JP5624489B2 - Melting process automatic creation device and melting process automatic creation method - Google Patents

Description

  The present invention relates to a melting process automatic creation apparatus and a melting process automatic creation method for automatically planning a melting process in the casting field.

  In a foundry, a plurality of casting lines composed of many processes such as molding, melting, and pouring are installed, and in order to manage the plurality of casting lines, an advanced process management method has been conventionally required. However, at present, the process management of the casting line is performed based on the experience of skilled technicians. Relying on the experience of skilled technicians does not allow standardization of work and visualization of processes, and therefore needs for standardization of work and visualization of processes are increasing. In particular, cost reduction by shortening lead time such as energy reduction in melting and heating process from melting furnace, which is a high energy consumption process, is an enduring proposition, but it is a general purpose introduced to overcome this proposition. IT process management software and energy monitoring software are not in line with the actual situation in the field, and the introduction effect is unknown.

  In order to overcome the above-mentioned proposition, Patent Document 1 shows an example in which the temperature control technology of a melting furnace is to be realized by using IT, and the melting material to be introduced into the melting furnace is completely determined from the weight and characteristic values of the melting material. The amount of electric power required for melting is calculated in advance by a calculation means, the molten material is melted by supplying electric power based on this electric energy, and the temperature of the molten metal is automatically measured by the temperature measuring means after the melting of the molten material is completed, The required supply power amount is obtained from the temperature difference between the automatically measured temperature of the melt and the target temperature of the melt, and the melt is raised to the target temperature from the required supply power amount and a preset melting time. The amount of power supplied is calculated by the calculation means. By doing this, it is possible to complete the dissolution accurately within a predetermined dissolution time, so when the cycle time is fixed, the remaining time is used for heat retention to reduce the energy loss as much as possible. .

JP-A-3-152390

  In general, the melting process is time consuming, and it is physically difficult to perform a small amount of melting compared to the capacity of the furnace, so it is impossible to do it immediately based on downstream process requirements In addition, it is difficult to control the melting process while looking at the situation such as pouring, and the casting process depends on the output of the melting process. Under the circumstances where the dissolution is not in time, the so-called hot water waiting state occurs and the production is stopped. From these reasons, in the present melting process, the melting process is always performed with full melting and waiting for the hot water.

  However, in the method of always dissolving and holding fully and waiting for the hot water, energy is consumed for holding, and this increases the manufacturing cost. In addition, when there are multiple furnaces, in order to operate the furnace so as not to hinder the production plan for the day, the furnace condition (cooling furnace melting and normal melting) and operation method (all hot water tapping hot water) Therefore, advanced work process planning and management by skilled technicians are necessary. Therefore, a limited number of technicians need to plan. In addition, when a line failure occurs during molding or pouring process, it is necessary to reconfigure the entire process in consideration of the status of the remaining hot water. It is necessary to change the operation method in consideration of the current situation and the situation of the pouring process.

  The present invention has been made in view of such circumstances, the purpose of which is to minimize the energy without disturbing the operation, and the melting process automatic creation device capable of planning a replan at the time of failure, Another object of the present invention is to provide a method for automatically creating a melting process.

In order to solve the above-mentioned problems, the present invention relates to a melting process automatic creation device for producing a cast product by moving a molten metal from a melting furnace to a pouring machine, and the necessary molten metal for each molding line from information notified from a production schedule. Based on the necessary molten metal amount holding means that reads and holds the information necessary for creating the melting process regarding the amount, material, and moving speed of the molding line, the first melting furnace A first pouring machine / melting furnace remaining hot water amount calculating means for calculating the amount of remaining hot water in the pouring machine and the remaining amount of the melting furnace in a time unit in seconds until “empty” or a specified weight, and the remaining molten metal amount of the melting furnace Select at least one of the second and subsequent smelting furnaces in time to become “empty” or when the specified weight is reached. Based on the selected smelting furnace, Calculate the amount of hot water and the remaining amount of melting furnace in time series in seconds At least a second pouring machine / melting furnace remaining hot water amount calculating means, wherein the second pouring machine / melting furnace remaining hot water amount calculating means is supplied from the first pouring machine / melting furnace remaining hot water amount calculating means. The melting furnace set in advance through the standard operation pattern setting screen based on the point of time when the first molten furnace remaining hot water amount is “empty” or becomes the designated weight upon receipt of the notification regarding the time when it becomes weight can be discharged. that takes to until the initial dissolution time, usually the dissolution time, going back by the time of the combined components adjustment time and temperature rise time to plan for the step of starting the dissolution of the second furnace, the first and second A pouring machine and a melting furnace residual hot water amount calculation result output means for obtaining a predetermined amount of time-series calculation by the second unit and outputting the result of the calculation. Features.

In the above, the information notified from the production schedule includes the name of the melting furnace that can be used to manufacture the casting, the specification of the melting furnace ( presenting the energy unit catalog value), the name of the pouring machine, and the movement of the molding line It is characterized by equipment data including speed and production process data including a material necessary for manufacturing a cast product, a planned production amount, and a scheduled production start time.

Further, in the above, the pouring machine / melting furnace remaining hot water amount calculation result output means includes the pouring machine remaining hot water amount and the melting furnace remaining hot water amount calculated by the first and second pouring machine / melting furnace remaining hot water amount calculating means. The calculation result is used to calculate the energy intensity and production amount and output as a melting process planning result, and the measurement information obtained from the output and various measuring instruments provided in the pouring machine and the melting furnace and the state of the melting furnace on the basis of the production schedule information, characterized by further comprising a planning and performance management means for managing the display to planning and performance-measuring changes pre energy consumption.

  In the above, the first and second pouring machine / melting furnace remaining hot water amount calculation means start a recalculation process for the line when a line failure occurs in the pouring process or molding, etc. Including the amount of hot water in the pouring machine and the amount of hot water in the melting furnace in the planned execution of this line, taking into account the amount of hot water in the pouring machine and the amount of hot water in the melting furnace at the start of recalculation in the line The apparatus further comprises means for re-creating.

In the above, when there are a plurality of furnaces, the second pouring machine-melting furnace the remaining hot water calculating means, to grasp the state of the three eyes of the furnace, which furnace has a tapping waiting Is selected as the first priority, and if the selection according to the first priority is not possible, the furnace in the stopped state after tapping is selected as the second priority, and the selection according to the second priority is not possible. In some cases, the furnace is selected in a stopped state.

In the above, in the case of selecting a furnace after the second priority, the priorities are set as follows: (b) priority set by the user, (b) good energy intensity, (c) furnace use order, (d) operation It is characterized by determining as time.

  In the above, when the first and second pouring machine / melting furnace remaining hot water amount calculation means must melt an amount of raw material less than the rated capacity of the furnace just before the melting process plan is finished, the melting process plan It is further characterized by further comprising means for checking whether or not the remaining hot water can be melted by using the free time in the process plan normally executed before the end.

Further, the present invention is a melting process automatic creation method in a melting process automatic creation apparatus for producing a cast product by moving a molten metal from a melting furnace to a pouring machine, and is necessary for each molding line from information notified from a production schedule. The first melting furnace is `` empty '' based on the process of reading and holding the information necessary for creating the melting process related to the amount of molten metal, material, and moving speed of the molding line, and holding the necessary amount of molten metal Alternatively, the first calculation process of calculating the remaining amount of the pouring machine and the remaining amount of the melting furnace in a time series in seconds until the specified weight is reached, the time when the remaining amount of the molten furnace is “empty” or reaches the specified weight. Select at least one of the second and subsequent melting furnaces, and based on the selected melting furnace, the amount of hot water in the pouring machine and the amount of hot water in the melting furnace are time-sequential in seconds as in the first. Including at least a second calculation process to calculate, Serial second calculation process, the pre-standard operation pattern the notified about the time at which the gravity first melting furnace the remaining hot water is in the base point time at which the gravity of the "empty" or specified from the first calculation process that the melting furnace set via the setting screen takes to until it can be tapped, the initial dissolution time, usually dissolution time, dissolution of furnace second back by the time of the combined components adjustment time and temperature rise time And a process of planning for the process of starting the process, and a process of obtaining the calculation for the predetermined time and outputting the result in the first and second calculation processes.

  In the above, the plan / result management means, as a method of analyzing energy consumption, a standard operation pattern and a result defined for each induction furnace in advance, a means for comparing and displaying time and power consumption, And a means for time-integrating and comparing power transitions in a certain period and another certain period according to the magnitude of power demand.

According to the present invention, the information necessary for creating the melting process related to the amount, material, and moving speed of the molding line required for each molding line is read from the information notified from the production schedule and retained, and the necessary necessary molten metal is retained. A first calculation process for calculating the amount of hot water remaining in the pouring machine and the amount of hot water remaining in the melting furnace in a time series in seconds until the first melting furnace becomes “empty” or reaches a specified weight based on the amount, the melting Select at least one of the second and subsequent smelting furnaces in time for the amount of remaining hot water to be “empty” or the specified weight, and note the same as the first based on the selected smelting furnace. It includes at least a second calculation process for calculating the remaining amount of hot water in the hot water and the remaining amount of melting furnace in a time series in seconds, and the second calculation process receives the notification about the time when the weight is obtained from the first calculation process. 1st melting furnace remaining hot water amount is empty or specified The melting furnace in the base point time at which the gravity was set through the pre-standard operation pattern setting screen that takes to until it can be tapped, the initial dissolution time, usually the dissolution time, the component adjustment time and temperature rise time The process of starting melting of the second furnace retroactively by the combined time is planned, and the calculation in the first and second calculation processes is obtained for a predetermined time and the result is output, thereby producing a cast product. The energy of casting production can be minimized without hindering the operation.

Moreover, since the melting | dissolving operation is started retroactively from the time when the amount of remaining hot water of a melting furnace becomes below fixed, the operating method of a furnace can reduce the energy loss for melt | dissolution maintenance.
In addition, since the third and subsequent furnaces can be selected when the furnace is required depending on the energy intensity and the order in which the furnaces are used, castings can be manufactured without hindering the operation of castings. The energy of can be minimized.

  In addition, since the replanning at the time of line stoppage can be performed quickly, delays in production planning can be minimized. In addition, it is possible to display the planned value by calculating the energy intensity based on the created process plan, and various measurement data in actual operation can be displayed here, so the casting process by visualizing the process It can contribute to the overall improvement.

  Moreover, since the energy consumption performance can be comparatively analyzed, it can contribute to energy saving activities.

It is a functional block diagram which implement | achieves the processing content of the melt | dissolution process automatic creation apparatus which concerns on embodiment of this invention. It is a block diagram which shows the hardware constitutions of the melt | dissolution process automatic creation apparatus which concerns on embodiment of this invention. It is a flowchart for demonstrating operation | movement of the melting process automatic creation apparatus which concerns on embodiment of this invention. It is a figure which shows the process image in each flow of the melt | dissolution process creation process shown in FIG. It is a schematic diagram for demonstrating the whole processing content in the melt | dissolution process automatic creation apparatus which concerns on embodiment of this invention. It is a figure which shows the relationship between the furnace which concerns on embodiment of this invention, and a pouring machine. It is a flowchart for demonstrating the casting process of the melt | dissolution process automatic creation apparatus which concerns on embodiment of this invention without a buffer. It is a flowchart for demonstrating the new furnace selection process in step S14, S22 shown to FIG. 7A. It is a flowchart for demonstrating the casting process of the melt | dissolution process automatic creation apparatus which concerns on embodiment of this invention with a buffer. It is a flowchart for demonstrating the processing content in step S53 shown to FIG. 8A. It is a flowchart for demonstrating the new furnace selection process in step S46, S56, S536 shown to FIG. 8A and 8B. It is a figure which shows the example of the casting process by the melt | dissolution process created by embodiment of this invention. It is a screen display example which shows the mode at the time of the completion of the plan by the melt | dissolution process automatic creation apparatus which concerns on embodiment of this invention. It is an example of a screen display which shows the plan and actual measurement of production amount and electric energy managed by the plan / result management means according to the embodiment of the present invention. It is a figure for demonstrating the restart function in the melt | dissolution process automatic creation apparatus which concerns on embodiment of this invention. It is a figure which shows the process flow outline | summary for determining the possibility of residual hot-metal melt | dissolution in the melt | dissolution process automatic preparation apparatus which concerns on embodiment of this invention. It is a screen display example which shows the comparison of a standard driving | operation pattern and actual measurement analyzed by the plan and results management means which concern on embodiment of this invention. It is an example of a screen display which compares the power transition of a certain period and another period analyzed by the plan / actual result management unit according to the embodiment of the present invention by integrating the time according to the magnitude of power demand.

Hereinafter, embodiments of the present invention will be described in detail.
FIG. 1 is a functional block diagram for realizing processing contents of a melting process automatic creation apparatus according to an embodiment of the present invention. The melting process automatic creation device 100 shown in FIG. 1 reads and holds information necessary for creating a melting process such as the amount of molten metal, quality (material), and tact information required for each line from information notified from the production schedule. Based on the required amount of molten metal holding means 110 and the amount of molten metal held, the amount of remaining hot water and the amount of molten metal remaining in the melting furnace until the first melting furnace is `` empty '' or reaches the specified weight in seconds The first pouring machine / melting furnace remaining hot water amount calculating means 120 for calculating the time series of the above, and any of the second and subsequent melting furnaces in time for the amount of remaining melting furnace water to be “empty” or to become the specified weight Select one of them, and then calculate the remaining amount of the pouring machine and the remaining amount of the melting furnace in the time series in seconds based on the selected melting furnace as in the first case. The hot water amount calculating means 130 to the nth pouring machine / melting furnace remaining hot water amount calculating means 140, the first to nth Time-series calculation in seconds by the pouring machine / melting furnace remaining water amount calculation means 120 to 140 is obtained for a predetermined time (eg 24 hours) and the result is output. The plan / actual data management based on the output of the means 150 and the output of the pouring machine / melting furnace residual quantity calculation result output means 150, the measurement information obtained from the pouring machine and the melting furnace, and the above production schedule information And a track record management means 155. In the above, n is an integer of 2 or more. However, in the case of n = 2, the nth pouring machine / melting furnace remaining hot water amount calculating means 140 is unnecessary because it overlaps with the second pouring machine / melting furnace remaining hot water amount calculating means 130.

  In FIG. 1, signal lines 160, 170, 180, and 190 between the respective pouring machines and melting furnace residual water amount calculation means are, for example, at the timing when the first melting furnace residual water amount is “empty” or becomes a specified weight. The second melting furnace is selected in time, or a different furnace is selected by changing the material, etc., and the calculation of the remaining amount of hot water and melting furnace in the selected furnace is entrusted.

  FIG. 2 is a block diagram showing a hardware configuration of the melting process automatic creating apparatus according to the embodiment of the present invention. The melting process automatic creating apparatus 1100 is controlled by a CPU (Central Processing Unit) 1101 as a whole. A random access memory (RAM) 1102, a hard disk drive (HDD) 1103, a graphics processing device 1104, an input interface 1105, and an external connection control unit 1107 are connected to the CPU 1101 via a bus 1106.

  The RAM 1102 temporarily stores at least part of an OS (Operating System) program and application programs to be executed by the CPU 1101. The RAM 1102 stores various data necessary for processing by the CPU 1101. The HDD 1103 stores an OS program and application programs.

  A monitor 21 is connected to the graphic processing device 1104. The graphic processing device 1104 displays an image on the screen of the monitor 21 in accordance with a command from the CPU 1101. A keyboard 22 and a mouse 23 are connected to the input interface 1105. The input interface 1105 transmits a signal sent from the keyboard 22 or the mouse 23 to the CPU 1101 via the bus 1106. A connection I / F 24 is connected to the external connection control unit 1107. The external connection control unit 1107 transmits a signal sent from the connection I / F 24, for example, production schedule information, to the CPU 1101 via the bus 1106.

With the hardware configuration described above, the processing functions of the present embodiment as described above or shown below can be realized.
FIG. 3 is a flowchart for explaining the operation of the melting process automatic creating apparatus according to the embodiment of the present invention. In FIG. 3, in STEP1, the required amount of molten metal is read and held. That is, information necessary for creating a melting process such as the amount of molten metal, quality (material), and tact information required for each molding line is read and held from information notified from the production schedule. Next, in STEP2, based on the required amount of molten metal held, the amount of hot water remaining in the pouring machine and the amount of molten metal remaining until the first melting furnace is “empty” or reaches the specified weight are calculated in time series in seconds. To do. In STEP 3, select one of the second and subsequent melting furnaces in time for the amount of remaining molten metal to be “empty” or the specified weight, and the first one based on the selected melting furnace. As with, calculate the amount of hot water remaining in the pouring machine and the amount of hot water in the melting furnace in a time series in seconds. Finally (Step 4 is omitted), it is determined whether or not the calculation of the remaining amount of the pouring machine / melting furnace has been completed for a predetermined time (eg, 24 hours). If not, the processing from STEP 2 is executed. If completed, the process is terminated.

  FIG. 4 is a diagram showing a processing image in each flow of the melting step creation processing shown in FIG. As shown in FIG. 3, in STEP1, the required amount of molten metal is read and held. That is, information necessary for creating a melting process such as the amount of molten metal, quality (material), and tact information required for each molding line is read and held from information notified from the production schedule. An example is shown in the upper part of the figure. That is, 0.2 tons per minute for 60 minutes, that is, 12 tons of molten metal is required, and 0.2 tons per minute for 30 minutes, that is, 6 tons of molten metal is required. In addition to reading and holding the required amount of molten metal for 24 hours along with the product type (material) and tact information for each molding line, for example, 0.3 tons are required for 60 minutes, that is, 18 tons of molten metal is required. Confirm by displaying on the screen. The tact information indicates information on how many seconds the hot water is poured into the mold installed on the molding line.

  Next, in STEP2, based on the required amount of molten metal held, the amount of hot water remaining in the pouring machine and the amount of molten metal remaining until the first melting furnace is `` empty '' or reaches the specified weight in a time series in seconds. calculate. In the illustrated example, the state where the No. 1 furnace is used and it becomes “empty”, that is, as shown in the middle stage in the figure, the state in which the remaining amount of hot water pouring machine transitions in a sawtooth shape from the upper limit to the lower limit is shown. The hot water transitioning in this way is repeated a plurality of times, and the remaining amount of the melting furnace becomes “empty”. The state in which the No. 1 furnace becomes “empty” is shown in the lower part of the figure.

  In STEP3, select one of the second and subsequent melting furnaces, in the example shown, No. 2 furnace in order to meet the timing when the amount of remaining molten metal is “empty” or the specified weight, and the selected melting furnace Based on the above, calculate the amount of hot water remaining in the pouring machine and the amount of hot water in the melting furnace in a time series in seconds as in the first case. In the illustrated example, the molten metal melted in the selected No. 2 furnace is poured into the molding line, and before it becomes “empty”, the No. 1 furnace is selected and the molten metal melted in the No. 1 furnace is used. The case of pouring hot water into the molding line is shown. In this case, two furnaces are used and scheduling is possible with at most two pouring machines / melting furnace residual water amount calculation means. It is what.

In the last step (the description of STEP 4 is omitted), a plan for using up the necessary amount of molten metal held in STEP 1 by repeating STEP 2 and STEP 3 as described above is made.
FIG. 5 is a schematic diagram for explaining the entire processing contents in the automatic melting process creation apparatus according to the embodiment of the present invention. The uppermost portion shown in FIG. 5 shows a state in which the products A, B, C, and D are cast by pouring hot water into a mold (tact) provided on a movable molding line. As shown in the figure, the products that are manufactured in the tact after the mold is exchanged in the middle of the molding line are partially different.

  The uppermost part in the square frame shown in FIG. 5 shows information on how much (weight display, unit kilogram) the above-mentioned product is made for each tact. The second from the top in the square frame shows the amount of molten metal required to make these products. And the 3rd from the top in a square frame shows transition of the amount of remaining hot water of a pouring machine as shown also in FIG.

  The fourth from the top in the square frame shows the transition of the selection of the furnace and the amount of remaining hot water in the furnace, and in the illustrated example, an example using the No. 1 furnace and No. 2 furnace is shown. The lowermost part of the square frame indicates the amount of electric power calculated based on the melting cycle set in advance in the furnaces of the No. 1 and No. 2 furnaces. The amount of power to be used is displayed in a graph depending on whether the power is used.

  FIG. 6 is a diagram showing the relationship between the furnace and the pouring machine according to the embodiment of the present invention. As shown in FIG. 6A, pouring is performed from the ladle 1 provided for the first furnace to the pouring machine 1, and from the pouring machine 1 to the mold of the molding line 1. An example is shown, and a hot water is poured into a buffer from a ladle 3 provided for the No. 3 furnace, and a hot water is poured from the buffer into a hot water pouring machine 2. An example in which pouring is performed on the mold is shown. Normally, pouring is performed directly from the ladle provided for the furnace (= ladle) to the pouring machine, or from the ladle provided for the furnace to the buffer, and from the buffer. The system is designed by either pouring the pouring machine. For this reason, in FIG. 6, the case of passing through the buffer is displayed with a broken line. In addition, a ladle is also necessary for the buffer, but it is not shown.

  6B is divided into a case where there is no buffer indicated by a solid line in FIG. 6A and a case where there is a buffer indicated by a broken line in FIG. 6A. It is outlined so that you can understand how. (1) When there is no buffer, pouring is performed directly from the ladle provided for each furnace to the pouring machine. On the other hand, (2) when there is a buffer, hot water is stored in the buffer from the ladle provided for each furnace, and hot water is poured into the pouring machine using the buffer ladle.

  FIG. 7A is a flowchart for explaining a casting process of the melting process automatic creating apparatus according to the embodiment of the present invention without a buffer. As a premise of starting the processing of FIG. 7A, it is limited to the use line (j: maximum use line number = 3) that loops in time (i: seconds, 24 hours = 86400 seconds) and is used as a molding line. To loop. Then, as shown in FIG. 7A, in step S11, it is determined whether or not there is a casting start / material change. If there is a casting start / material change, the process proceeds to step S12. As a premise of proceeding to step S12, the processing is executed only for the furnace to be used (k: maximum number of furnaces = 5). In step S12, it is determined whether material (k, i) = same material and state (k, i) = waiting hot water. If the same material and hot water are waiting, the furnace is set as the supply furnace in step S13. If it is not waiting for the same material and hot water, the process proceeds to step S14, and a new furnace selection process shown in FIG. 7B is executed in step S14. If no furnace matching the conditions is found in all the furnaces in the new furnace selection process in step S14, the process proceeds to step S15 and the scheduling ends. If the furnace can be selected, the process proceeds to step S16, and the selected furnace is set as the supply furnace.

  After the source furnace is set in step S16 or step S13, and if there is no casting start / material change in step S11, the process proceeds to step S17, and in step S17, the amount of hot water remaining in the pouring machine (j, i) = remaining The amount of hot water (j, i-1) is set to the casting amount. In this case, the arrangement of the remaining amount of hot water pouring machine (time i × line j) is referred to.

  Next, in step S18, it is determined whether the remaining amount of hot water pouring machine (j, i) ≦ lower limit. If the amount of remaining hot water in the pouring machine (j, i) is below the lower limit, the process proceeds to step S19, where the remaining amount of hot water in the pouring machine (j, i) = remaining hot water (j, i) + ladle amount is set. The In this case, reference is made to the ladle of the source furnace (j, i) supplied to the pouring machine j at the time point i and the arrangement of the remaining amount of hot water pouring machine (time i × line j). One ladle is provided for each furnace, and the amount of ladle varies depending on each furnace. Then, the process proceeds to step S20. In step S20, the amount of remaining hot water (k, i-ladle movement time) = remaining hot water amount (j, i-ladle movement time-1)-ladle amount is calculated. In this case, k = supplier furnace (j, i), and the movement starts before the “movement time” before the pouring machine falls below the lower limit.

  In step S21, it is determined whether the remaining furnace water amount (k, i) ≦ lower limit. If the remaining furnace water amount (k, i) is less than or equal to the lower limit, the process proceeds to step S22, and a new furnace selection process shown in FIG. 7B is executed in step S22. If no furnace matching the conditions is found in all the furnaces in the new furnace selection process in step S22, the process proceeds to step S23 and the scheduling is terminated. If the furnace can be selected, the process proceeds to step S24, where the selected furnace is set as the supply furnace, the head is returned to the next for the next scheduling, and the scheduling is repeated. On the other hand, if the remaining furnace water amount (k, i) is not less than the lower limit in the determination in step S21, and if the remaining hot water amount (j, i) is not less than the lower limit in the determination in step S18, the next scheduling is performed. Therefore, go back to the top and repeat the scheduling.

  FIG. 7B is a flowchart for explaining a new furnace selection process in steps S14 and S22 shown in FIG. 7A. As a premise for starting the new furnace selection process shown in FIG. 7B, k is set to one of the maximum number of furnaces for furnace selection, and the furnace is used as a furnace (k: maximum furnace) Processing is limited to number = 5). In step S31, the furnace (k) is selected according to the priority order. In this case, the priority is determined from (1) priority set by the user, (2) basic unit, (3) order, and (4) operating time. Note that the operating time is selected from the reset immediately after the maintenance and the one with less integrated power (kWh) or rated kW.

  Next, the process proceeds to step S32, and in step S32, it is determined whether or not the furnace use state (k, i-melting time (k)) is hot water completion / remaining hot water holding / stopping. If the use state of the furnace in step S32 is any of hot water completion / remaining hot water holding / stopping, the process proceeds to step S33, the furnace is set as a supply furnace in step S33, and the furnace is set in step S32. If the furnace used is not in the state of hot water completion / remaining remaining hot water / stopped, the next furnace selection process is executed. If the maximum furnace number is not found, proceed to step S34 to select the furnace. Processing is terminated as impossible.

  FIG. 8A is a flowchart for explaining a casting process of the melting process automatic creating apparatus according to the embodiment of the present invention with a buffer. As a premise of starting the processing of FIG. 8A, it is limited to the use line (j: maximum number of use lines = 3) that loops in time (i: seconds, 24 hours = 86400 seconds) and is used as a molding line. To loop. Then, as shown in FIG. 8A, in step S41, it is determined whether or not casting starts / materials are changed. If there is a casting start / material change, the process proceeds to step S42. In step S42, it is determined whether the buffer is made of material = same material and state = waiting for hot water. If the same material and hot water are waiting, the process proceeds to step S43, and the buffer is set as the supply source. If it is not waiting for the same material and hot water, the process proceeds to step S44. As a premise for proceeding to step S44, the processing is executed only for the furnace to be used (k: maximum number of furnaces = 5). In step S44, it is determined whether material (k, i) = same material and state (k, i) = waiting hot water. If the same material and hot water are waiting, the furnace is set as the supply furnace in step S45. If it is not waiting for the same material and hot water, the process proceeds to step S46, and a new furnace selection process shown in FIG. 8C is executed in step S46. If no furnace matching the conditions is found in all the furnaces in the new furnace selection process in step S46, the process proceeds to step S47 and the scheduling is terminated. If the furnace can be selected, the process proceeds to step S48, and the selected furnace is set as the supply furnace.

  After the source furnace is set in step S43, step S45 or step S48, and if there is no start of casting / material change in step S41, the process proceeds to step S49, and in step S49, the remaining amount of hot water in the pouring machine (j, i ) = Residual hot water amount (j, i-1)-Casting amount. In this case, the arrangement of the remaining amount of hot water pouring machine (time i × line j) is referred to.

  Next, in step S50, it is determined whether the remaining amount of hot water pouring machine (j, i) ≦ lower limit. If the pouring machine remaining hot water amount (j, i) is less than the lower limit, the process proceeds to step S51, and in step S51, the pouring machine remaining hot water amount (j, i) = remaining hot water amount (j, i) + ladle amount is set. The In this case, reference is made to the ladle of the source furnace (j, i) supplied to the pouring machine j at the time point i and the arrangement of the remaining amount of hot water pouring machine (time i × line j). One ladle is provided for each furnace, and the amount of ladle varies depending on each furnace. In step S52, it is determined whether or not the supply source is a buffer. If the supply source is a buffer in step S52, the process proceeds to step S53. The processing content of step S53 will be described in detail with reference to FIG. If the supply source is not a buffer in step S52, the process proceeds to step S54.In step S54, the remaining hot water amount (k, i-ladder movement time) = remaining hot water amount (j, i-ladder movement time-1)-ladle amount. Is calculated. In this case, k = supplier furnace (j, i), and the movement starts before the “movement time” before the pouring machine falls below the lower limit.

  In step S55, it is determined whether the amount of remaining furnace water (k, i) ≦ lower limit. If the remaining furnace water amount (k, i) is equal to or lower than the lower limit, the process proceeds to step S56, and a new furnace selection process shown in FIG. 8C is executed in step S56. If no furnace matching the conditions is found in all the furnaces in the new furnace selection process in step S56, the process proceeds to step S57, and the scheduling ends. If the furnace can be selected, the process proceeds to step S58, the selected furnace is set as the supply furnace, the head is returned to the next scheduling, and the scheduling is repeated. On the other hand, if it is determined in step S55 that the remaining furnace hot water amount (k, i) is not less than the lower limit, and if it is determined in step S50 that the remaining hot water amount (j, i) is not less than the lower limit, then step S53 If the processing result is output to the output terminal (B) in the above process, the process returns to the beginning for the next scheduling, and the scheduling is further repeated.

  FIG. 8B is a flowchart for explaining the processing content in step S53 shown in FIG. 8A. As shown in FIG. 8B, in step S531, the remaining buffer hot water amount (i-litter 1 movement time) = buffer remaining hot water amount (i-litter 1 movement time-1)-ladle 1 amount is set. In this case, the movement starts before the “movement time” before the pouring machine falls below the lower limit, and ladle 1 indicates the ladle of the buffer.

  Next, in step S532, it is determined whether the amount of remaining hot water in the buffer (i-ladder 1 movement time) ≦ lower limit. If the remaining amount of buffer hot water (i- ladle 1 movement time) is less than the lower limit, the process proceeds to step S533, and in step S533, the remaining amount of buffer hot water (i- ladle 1 movement time) = the remaining amount of buffer hot water (i- ladle 1 movement) Time) + ladle amount. As described above, the ladle 1 indicates the ladle of the buffer. Further, in this case, the ladle amount is an amount due to the ladle of the buffer supply source furnace (i) that is being supplied to the buffer at the time [i- ladle movement time].

  In step S534, the amount of remaining hot water in the furnace (k, i- ladle 1 movement time-ladle 2 movement time) = the amount of remaining furnace water (k, i-ladle 1 movement time-ladle 2 movement time-1)- The total is set to 2 quantities. In this case, k = supplier furnace to the buffer, and the movement starts before the “movement time” before the buffer falls below the lower limit. Ladle 2 refers to the ladle for the selected furnace (k).

  Next, in step S535, it is determined whether the amount of remaining hot water in the furnace (k, i- ladle 1 movement time-ladle 2 movement time) ≤ lower limit. If the amount of remaining furnace water (k, i-ladle 1 movement time-ladle 2 movement time) is equal to or lower than the lower limit, the process proceeds to step S536, and a new furnace selection process shown in FIG. 8C is executed in step S536. If no furnace matching the conditions is found in all the furnaces in the new furnace selection process in step S536, the process proceeds to step S537 and the scheduling ends. If a furnace can be selected in the new furnace selection process in step S536, the process proceeds to step S538, where the selected furnace is set as the supply furnace, and the processing result is output to the output terminal (B). Further, if the amount of remaining furnace water (k, i-ladle 1 movement time-ladle 2 movement time) is not less than the lower limit in step S535, the processing result is output to the output terminal (B). Furthermore, if the buffer remaining hot water amount (i- ladle 1 movement time) is not less than the lower limit in step S532, the processing result is output to the output terminal (B).

  FIG. 8C is a flowchart for explaining a new furnace selection process in steps S46, S56, and S536 shown in FIGS. 8A and 8B. As a premise for starting the new furnace selection process shown in FIG. 8C, k is set to one of the maximum number of furnaces for furnace selection, and the furnace is used as a furnace (k: maximum furnace). Processing is limited to number = 5). In step S61, the furnace (k) is selected according to the priority order. In this case, the priority is determined from (1) priority set by the user, (2) basic unit, (3) order, and (4) operating time. Note that the operating time is selected from the reset immediately after the maintenance and the one with less integrated power (kWh) or rated kW.

  Next, the process proceeds to step S62, and in step S62, it is determined whether or not the furnace use state (k, i-melting time (k)) is hot water completion / remaining hot water holding / stopping. If the use state of the furnace in step S62 is any of the completion of hot water discharge / remaining remaining hot water / stopped, the process proceeds to step S63, the furnace is set as the supply furnace in step S63, and the furnace is in step S62. If the furnace used is not in the state of hot water completion / remaining remaining hot water / stopped, the next furnace selection process is executed. If the number of furnaces that can be selected is not found, the process proceeds to step S64 and the furnace is selected. Processing is terminated as impossible.

  7A, 7B, FIG. 8A, FIG. 8B, and FIG. C, when scheduling is terminated because the furnace selection is not possible, the production plan is secured with a minimum waiting time automatically or manually so that a new furnace can be selected. Adjust the pouring start time and the production schedule after the pouring start time.

  As a method of automatically adjusting the start time and production schedule, the start time was shifted until the time when one of the multiple furnaces in use was discharged or the remaining hot water was held or stopped, and subsequent schedules were shifted. There is a way to shift the time.

  FIG. 9 is a diagram showing an example of a casting process by a melting process created according to the embodiment of the present invention. In the example shown in FIG. 9, casting (pouring) of 15 kg is started on the setting time (24 hours and minutes are displayed in seconds) on the molding line 1 set to tact time 6 seconds (Material 1) ). Then, after 30 minutes, that is, at a set time of 1801 seconds, casting of 10 kg (pouring) is started on the molding line 2 set at a takt time of 5 seconds (Material 1). Then, after 1 hour, that is, at a setting time of 3601 seconds, the material is changed (changed from material 1 to material 2) in the molding line 1 and casting of 20 kg (pouring) is performed. FIG. 9 only shows an example of the casting process by the melting process for an elapsed time of at least one hour in seconds, and it is very impossible to show an example of the casting process for 24 hours in this figure. In addition, it is noted that a predetermined amount of casting (pouring) is performed with a predetermined material in a tact surrounded by a black frame on the right side of each line.

  FIG. 10 is a screen display example showing a state at the time of completion of the plan by the melting process automatic creating apparatus according to the embodiment of the present invention. The top part of the screen display shown in FIG. 10 shows the production plan of the casting product in each molding line. In the illustrated example, the production plan of the product to be cast from 2 o'clock to 21:00 in the 2 molding line is time. Shown in the unit.

  Next, from the top of the screen display, the required amount of molten metal [kg] is displayed as a bar graph in units of 30 minutes. The third screen from the top shows the state of repeating the saw-tooth transition from the upper limit value to the lower limit value, that is, the furnace weight of the pouring furnace, for each molding line. Incidentally, in the graphs of the remaining amount of the pouring machine shown in FIGS. 4 and 5, the time scale is large, so the change is not so steep, but on the screen that displays 24 hours. Then the time scale becomes smaller and the change becomes steep. Actually, each molding line is displayed in different colors so that it is easy to see even if there is an overlap.

  Next, on the fourth screen from the top, the melting furnace operation plan [kg] is shown for 24 hours divided into Units 1 to 3. In this illustrated example, melting is first started in the No. 3 furnace before the casting is started, then melting is started in the No. 1 furnace, and further melting is started in the No. 2 furnace. The portion expressed in a staircase shape shows a state where pouring is performed in each line. At the bottom of the screen display, the power consumption [kg] in the melting furnace is displayed as a bar graph, actually displayed by color for each furnace, and displayed as the total value of all furnaces. Since the power consumption needs to be contracted with a power company as a demand every 30 minutes, displaying the power consumption on the screen is a mind for saving costs.

  FIG. 11 is a screen display example showing the plan and actual measurement of the production amount and the electric energy managed by the plan / result management means according to the embodiment of the present invention. As described above, the plan / result management means 155 according to the embodiment of the present invention is obtained from the output of the pouring machine / melting furnace residual water amount calculation result output means 150 and various measuring instruments provided in the pouring machine and the melting furnace. Based on the measurement information and production schedule information, the status of the melting furnace, transition prediction of energy consumption, etc. are displayed to manage the plan / actual results. In that case, create an online transition graph of the plan and actual amount of formwork and casting weight and display it, or display the basic unit online and create daily and monthly reports on production volume, electric energy, basic unit, etc. Can also be displayed. In the screen display example shown in FIG. 11, the item name is written on the left part of the screen, then the planned value and then the actual value are written in the central part of the screen, the difference between the plan and the actual result is written on the right side of the screen, As a table. A minus sign on the right side of the screen indicates that the actual results exceeded the plan. When a plan is executed based on a plan, it is desirable to leave such production plan result information as a journal.

  FIG. 12 is a diagram for explaining a restart function in the automatic melting process creation apparatus according to the embodiment of the present invention. The restart function is for re-calculating the furnace operation plan by reviewing the molten metal supply from the furnace when the molding line under execution of the plan stops. The upper half of FIG. 12 shows the molding line when the operation plan is finalized and the pouring that has been determined from the furnaces 1 and 2 to the molding lines 1 to 3 in a time series in units of seconds per line is executed. 1 shows a state in which a line 1 has failed during pouring into form 1- (2) and the line is stopped. Due to the line stoppage, the pouring plan from the furnace 2 to the mold 1- (4) of the molding line 1 cannot be performed as scheduled.

  Therefore, as shown in the lower half of FIG. 12, a restart process (failed molding line (line 1)) is selected and a restart instruction is issued. In the restart instruction, recalculation is instructed by changing the input of restart time, the state after restart of the furnace, the amount of hot water remaining in the pouring machine, and the like. Then, the time is changed so that the process from the selected process to the end of the day starts from the restart time, and the furnace operation plan is automatically recalculated. Furthermore, based on the recalculated schedule and the schedule before restarting, the power consumption of the furnace, the amount of remaining hot water, etc. are displayed together on the screen. This recalculation is realized by redoing the processing shown in FIGS. 7A and 7B (operation plan without buffer) or FIGS. 8A to 8C (operation plan with buffer). In the example shown in the figure, by recalculation, the plan for pouring from the furnace 2 to the mold 1- (4) of the molding line 1 before the line was stopped was changed to the mold 2- ( This indicates that the pouring plan for 4) has been changed.

  FIG. 13: is a figure which shows the process flow outline | summary for determining the possibility of the remaining molten metal in the melting process automatic preparation apparatus concerning embodiment of this invention. It is desirable to schedule so that the remaining hot water volume of all furnaces becomes zero at the end of the day, but in order to achieve this, if the molten metal that is less than the rated capacity of the furnace has to be performed just before the end, It is checked whether or not the amount of remaining hot water can be reduced to 0 at the end of the day. FIG. 13 shows an outline of the process for determining whether or not the remaining molten metal can be used. As shown in the left part of FIG. 13, normally, when the pouring machine reaches the lower limit, Change the process plan for the pouring machine, take the pouring machine from the furnace to the pouring machine when the pouring machine reaches the upper limit-ladle amount, and use the free time in the process plan that is normally executed Check whether molten metal is possible. And if the remaining molten metal is possible, as shown in the upper right part of FIG. 13, it shifts ahead and checks whether it can be supplied until the start. When supply is not possible in the supply availability check here and when it is impossible in the remaining molten metal availability check shown in the left part of FIG. 13, as shown in the lower right part of FIG. Present the process and finish. In other words, in this case, the process is unavoidably terminated with remaining hot water.

  FIG. 14 is a screen display example showing a comparison between the standard operation pattern and the actual measurement, which is analyzed by the plan / result management unit according to the embodiment of the present invention. The standard operation pattern is divided into initial melting, normal melting, component adjustment, temperature increase, and heat retention stages, and the time and power required for each induction furnace are defined. The power is actually measured at a constant cycle such as a one second cycle, the initial melting, the normal melting, the heat retaining, and the stop are determined according to the power value, and the time and the electric energy are integrated. By comparing the time defined in the standard operation pattern, the amount of power and the time based on the measured data, and the amount of power, it is confirmed in which phase the amount of time and power is consumed relative to the standard operation pattern. Therefore, it is possible to improve the operation closer to the standard operation pattern at the next operation.

  FIG. 15 is an example of a screen display that is analyzed by the plan / actual result management unit according to the embodiment of the present invention and compares power transitions in a certain period and another period by time integration for each power demand. By displaying the power measurement data for the comparison source period and the comparison target period by time integration according to the size of power demand (the rated power of the furnace is approximately 15 equal parts), it is usually the rated power of the furnace. You can confirm the time required for normal melting to be performed, the time required for heat insulation to be performed with low power, and the time required for initial melting to increase the power applied stepwise. Therefore, by comparing the days when the basic unit is good and the days when the basic unit is bad, the factor of the bad basic unit can be analyzed and can be improved at the next driving.

21 Monitor 22 Keyboard 23 Mouse 24 Connection interface (I / F)
100 melting process automatic creation device
110 Required molten metal retention means
120 1st pouring machine / melting furnace remaining hot water amount calculation means
130 2nd pouring machine / melting furnace remaining hot water amount calculation means
140 nth pouring machine / melting furnace remaining hot water amount calculation means
150 Pouring machine / melting furnace residual water volume calculation result output means
155 Plan / actual management means
160-190 signal line
1100 Melting process automatic creation device
1101 CPU (Central Processing Unit)
1102 RAM (Random Access Memory)
1103 HDD (Hard Disc Drive)
1104 Graphics processing unit
1105 Input interface
1106 bus
1107 External connection controller

Claims (11)

In the melting process automatic creation device that moves the molten metal from the melting furnace to the pouring machine to produce a cast product,
The necessary melt amount holding means for reading and holding the information necessary for creating the melting process related to the amount of molten metal necessary for each molding line, material, and the moving speed of the molding line from the information notified from the production schedule,
Based on the required amount of molten metal held, a first time for calculating the remaining amount of the pouring machine and the amount of remaining molten metal in a time series in seconds until the first melting furnace is “empty” or reaches a specified weight. No water pouring machine / melting furnace residual water amount calculation means,
Select at least one of the second and subsequent melting furnaces in time for when the amount of remaining molten steel is “empty” or reaches the specified weight, and the same as the first based on the selected melting furnace At least a second pouring machine / melting furnace residual water amount calculating means for calculating the remaining amount of molten metal and the melting furnace residual water in a time series in seconds;
It said second pouring machine-melting furnace the remaining hot water calculating means comprises a weight said first melting furnace remaining hot water is "empty" or specified from the first pouring machine-melting furnace remaining hot water calculating means Upon receiving the notification about the time, the melting furnace set in advance through the standard operation pattern setting screen from the time when the first melting furnace remaining hot water amount becomes “empty” or becomes the designated weight until the hot water can be discharged. that Yosu, initial dissolution time, usually the dissolution time, going back by the time of the combined components adjustment time and temperature rise time to plan for the step of starting the dissolution of the second furnace,
A first time pouring machine / melting furnace remaining hot water amount calculating means for obtaining a predetermined amount of time-series calculation in units of seconds and outputting the result; Further comprising
An apparatus for automatically creating a melting process. Information notice from the production schedule, manufacturing melting furnace names that can be used for the production of castings, melting furnace of specifications, pouring machine name, and equipment data, including the speed of movement of the molding line, the castings In doing so, it is production process data including necessary material quality, production expected quantity, and scheduled production start time.   The said pouring machine / melting furnace remaining hot water amount calculation result output means uses the calculation results of the remaining hot water amount and the remaining molten metal amount calculated by the first and second pouring machine / melting furnace remaining water amount calculating means. The energy intensity and production amount are calculated and output as a melting process planning result, the output, measurement information obtained from various measuring instruments provided in the pouring machine and the melting furnace, and the production schedule The melting process automatic creation apparatus according to claim 1, further comprising a plan / actual management means for displaying a transition prediction of the state of the melting furnace and energy consumption based on the information and managing the plan / actual result. The first and second pouring machine / melting furnace residual water amount calculation means start a recalculation process for a line including a pouring process or molding, and start the other line. Means for recreating the melting process in consideration of the amount of hot water in the pouring machine and the amount of hot water in the melting furnace at the start of recalculation in the line, including the amount of hot water in the pouring machine and the amount of hot water in the melting furnace in the planned execution The melting process automatic creating apparatus according to claim 1, further comprising:   In the case where there are a plurality of furnaces, the second pouring machine / melting furnace remaining water amount calculation means grasps the state of the third furnace and prioritizes the one in which the furnace is waiting for tapping. If the selection with the first priority is not possible, the furnace in the stopped state after tapping is selected as the second priority, and if the selection with the second priority is not possible, The melting process automatic creation apparatus according to claim 1, wherein a furnace in a stopped state is selected.   In the case of selecting furnaces after the second priority, the priorities are as follows: (b) priority set by the user, (b) good energy intensity, (c) furnace use order, and (d) operating time. The melting process automatic creating apparatus according to claim 5, wherein the melting process automatic creating apparatus is determined.   The first and second pouring machines / melting furnace remaining hot water amount calculation means are usually used before the melting process plan ends when the amount of iron less than the rated capacity of the furnace must be melted just before the melting process plan ends. The melting process automatic creating apparatus according to claim 1, further comprising means for checking whether or not the remaining molten metal can be used by using a free time in the process plan being executed. A melting process automatic creation method in a melting process automatic creation device for producing a cast product by moving a molten metal from a melting furnace to a pouring machine,
The process of reading and holding information necessary for creating a melting process related to the amount of molten metal required for each molding line, material, and moving speed of the molding line from the information notified from the production schedule,
Based on the required amount of molten metal held, a first time for calculating the remaining amount of the pouring machine and the amount of remaining molten metal in a time series in seconds until the first melting furnace is “empty” or reaches a specified weight. Calculation process,
Select at least one of the second and subsequent melting furnaces in time for when the amount of remaining molten steel is “empty” or reaches the specified weight, and the same as the first based on the selected melting furnace Including at least a second calculation step of calculating the remaining amount of the pouring machine and the remaining amount of the melting furnace in a time series of seconds,
It said second calculation process, the first said of the calculation process the first melting furnace the remaining hot water is notified about the "empty" or time at which a specified weight first melting furnace the remaining hot water is "empty" or the melting furnace set through the pre-standard operation pattern setting screen point to be specified by weight in the base point that takes to until it can be tapped, the initial dissolution time, usually the dissolution time, component adjustment time and heated process plan for a process to start the dissolution of second furnace back by the time of the combined time and,
Obtaining a predetermined amount of calculation in the first and second calculation processes and outputting the result;
The dissolution process automatic preparation method characterized by further including these.   The output process is a process of calculating a basic unit of energy and a production amount using the calculation results of the remaining amount of hot water pouring machine and the remaining amount of melting furnace in the first and second calculation processes and outputting the result as a melting process planning result. , And display the transition prediction of the state of the melting furnace and the energy consumption based on the output and the measurement information obtained from the various measuring instruments provided in the pouring machine and the melting furnace and the production schedule information. The method for automatically creating a dissolution process according to claim 8, further comprising a step of managing the process.   In the first and second calculation processes, when a line failure including a pouring process or molding occurs, recalculation processing is started for the line, and the remaining pouring machine in the planned execution of the other line is started. Including the amount of hot water and the amount of remaining hot water in the melting furnace, the method further includes a step of recreating the melting process in consideration of the amount of hot water in the pouring machine and the amount of hot water in the melting furnace at the start of recalculation in the line. The dissolution process automatic creation method according to claim 8.   In the plan / result management means, as a method of analyzing energy consumption, a standard operation pattern and a result defined in advance for each induction furnace are compared and displayed by comparing time and power consumption with a certain period. The melting process automatic creating apparatus according to claim 3, further comprising means for integrating and displaying power transitions during a certain period of time according to the magnitude of power demand for comparison.