KR100906016B1 - Automated melting system and method - Google Patents

Abstract

The present invention relates to an automated dissolution system and method, wherein the automated dissolution system according to the present invention includes a dissolution device for dissolving a dissolving material in a crucible to obtain a high purity material, and a PLC device for controlling the dissolution device. The apparatus of claim 1, wherein the PLC device includes an input part, a storage part, a process input / output part connected to a temperature sensor and a heater of the melting apparatus, and a first control part, wherein the first control part includes an ID and a password through the input part. Is entered, authenticates the operator, controls the storage unit to store manually inputted parameters for each melting operation of a specific material through the input unit, and the melting apparatus performs the melting operation using the parameters stored in the storage unit. Control the process input and output unit so that the melting apparatus is manually input parameters When N times subjected to dissolution operation according to characterized in that the control by selecting the optimum parameters in the parameter N times stored in the storage unit is the melting apparatus to perform the dissolving action of the particular material automatically. Thereby, the parameters for the material and the dissolution conditions can be programmed so that anyone can carry out the same work continuously.

Automation, melting, parameterization

Description

Automated Melting System and Method {AUTOMATED MELTING SYSTEM AND METHOD}

FIELD OF THE INVENTION The present invention relates to automated dissolution systems and methods, and more particularly to automated dissolution systems and methods in which parameters for materials and dissolution conditions are programmed so that anyone can perform the same task continuously.

Conventionally, vacuum induction dissolving apparatuses are widely used to dissolve titanium, alloy materials, zirconium, and alloy materials, which are general materials, special metal materials including special steel or super heat-resistant alloy, and poorly soluble materials.

Hereinafter, a vacuum induction melting apparatus of the related art will be described with reference to FIG. 6.

6 is a schematic diagram of a vacuum induction melting apparatus of the prior art.

As shown in FIG. 6, the vacuum induction dissolving device 50 is provided with a dissolving furnace 52 into which a workpiece is to be charged, and a melting part 51 having a main exhaust line formed at one side thereof, and charged into the melting furnace 52. A heating part for induction heating the processed object, a casting part 53 disposed under the melting part 51 and casting the object to be melted through the heating part by casting the mold 54, the casting part It is provided at the lower portion of the 53 and includes a lifting unit 55 for modifying the height of the mold 54, and a control unit for controlling the operation of the entire vacuum induction melting apparatus.

In the case of the melting furnace of the vacuum induction melting apparatus, the melting and tapping operations are performed according to the operator's working method, and there may be a difference in the melting level of the molten metal and the quality of the final product according to the change of the operator.

Accordingly, there is a need for an automated dissolution system and method capable of shortening the time required to find a condition for securing parameters for a certain period of time when the operator is changed or does not know the working conditions of the senior.

Accordingly, in order to solve the above problem, the present invention can perform the same work continuously by using the optimal parameters when performing continuous work by inputting the processes working with the optimal parameters into the program through the storage function. It is an object of the present invention to provide an automated dissolution system and method.

The automated dissolution system according to the present invention for achieving the above object is a PLC device for dissolving a melting device into a crucible to obtain a high purity material, and a PLC device for controlling the dissolution device, the PLC device Includes an input unit, a storage unit, a process input / output unit connected to a temperature sensor and a heater of the melting apparatus, and a first control unit, wherein the first control unit authenticates an operator when an ID and a password are input through the input unit. The controller controls the storage unit to store manually inputted parameters for each melting operation of a specific material through the input unit, and controls the process input / output unit to perform the melting operation by the melting apparatus using the parameters stored in the storage unit. And the dissolution device performs the dissolution operation N times according to the manually entered parameters. Display side selecting the optimal parameters in the parameter N times stored in the storage unit and is characterized in that the control device so as to carry out the dissolving operation dissolution of the particular material automatically.

In addition, the automated dissolution method according to the present invention comprises the steps of authenticating the operator using the ID and password; Storing manually entered parameters for each melting operation of a particular material and particular products; Performing a dissolution operation using the stored parameters; Conducting dissolution operation N times according to the parameters to select an optimal parameter from the stored N times parameters; And automatically dissolving the specific material using the optimum parameters.

According to the present invention, by programming the parameters for the material and the dissolution conditions, anyone can perform the same operation continuously, it is possible to shorten the time taken to find the conditions for securing the parameters for a certain period of time.

Hereinafter, with reference to the accompanying drawings, preferred embodiments of the present invention will be described in detail.

1 is a block diagram of an automated dissolution system according to an embodiment of the present invention, Figure 2 is a block diagram showing the configuration of a PLC device according to an embodiment of the present invention, Figure 3 is an embodiment of the present invention 4 is a block diagram illustrating a configuration of a PLC control apparatus according to an embodiment of the present invention, and FIG. 4 is a table illustrating parameters stored in a storage unit of a PLC apparatus according to an embodiment of the present invention.

As shown in FIG. 1, the automated dissolution system 10 includes a dissolution device 100, 100 ′, a PLC device 200, 200 ′, and a control PC (PLC control device) 300. In FIG. 1, two PLCs 200 and 200 ′ are connected to the control PC 300, but only one PLC 200 may be connected to the control PC 300.

Melting apparatus (100,100 ') is a device to obtain a high purity material by dissolving the dissolved material in the crucible, as shown in Figure 2, includes a temperature sensor 110, a heater 120, and a hydraulic cylinder 130 have.

The PLC device 200, 200 ′ is a device for controlling the melting device, and includes a first power supply 210, a user interface (UI) unit 220, a process input / output unit 230, a storage unit 240, The first interface unit 250 and the first control unit 260 are included.

When the user presses a power button (not shown), the first power supply 210 supplies a rated voltage necessary for each component of the PLC device 200, that is, the storage 240 and the first controller 260.

The UI unit 220 is for an interface with a user, and includes an input unit (not shown) through which the user can input data, and a display unit (not shown) for displaying data to the user. The operator can input the ID and password through the input unit.

The process input / output unit 230 is for interfacing with the dissolution apparatus 100, and is connected to the temperature sensor 110 of the dissolution apparatus 100 to receive a detection value of the temperature sensor 110, and is connected to the heater 120. Thus, the heater 120 provides the data necessary to adjust the temperature according to the process conditions, and is connected to the hydraulic cylinder 130 to provide data required for driving the hydraulic cylinder 130.

The storage unit 240 stores manually entered parameters for each melting operation of a specific material through the UI unit 220. In addition, an operation program for operating the PLC device 200 is stored, and process data input or output through the process input / output unit 230 are stored. The operating program has an operating unique value corresponding to the program unique value of the master program, and this operating unique value can be stored in a designated area.

On the other hand, the storage unit 240 includes not only RAM but also ROM, EEPROM, FLASH or magnetic storage media. When the power is supplied, the operating program may be stored in the memory in these non-volatile memory and then loaded into the RAM.

The first interface unit 250 is an interface for communicating with the control PC 300, receives a stop signal and recovery data for stopping the operation of the operation program of the PLC device 200 from the control PC 300, the control The operation 300 transmits the unique values and process data stored in the storage unit 240 to the PC 300.

The first controller 260 controls the UI unit 220, the process input / output unit 230, the storage unit 240, and the first interface unit 250 according to an operation program of the storage unit 240.

The first control unit 260 authenticates the operator when the ID and password are input through the UI unit 220, and stores the manually inputted parameters for each melting operation of a specific material through the UI unit 220. ), The process input / output unit 230 is controlled so that the dissolution device 100 performs the dissolution operation using the parameters stored in the storage unit 240, and the dissolution device 100 controls the manually inputted parameters. Accordingly, if the melting operation is performed N times, the melting device 100 may be controlled to automatically perform the melting operation of a specific material by selecting an optimal parameter from the N times stored in the storage unit 240.

In addition, when the optimal parameters are selected, the first controller 260 may control the storage 240 to erase N-1 times of parameters other than the optimal parameters among the parameters stored in the storage 240. .

In addition, the first control unit 260 may divide the parameters into preheating information, dissolution information, and tapping information and receive the inputs through the UI unit 220, and store them in the storage unit 240 as shown in FIG. 4.

As shown in FIG. 4, the storage unit 240 includes preheating information, melting information, and tapping information for every N melting operations, and specifically includes output, crucible position, and holding time information as parameters related to preheating information. And the output, the crucible position, the holding time and the temperature information as parameters related to the melting information, and the output, the crucible position, the holding time and the temperature information as parameters related to the tapping information.

Meanwhile, when the first control unit 260 receives a stop signal for stopping the operation of the operation program through the first interface unit 250, the first control unit 260 controls the operation program stored in the storage unit 240 not to operate, and restores data. If received, it is stored in the recovery data storage area of the storage unit 240. When the detection value of the temperature sensor 110 of the melting apparatus 100 and the on / off information of the heater 120 are input through the process input / output unit 230, these data are stored in the process data area of the storage unit 240. Save it. In addition, when process data for controlling the hydraulic cylinder 130 of the dissolution apparatus 100 is input through the UI unit 220, the data is stored in the process data area of the storage unit 240.

Next, when the user presses a power button (not shown), the second power supply 310 supplies a rated voltage necessary for each component of the control PC 300, that is, the RAM 370, the second controller 390, and the like.

The user input unit 320 is for receiving data from an operator and includes a keyboard (not shown).

The display unit 330 displays a state of the PLC device 200, and displays a warning message when a problem occurs. The audio unit 340 generates an alarm alert through sound.

The second interface unit 350 is an interface for communicating with the PLC device 200 and is connected to the first interface unit 250 through RS232. The second interface unit 350 receives operation specific values and process data stored in the storage unit 240 from the PLC device 200, and transmits the operation program of the PLC device 200 to the PLC device 200. A stop signal and recovery data for stopping the operation are transmitted.

The master program storage unit 360 is a storage medium consisting of a ROM or a key lock that stores a master program. These storage media are preferably removable from the control PC 300.

The master program includes a program intrinsic value corresponding to an operation intrinsic value of the operation program of the PLC device 200. The program eigenvalues may include versions as well as operational eigenvalues of the dissolution apparatus 100, in which the values should not be changed by the program operation, and may include ranges that process data may have.

In addition, the master program includes a self-recovery program that modifies the operating eigenvalue to the program eigenvalue when the program eigenvalue and the operating eigenvalue do not match.

The RAM 370 stores a master program storage area for loading and storing a master program stored in the master program storage unit 360 and an operation specific value received through the second interface unit 350.

The third interface unit 380 is an interface for communicating with a management server (not shown) and may be connected to the management server through the Internet.

When the control PC 300 is connected to the management server through the third interface unit 380, the first control unit 260 detects this and drives the macro program to stop the operation of the operation program. Thereby, malfunction of the dissolution apparatus 100 by hacking etc. can be prevented.

The second control unit 390 according to the operation of the OS program stored in the RAM, the user input unit 320, the display unit 330, the audio unit 340, the second interface unit 350, the master program storage unit 360 ), The RAM 370 and the third interface unit 380 are controlled.

The second control unit 390 may control the display unit 330 to receive the parameters from the PLC device 200 before the melting operation and display them in a simulation form. In addition, when power is supplied to the PLC device 200, the second control unit 390 receives an operation program stored in the storage unit 240, compares the master program with each other, and dissolves the melting device 100. The stop signal may be output to the PLC device 200 so as not to.

The second controller 390 may load the master program from the master program storage 360 into the RAM 370 in various ways. That is, the power button (not shown) is turned on so that the operating voltage is supplied from the second power supply unit 310, or the operator inputs the operation of the master program through the user input unit 320, or operates the master program at a predetermined time. In this case, the second control unit 390 loads the master program from the master program storage unit 360 to the RAM 370.

In addition, the master program stored in the RAM 370 is always driven, such as a virus scan program, to check for malfunctions. In some cases, the master program may be driven directly from the master program storage unit 360 without being loaded into the RAM 370.

The second control unit 390 compares the master program and the operating program with each other, and controls the display unit 330 or the audio unit 340 to sound an alarm when displaying a mismatch.

The second control unit 390 compares the master program and the operating program with each other, if there is a mismatch, the PLC device 200 through the second interface unit 350 to drive the self-recovery program to be the same as the master program. To control.

The second controller 390 controls the third interface unit 380 to access the management server through the Internet if the operation program is not restored even by the self-recovery program. As a result, the management server can control the control PC 300 or the PLC device 200. The management server analyzes the cause of the problem of the PLC device 200 by operating a self-diagnostic program and provides information on the presence or absence of parts replacement.

Next, an embodiment of the automated dissolution method will be described with reference to FIGS. 5A and 5B.

5A and 5B are flowcharts of an automated dissolution method according to one embodiment of the present invention.

As shown in FIG. 5A, when the operator inputs an ID through the UI unit 220 of the PLC device 200 and inputs a password (S20) for the melting operation (S20), the automatic melting system can be accessed. You will be authenticated as an appropriate operator.

Accordingly, when an operator who is not allowed to access the system approaches, that is, when the operator authentication fails (S30 in 'N'), the user is allowed to input the password up to three times and eventually fails in all three times (S100 in 'Y'). The system is automatically shut down to block access to the automatic melting system.

On the other hand, if the operator authentication is successful ('Y' in S30), using the melting apparatus 100 to select a specific material to be dissolved (S40), the parameters required for the melting operation as preheating information, melting information and tapping information If the input is divided manually, the storage unit 240 of the PLC device 200 stores the parameters input by the operator in a table form (S50).

The first controller 260 controls the process input / output unit 230 so that the dissolution device 100 performs the dissolution operation using the parameters stored in the storage 240 (S60).

Accordingly, when the dissolution device 100 performs the dissolution operation N times according to the manually inputted parameters ('Y' in S70), the first control unit 260 performs N times of parameters stored in the storage unit 240. The optimal parameter is selected from the list (S80). Here, when the optimal parameters are selected, the first controller 260 may control the storage unit 240 to erase N-1 times of parameters other than the optimal parameters among the parameters stored in the storage unit 240. .

Next, the first control unit 260 controls the dissolution apparatus 100 to automatically dissolve the specific material and the specific product (S90).

Meanwhile, in FIG. 5A, a program intrinsic value and an operation intrinsic value comparison step may be added between the operator authentication step S30 and the material selection step S40 as shown in FIG. 5B.

Specifically, as shown in FIG. 5B, after operating the self-diagnosis function, the master program is stored in the RAM 370 from the master program storage unit 360 formed of a storage medium consisting of a ROM or a KEY LOCK storing the master program. Save it (S31).

Next, an operation program having an operation specific value is received from the storage unit 240 of the PLC device 200 through the second interface unit 350 (S32).

Next, the program unique value is read from the master program stored in the RAM 370 (S33).

Next, the second control unit 390 compares the program intrinsic value and the operation intrinsic value received through the second interface unit 350 (S34). In this case the comparison of program eigenvalues to operational eigenvalues includes not only constants but also letters and symbols. In addition, the process data stored in the storage unit 240 may also be included. In this case, it may be compared whether the process data is out of a predetermined range.

Next, if the program intrinsic value and the operation intrinsic value are inconsistent (if 'N' in S34), the second control unit 390 transmits a stop signal for stopping the operation program of the PLC device 200. ), And the first control unit 260 stops the operation program in accordance with the stop signal (S35). As a result, the dissolution apparatus 100 may not proceed any further work or may proceed only with the current work.

While the present invention has been particularly shown and described with reference to specific embodiments, it will be understood by those skilled in the art that the present invention is not limited thereto but may be variously modified.

1 is a block diagram of an automated dissolution system according to an embodiment of the present invention.

Figure 2 is a block diagram showing the configuration of a PLC device according to an embodiment of the present invention.

Figure 3 is a block diagram showing the configuration of a PLC control apparatus according to an embodiment of the present invention.

4 is a table showing parameters stored in a storage unit of a PLC device according to an embodiment of the present invention.

5A and 5B are flow charts of an automated dissolution method in accordance with one embodiment of the present invention.

6 is a schematic diagram of a vacuum induction melting apparatus of the prior art.

[Explanation of symbols on the main parts of the drawings]

10: automated dissolution system 50: vacuum induction melter

51: melting part 52: melting furnace

53: casting 54: mold

55: lifting part 100,100 ': melting apparatus

110: temperature sensor 120: heater

130: hydraulic cylinder 200,200 ': PLC

210: first power supply unit 220: UI unit

230: process input and output unit 240: storage unit

250: first interface unit 260: first control unit

300: control PC 310: second power supply unit

320: user input unit 330: display unit

340: audio unit 350: second interface unit

360: master program storage unit 370: RAM

380: third interface unit 390: second control unit

Claims (10)

In the automated melting facility comprising a melting device to put a dissolved material in a crucible to obtain a high purity material, and a PLC device for controlling the melting device, The dissolution device comprises a heater, The PLC device includes an input unit, a storage unit, a process input / output unit connected to the heater of the melting apparatus, and a first control unit, The first control unit authenticates the operator when an ID and password are input through the input unit, and parameters related to N times of preheating information, melting information, and tapping information, which are manually inputted for dissolving a specific material through the input unit. Controlling the storage unit to store the control unit, controlling the process input / output unit using N parameters of the storage unit so that the heater of the melting apparatus is heated to perform the melting operation, and performing the melting operation of the melting apparatus N times. Selecting an optimal parameter from the N times of the storage unit of the automated melting facility characterized in that the dissolution device is controlled to automatically perform the dissolution of the specific material. The method of claim 1, And the first control unit controls the storage unit to erase N-1 times of parameters other than the optimal parameters among the parameters stored in the storage unit when the optimal parameters are selected. delete The method of claim 1, And a PLC control device having a display unit and a second control unit for receiving the stored N times of parameters before the dissolving operation of the dissolution device and controlling the display unit to display the display unit in a simulation form. . The method of claim 4, wherein The first control unit transmits the occurrence time and cause to the PLC control apparatus when a program error or abnormality occurs, And the second control unit manages the time adjustment for the recovery time point to operate the recovery program. The method according to claim 4 or 5, When power is supplied to the PLC device, the second controller receives an operation program stored in the storage unit and outputs a stop signal to the PLC device so that the melting operation of the dissolution device does not proceed if there is a mismatch by comparing with the master program. Automated melting facility characterized in that. In the automated dissolution method comprising a dissolving device to put a dissolving material in the crucible to dissolve to obtain a high purity material, Authenticating the operator using the ID and password; Storing parameters relating to N times of preheating information, melting information, and tapping information, which are manually input for a melting operation of a specific material; Performing a dissolution operation of the dissolution device using the stored N times parameters; Performing an N dissolution operation of the dissolution device to select an optimal parameter from the stored N times parameters; And And automatically dissolving the specific material using the optimal parameters. The method of claim 7, wherein And if said optimal parameter is selected, deleting N-1 parameters other than said optimal parameter among said stored N parameters. delete The method of claim 7, wherein Receiving the stored N times the parameters before the dissolution operation of the dissolution device further comprising the step of displaying in a simulated form.

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