电压成比例压力、流量输出的元件。阀芯位置可以以机械、液压或电形式进行反馈。电液压比例阀组成使用电气及计算机控制电液系统,控制精度高,安装使用灵活且抗污染能力强。Electromagnetic proportional valve 5, the input voltage signal of the proportional electromagnet in the valve produces corresponding actions, which causes the displacement of the valve core of the working valve and the change of the valve port size, and completes the output of pressure and flow proportional to the input voltage. Spool position feedback can be mechanical, hydraulic or electrical. The electro-hydraulic proportional valve is composed of electric and computer-controlled electro-hydraulic system, which has high control precision, flexible installation and use, and strong anti-pollution ability.
接近开关7依次安装在中间包、浇铸包的回位位置以及转动圆盘内径确定位置的机构上。Proximity switch 7 is successively installed on the return position of tundish, casting ladle and the mechanism that rotates the internal diameter of disc to determine the position.
控制按钮8安装在控制柜操作面板上,作为PLC控制器1的数字输入信号。The control button 8 is installed on the operation panel of the control cabinet as the digital input signal of the PLC controller 1 .
变频器9,利用电力半导体器件的通断作用将工频电源变换为另一频率,实现对交流异步电机的软启动、变频调速、提高运转精度、改变功率因数、过流/过压/过载保护的功能。Inverter 9, using the on-off function of the power semiconductor device to convert the power frequency power supply to another frequency, realize the soft start of the AC asynchronous motor, frequency conversion speed regulation, improve operation accuracy, change power factor, overcurrent/overvoltage/overload protection function.
电磁换向阀12安装在中间包进油管道中,并可由PLC控制器1来控制其开关。The electromagnetic reversing valve 12 is installed in the oil inlet pipeline of the tundish, and its switch can be controlled by the PLC controller 1 .
一种铜阳极板自动定量浇铸控制系统的控制方法,包括,A control method for an automatic quantitative casting control system for copper anode plates, comprising:
如图5自动模式程序流程图所示,系统启动后,可通过操作室内控制柜上的按钮启动和停止自动浇铸。熔融状态下的铜水经溜槽流入中间包之后,到达一定重量后PLC控制器1通过控制电磁换向阀12使高压油进入控制中间包液压缸使中间包启动,铜水流入浇铸包内,浇铸包底座下称重装置内的称重传感器4将铜水重量压力值转换成电压信号传递到PLC控制器1的称重模块3内,将电压信号调理、滤波并进行模数转换传递到上位系统供PLC控制器1CPU调用处理;当浇铸包内的铜水重量达到设定值时,PLC控制器1通过输出单元11控制电磁换向阀12切换电磁阀位置使中间包回落;As shown in the automatic mode program flow chart in Figure 5, after the system is started, the automatic casting can be started and stopped through the buttons on the control cabinet in the operating room. After the copper water in the molten state flows into the tundish through the chute, when it reaches a certain weight, the PLC controller 1 controls the electromagnetic reversing valve 12 so that the high-pressure oil enters the hydraulic cylinder of the tundish to start the tundish, and the copper water flows into the casting ladle, and the casting The weighing sensor 4 in the weighing device under the package base converts the weight and pressure value of the copper water into a voltage signal and transmits it to the weighing module 3 of the PLC controller 1, and the voltage signal is conditioned, filtered, and converted to an analog-to-digital conversion and transmitted to the upper system For PLC controller 1 CPU to call and process; when the weight of copper water in the casting ladle reaches the set value, PLC controller 1 controls the electromagnetic reversing valve 12 through the output unit 11 to switch the position of the electromagnetic valve to make the tundish fall back;
等待圆盘运行到位后,接近开关7通过输入单元6会传递给PLC控制器1信号,从而形成浇铸包浇铸条件,PLC控制器1通过发送特定值电压给电磁比例阀5来控制浇铸包的浇铸速度,阀内比例电磁铁输入电压信号产生相应的动作,工作阀阀芯产生位移,阀口尺寸发生改变,并以此完成与输入电压成比例流量输出。阀芯位置可以以机械、液压或电形式进行反馈,如图6电磁比例阀反馈调节流程图。电液压比例阀组成使用电气及计算机控制电液系统,控制精度高,安装使用灵活且抗污染能力强;After waiting for the disk to run in place, the proximity switch 7 will pass the signal to the PLC controller 1 through the input unit 6, thereby forming the casting condition of the ladle. The PLC controller 1 controls the casting of the ladle by sending a specific value voltage to the electromagnetic proportional valve 5 The input voltage signal of the proportional electromagnet in the valve produces corresponding action, the valve core of the working valve is displaced, and the size of the valve port is changed, so as to complete the flow output proportional to the input voltage. The position of the spool can be fed back in the form of mechanical, hydraulic or electric, as shown in Figure 6 the flow chart of the feedback adjustment of the electromagnetic proportional valve. The electro-hydraulic proportional valve is composed of electric and computer-controlled electro-hydraulic systems, with high control precision, flexible installation and use, and strong anti-pollution ability;
阳极板浇铸时,中间包向浇铸包倾倒铜液,倾倒量由浇铸包称重传感器4检测,当达到设定值时,停止倾倒,待浇铸圆盘到位后,浇铸包开始倾倒铜液,同时PLC控制器1根据称重传感器4检测,对采集的称重信号进行分析,来控制浇铸包的倾倒速度,形成浇铸速度上的反馈调节,如图7浇铸速度反馈调节流程图;称重传感器4实时监测浇铸包内铜水重量,并将重量信号实时反馈从而形成铜水浇铸重量上的反馈调节,并在倾倒量达到收包重量的铜水时快速返回,从而达到实现铜阳极板精确定量浇铸的目的,如图8铜水浇铸重量反馈调节流程图。When the anode plate is being cast, the tundish pours copper liquid into the casting ladle, and the pouring amount is detected by the ladle weighing sensor 4. When the set value is reached, the pouring is stopped. After the casting disc is in place, the casting ladle starts pouring copper liquid, and The PLC controller 1 analyzes the collected weighing signal according to the detection of the weighing sensor 4 to control the pouring speed of the casting ladle and form a feedback adjustment on the casting speed, as shown in Figure 7. The flow chart of the casting speed feedback adjustment; the weighing sensor 4 Monitor the weight of copper water in the casting ladle in real time, and feed back the weight signal in real time to form a feedback adjustment on the casting weight of copper water, and return quickly when the amount of poured copper water reaches the weight of the bag, so as to achieve accurate and quantitative casting of copper anode plates For the purpose, as shown in Figure 8, the flow chart of copper water casting weight feedback adjustment.
PLC根据对浇铸包重量的采样值计算出已浇铜水量,产生速度控制信号,作用于浇铸液压回路中的电液伺服调节阀,使浇铸速度跟随给定的轨迹。速度控制的信号的产生,首先要依据称重模块3对浇铸包的重量采集值,来计算出当前的浇铸速度,对于浇铸速度的计算,称重模块3采集5个或10个浇铸包重量的点,运用最小二乘法计算出该时刻的速度值。要采集某个时刻t1该点的浇铸速度,以t1时刻的重量值为起点(包括t1时刻的重量值)开始连续采集其后的5(或10)个时刻点的重量值,运用最小二乘法计算出的值作为该时刻t1的速度值,如图11重量采集点示意图所示。The PLC calculates the amount of copper poured water based on the sampling value of the weight of the casting ladle, generates a speed control signal, and acts on the electro-hydraulic servo regulating valve in the casting hydraulic circuit to make the casting speed follow a given trajectory. For the generation of the speed control signal, the current casting speed must be calculated based on the weight collection value of the casting ladle by the weighing module 3. For the calculation of the casting speed, the weighing module 3 collects the weight of 5 or 10 casting ladles. Point, using the least square method to calculate the velocity value at this moment. To collect the casting speed at this point at a certain time t1, starting from the weight value at time t1 (including the weight value at time t1), start to continuously collect the weight values at the subsequent 5 (or 10) time points, and use the least square method The calculated value is used as the speed value at the time t1, as shown in the schematic diagram of the weight collection point in FIG. 11 .
给定轨迹的设定,该曲线与浇铸秤称重传感信号配合,通过浇铸数学模型对采集的浇铸秤称重信号进行分析,经PLC控制器1对浇铸秤各阶段动作输出适当的电压来控制浇铸包液压缸比例阀的精确动作。输出电压包括6个阶段:启动段、等待出铜段、加速段、均速段、减速段、收包段,如图12为电压(即浇铸速度)曲线图。Given the setting of the trajectory, the curve is coordinated with the weighing sensor signal of the casting scale, and the collected weighing signal of the casting scale is analyzed through the casting mathematical model, and the appropriate voltage is output for each stage of the casting scale through the PLC controller 1. Control the precise movement of the hydraulic cylinder proportional valve of the casting ladle. The output voltage includes 6 stages: start-up stage, waiting for copper out stage, acceleration stage, constant speed stage, deceleration stage, and package receiving stage, as shown in Figure 12 for the voltage (casting speed) curve.
浇铸包在倾倒铜水的过程中,各浇铸曲线之间通过状态量进行切换,状态量的方式为:During the process of pouring copper water in the casting ladle, each casting curve is switched through the state quantity, and the state quantity is in the following way:
1)浇铸包在启动段进行并保持2秒后,即进入等待出铜段;1) After the casting ladle is carried out in the start-up section and held for 2 seconds, it enters the waiting section for copper discharge;
2)等待出铜段、加速段、匀速段、减速段、收包段之间以设定重量与实际重量的比较结果来切换,当各段的实际重量大于或等于设定重量后,即进入到下一曲线段;2) Waiting to switch between the copper output section, acceleration section, constant speed section, deceleration section, and package receiving section based on the comparison results between the set weight and the actual weight. When the actual weight of each section is greater than or equal to the set weight, enter to the next curve segment;
3)减速段与收包段之间的切换以收包点重量为切换标志。3) The switch between the deceleration section and the packet receiving section takes the weight of the packet receiving point as the switch symbol.
启动段电磁比例阀的控制电压先以恒定的增加速率增加,增加到设定的最大值后保持最大值不变,延时设定时间后达到等待出铜段;The control voltage of the electromagnetic proportional valve in the start-up section increases at a constant rate of increase first, and then keeps the maximum value unchanged after increasing to the set maximum value, and reaches the waiting copper output section after a delay of the set time;
等待出铜段电磁比例阀的控制电压以恒定速率递减,递减到设定值后到达出铜段;Wait for the control voltage of the electromagnetic proportional valve in the copper outlet section to decrease at a constant rate, and reach the copper outlet section after decreasing to the set value;
出铜段电磁比例阀的控制电压保持设定值不变,经过设定延时后到达加速段;The control voltage of the electromagnetic proportional valve in the copper outlet section keeps the set value unchanged, and reaches the acceleration section after the set delay;
加速段给电磁比例阀的电压值逐渐减小,模型公式为指数函数e^x+f,由于浇铸包内铜水液面变宽,铜水仍快速流出,到达设定值后进入匀速段;The voltage value of the electromagnetic proportional valve in the acceleration section decreases gradually, and the model formula is an exponential function e^x+f. Since the copper water liquid level in the casting ladle becomes wider, the copper water still flows out quickly, and enters the constant speed section after reaching the set value;
匀速段输出较小恒定电压给比例伺服阀,此时曲线模型公式为恒定值g,经过设定延时后到达减速段;The constant speed section outputs a small constant voltage to the proportional servo valve. At this time, the curve model formula is a constant value g, and it reaches the deceleration section after a set delay;
减速段系统输出给电磁比例阀的电压越来越小,以便捕捉和确定浇铸包收包点,曲线模型公式为指数函数h^x+I,到达设定值后再以恒定速率增加,增加到设定之后达到收包段;The voltage output from the deceleration section system to the electromagnetic proportional valve is getting smaller and smaller in order to capture and determine the casting wrapping point. The formula of the curve model is an exponential function h^x+I. After reaching the set value, it increases at a constant rate until it reaches the set value. After setting, it reaches the packet receiving segment;
收包段输出给电磁比例阀的电压以恒定的速率迅速减小到0,使铜水尽量少的流出,减少浇铸误差。The voltage output from the receiving section to the electromagnetic proportional valve is rapidly reduced to 0 at a constant rate, so that the copper water flows out as little as possible and the casting error is reduced.
本控制系统除了包括以上的自动控制外还可以包括运行于手动控制模式和测试功能模式。In addition to the above automatic control, the control system can also include a manual control mode and a test function mode.
手动控制模式:如图3手动模式流程图所示,系统启动后,将旋转开关选择到手动模式。可通过操作室内控制柜上的控制开关8通过输入单元6发送信号给PLC控制器来控制中间包倾倒及回落、浇铸包的启动浇铸及回落,浇铸圆盘机正转与反转等动作。在调试设备时以及自动模式出现故障时可切换到手动模式进行操作。Manual control mode: As shown in the flow chart of manual mode in Figure 3, after the system starts, select the rotary switch to manual mode. The control switch 8 on the control cabinet in the operation room can send signals to the PLC controller through the input unit 6 to control the dumping and falling of the tundish, the starting and falling of the casting ladle, the forward and reverse rotation of the casting disc machine, etc. It can be switched to manual mode for operation when debugging the equipment and when the automatic mode fails.
功能测试模式:如图4测试功能模式流程图所示,将旋转按钮选择到测试功能模式时,设备将在无负载情况下依次启动中间包、浇铸包以及运行圆盘,完成浇铸流程动作,此模块的功能是在铜水浇铸开始前,对整个浇铸系统的各个环节进行模拟运行,可提前检测出潜在系统错误及机械故障。Function test mode: as shown in the flow chart of test function mode in Figure 4, when the rotary button is selected to test function mode, the equipment will start the tundish, casting ladle and running disc in sequence under no-load conditions to complete the casting process action. The function of the module is to simulate each link of the entire casting system before the copper water casting starts, so as to detect potential system errors and mechanical failures in advance.
上述虽然结合附图对本发明的具体实施方式进行了描述,但并非对本发明保护范围的限制,所属领域技术人员应该明白,在本发明的技术方案的基础上,本领域技术人员不需要付出创造性劳动即可做出的各种修改或变形仍在本发明的保护范围以内。Although the specific implementation of the present invention has been described above in conjunction with the accompanying drawings, it does not limit the protection scope of the present invention. Those skilled in the art should understand that on the basis of the technical solution of the present invention, those skilled in the art do not need to pay creative work Various modifications or variations that can be made are still within the protection scope of the present invention.
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