CN-121972622-A - Horizontal centrifugal casting high-precision active control equipment and process method based on magnetic suspension technology

CN121972622ACN 121972622 ACN121972622 ACN 121972622ACN-121972622-A

Abstract

The invention relates to the technical field of horizontal centrifugal casting equipment, in particular to horizontal centrifugal casting high-precision active control equipment and a process method based on a magnetic suspension technology, wherein the equipment comprises an electric control cabinet, a cold mold, a carrier roller shaft and a transmission system, wherein the transmission system is used for providing power for the equipment; the integrated position detection and active control system can collect radial and axial position deviation signals in the cold type rotation process in real time, dynamically adjust the suspension supporting force through the magnetic suspension system, realize high-precision active control on the cold type rotation gesture, effectively inhibit gesture deviation in the rotation process, avoid contact friction between the cold type and peripheral components, radically reduce abrasion of the outer surface of the cold type and prolong the service life of the cold type.

Inventors

WANG YIN
YANG CHENGWEI
LI CHANG
YANG LINLI
WANG HAITAO

Assignees

鞍钢轧辊有限公司

Dates

Publication Date: 20260505
Application Date: 20260227

Claims (10)

1. Horizontal centrifugal casting high accuracy initiative control equipment based on magnetic suspension technique, including automatically controlled cabinet (7), cold form (1) and roller bearing axle, its characterized in that still includes: A transmission system for providing power to the apparatus; A radial suspension support structure providing radial force support for the idler shafts to effect suspension in a radial direction; an axial suspension support structure providing axial force support for the idler shaft to effect suspension in an axial direction; The speed and position detection system is used for detecting the position state and the rotating speed of the carrier roller shaft in real time and feeding back detection signals in real time so as to control the carrier roller shaft to be in a horizontal suspension state; And the protection bearing is used for enabling the cold type roller shaft (2) to have rotation conditions.
2. The horizontal centrifugal casting high-precision active control device based on the magnetic suspension technology as claimed in claim 1, wherein the transmission system is composed of a driving motor (6), a universal coupling (5), a cold type carrier roller (3) and a cold type carrier roller shaft (2), a power input end of the universal coupling (5) is rigidly connected with an output shaft of the driving motor (6), the cold type carrier roller (3) and the carrier roller shaft are coaxial and sleeved on the outer side of the carrier roller shaft, and a roller surface of the cold type carrier roller (3) and an annular groove on the outer surface of the cold type carrier roller (1) are in contact with each other and are in friction transmission.
3. The horizontal centrifugal casting high-precision active control device based on the magnetic suspension technology according to claim 1, wherein the radial suspension supporting structure is composed of an octupole radial magnetic suspension bearing (10), a displacement detection module, a controller and a power amplifier, the octupole radial magnetic suspension bearing (10) is composed of an octupole radial magnetic suspension bearing rotor (16) and an octupole radial magnetic suspension bearing stator (15), the octupole radial magnetic suspension bearing rotor (16) is coaxially and fixedly connected to the outer side of a carrier roller shaft, the octupole radial magnetic suspension bearing stator (15) is coaxially sleeved on the outer side of the octupole radial magnetic suspension bearing rotor (16), magnetic poles are arranged on the inner wall of a stator of the octupole radial magnetic suspension bearing (10) in an annular array, the number of the magnetic poles is 8, a micron-sized uniform air gap is reserved between the magnetic poles and the outer wall of the octupole radial magnetic suspension bearing rotor (16), the surface of the octupole radial bearing (10) is provided with a bearing seat (4), the octupole radial magnetic suspension bearing (10) is assembled on the inner side of the bearing seat (4), and a winding coil A (14) is wound on the magnetic poles.
4. The horizontal centrifugal casting high-precision active control device based on the magnetic suspension technology according to claim 1, wherein the axial suspension supporting structure is composed of two axial magnetic suspension bearings (11), a thrust disc (12), axial displacement detection sensors, a main control unit and a power driving module, wherein the axial magnetic suspension bearings (11) are symmetrically arranged, the thrust disc (12) is coaxially and fixedly connected to the end parts of a cold type roller shaft (2), the two axial magnetic suspension bearings (11) are respectively assembled on supports on two sides of the thrust disc (12), the axial displacement detection sensors are assembled on the supports of the thrust disc (12), the main control unit is electrically connected with the axial displacement detection sensors and the power driving module, winding coils B (17) are arranged in the axial magnetic suspension bearings (11), the power driving module is electrically connected with the winding coils B (17), and the whole axial suspension supporting structure is assembled on a bearing seat (4).
5. The horizontal centrifugal casting high-precision active control device based on the magnetic suspension technology according to claim 1, wherein the speed position detection system is composed of a radial speed position sensor (9), an axial speed position sensor (13) and a signal conditioning unit, the radial speed position sensor (9) is composed of a radial speed sensor probe (18) and a radial position sensor probe (19), the axial speed position sensor (13) is composed of an axial speed sensor probe (20) and an axial position sensor probe (21), and the signal conditioning unit is integrated in an electric control cabinet (7).
6. The horizontal centrifugal casting high-precision active control device based on the magnetic suspension technology as claimed in claim 1, wherein the protection bearing (8) is coaxially sleeved on the outer side of the cold-type carrier roller shaft (2), a preset safety gap is reserved between the inner ring of the protection bearing (8) and the outer wall of the cold-type carrier roller shaft, and the safety gap is smaller than a working air gap of the radial magnetic suspension bearing.
7. A horizontal centrifugal casting high-precision active control process method based on a magnetic suspension technology is characterized by comprising the following steps of: Firstly, equipment assembly and early preparation, namely placing a cold mould (1) on a cold mould carrier roller (3), ensuring contact fit between a preset annular groove of a cold mould shell and a precise surface of the carrier roller, checking that the assembly state of each part is qualified, and simultaneously finishing casting mould pretreatment, raw material smelting refining and cold mould preheating; Secondly, two axial magnetic suspension bearings (11) of the winding coil generate balanced bidirectional axial adsorption force on a thrust disc (12), so that a winding coil A (14) turns to realize a cold-type roller shaft starting magnetic suspension support system according to the orthogonal directions of X+, X-, Y and Y-, a control system is started through an electric control cabinet (7), constant bias current is introduced into a winding coil B (17) in the axial magnetic suspension bearings (11), the two axial magnetic suspension bearings (11) generate balanced bidirectional axial adsorption force on the thrust disc (12), the roller shaft is initially suspended at a preset balance position in the axial direction, meanwhile, 8 groups of winding coils A (14) of an octal radial magnetic suspension bearing (10) generate radial support force according to the orthogonal directions of X+, X-, Y and Y-, so that the cold-type roller shaft is suspended in the radial direction, and the cold-type roller shaft non-contact suspension posture initialization is completed; Starting a driving motor (6), driving a cold type roller shaft (2), a cold type roller (3) and a cold type (1) to rotate through a universal coupling (5), simultaneously starting a radial speed position sensor (9) and an axial speed position sensor (13) to acquire signals in real time, filtering, amplifying, linearizing, filtering, amplifying and linearizing the signals by a signal conditioning unit, and feeding back the signals to a main control unit, wherein the main control unit adjusts the output torque of the driving motor (6) to enable the cold type (1) to reach a preset stable rotating speed; Step four, performing layered pouring operation, namely after the rotating speed of the cold mold (1) is stable, sequentially injecting outer wear-resistant alloy metal liquid and inner ductile material metal liquid into the cold mold (1), continuously receiving position and rotating speed detection signals by a main control unit in the pouring process, and immediately dynamically adjusting exciting current corresponding to a magnetic suspension bearing to push the cold mold roller shaft (2) to reset if radial or axial deviation of the cold mold roller shaft (2) is detected, so as to ensure stable cold mold rotating posture; step five, solidification cooling and posture maintenance, namely keeping the cold mold (1) to rotate at a specific rotating speed until molten metal is naturally solidified, and then cooling to room temperature by forced cooling and natural cooling, wherein a magnetic suspension supporting and detecting system continuously works in the cooling process; and step six, subsequent treatment, namely closing the driving motor (6) and the magnetic suspension bearing system, demoulding, cleaning and checking, and carrying out annealing treatment on qualified castings, and quenching and tempering treatment if necessary to obtain finished products.
8. The horizontal centrifugal casting high-precision active control process method based on the magnetic levitation technology, which is characterized in that the inter-cooling preheating temperature in the first step is 200-400 ℃, the preheating time is 1-2 hours, and the fluctuation of the preset stable rotating speed in the third step is less than or equal to +/-5 r/min.
9. The horizontal centrifugal casting high-precision active control process method based on the magnetic levitation technology, which is characterized in that the casting temperature of the outer layer wear-resistant alloy metal liquid in the fourth step is 1400-1500 ℃, the casting temperature of the inner layer ductile material metal liquid is 1380-1480 ℃, the casting speed is 0.5-2 kg/s, and the interval between two casting is 3-10 minutes.
10. The horizontal centrifugal casting high-precision active control process method based on the magnetic suspension technology according to claim 7, wherein the rotation time of the natural solidification stage of the molten metal in the fifth step is 10-30 minutes, the forced cooling speed is 5-15 ℃ per minute, the forced cooling end temperature is 200-300 ℃, the annealing temperature in the sixth step is 600-700 ℃, and the annealing time is 2-4 hours.

Description

Horizontal centrifugal casting high-precision active control equipment and process method based on magnetic suspension technology Technical Field The invention relates to the technical field of horizontal centrifugal casting equipment, in particular to horizontal centrifugal casting high-precision active control equipment and a process method based on a magnetic suspension technology. Background Under the industry transformation surge that the national development of green low carbon is greatly advanced, the enterprises focus on energy conservation, emission reduction, quality improvement and synergy, the manufacturing enterprises face urgent pressure on process upgrading, and the strategic opportunity of optimizing the industrial structure is met. The horizontal centrifugal casting has the technical advantages of smooth and stable filling, high casting yield, excellent compactness, low defect occurrence rate of air holes, slag inclusion and the like and outstanding mechanical properties, can form a composite layer structure, effectively improves the comprehensive cost performance, becomes one of core processes for forming roller parts at present, and occupies an irreplaceable position in the field of roller production. Compared with the traditional casting process, the horizontal centrifugal casting can accurately realize perfect combination of the wear-resistant layer of the roller body and the ductile layer of the core, greatly improve the service life and service stability of the roller, effectively improve the utilization rate of metal materials, reduce the energy consumption and waste discharge in the production process, and completely meet the development requirements of high quality and greenization of the current manufacturing industry. In the horizontal centrifugal casting process, the centrifugal machine is operated, casting mould is rotated, uneven density of a molten metal pouring solidification layer and the like causes offset load superposition, so that the system bears the dynamic load effect caused by the fluctuation effect of centrifugal force and the impact of molten metal for a long time, and the system is extremely easy to induce vibration due to the coupling effect of high-speed rotation, high-temperature radiation, the force of the impact of molten metal flowing, heat and flow multi-field intensity. The vibration causes have multisource property, such as main shaft abrasion, coaxiality deviation, bearing damage or insufficient lubrication of a device layer, unstable installation caused by fluctuation of rotation speed of a driving system and loosening of foundation bolts, uneven wall thickness of a casting mold layer, gravity center deviation caused by unbalance of material density and overlarge assembling clearance with the main shaft, unstable pouring speed and flow of molten metal of a process layer, improper control of two pouring intervals and too high cooling speed, excessive impurities of molten metal of the material layer, uneven solidification shrinkage caused by large temperature fluctuation, internal stress and the like, and become vibration causes. The vibration is obviously harmful to horizontal centrifugal casting production and casting quality, uneven inner wall and uneven wall thickness of the casting can be caused, the metallurgical bonding effect of a roller wear-resistant layer and a core part is damaged, the defect occurrence rate of air holes, slag inclusion, cracks and the like is greatly increased, the compactness and mechanical property of the casting are reduced, the abrasion of key parts such as a centrifuge main shaft and a bearing is further aggravated, the service life of equipment is shortened, equipment failure shutdown is caused during serious conditions, even casting mould deviation, molten metal splashing and other safety accidents are caused, and serious influence is caused on continuous casting production operation of the roller. However, the conventional vibration prevention and control measures, such as conventional equipment calibration, casting mold optimization, process parameter regulation and control and the like, can alleviate the vibration problem to a certain extent, are limited by the technical characteristics of the conventional vibration prevention and control measures, are difficult to cope with complex dynamic loads under high-speed rotation and multi-field coupling, have the defects of insufficient vibration suppression precision, narrow adaptive working condition range, poor long-term service stability and the like, and cannot radically solve the influence of vibration causes on a casting system. For this reason, it is highly desirable to introduce more advanced support and vibration damping techniques to reduce or suppress the casting defects and hazards caused by vibration. The magnetic suspension technology has the characteristics of quick response, high precision, compact structure and easy realization of multi-degree-of-freedom