CN-122007361-A - Aluminum ingot alignment device and method for aluminum ingot continuous casting production line

CN122007361ACN 122007361 ACN122007361 ACN 122007361ACN-122007361-A

Abstract

The invention relates to an automatic control technology for aluminum ingot continuous casting production, and discloses an aluminum ingot alignment device and method for an aluminum ingot continuous casting production line, wherein the method is characterized in that the instantaneous speed and acceleration of the production line, the attitude angular speed of the aluminum ingot, the bottom surface temperature, the thickness of a cooling water residual water film, the spraying amount of a release agent, the vibration amplitude and the quality of the aluminum ingot are collected in real time, and running state data of the sensor and the executing mechanism are sequentially calculated, namely a motion instability coefficient, a surface slip coefficient, a risk coupling coefficient and a system reliability coefficient are sequentially calculated, and the target PLC delay trigger time is dynamically calculated based on the coefficients, so that the self-adaptive accurate adjustment of the timing machine is realized. The invention solves the problems that the traditional fixed delay or single parameter feedback control method can not adapt to complex working conditions and is easy to cause inaccurate alignment, and remarkably improves the accuracy of aluminum ingot alignment, the running stability of a production line and the consistency of product quality.

Inventors

LU JIANXING
YU DONGPING
Nie Jinfei
WU WENHAO

Assignees

江西宏成铝业有限公司

Dates

Publication Date: 20260512
Application Date: 20260228

Claims (7)

1. An aluminum ingot alignment method for an aluminum ingot continuous casting production line, comprising the steps of: calculating and acquiring a motion instability coefficient based on the instantaneous speed and the instantaneous acceleration of the production line and the attitude angular speed of the aluminum ingot; calculating and obtaining a surface slip coefficient based on the bottom surface temperature of the aluminum ingot, the thickness of the residual water film of the cooling water and the spraying amount of the release agent; Calculating and obtaining a risk coupling coefficient based on the motion instability coefficient, the surface slip coefficient, the aluminum ingot vibration amplitude and the aluminum ingot mass; Calculating and acquiring a system reliability coefficient based on the debounce time of the sensor signals, the standard deviation of the multi-sensor readings and the response time deviation of the actuating mechanism; based on the basic delay, the risk coupling coefficient and the system reliability coefficient, calculating and obtaining the PLC delay trigger time of the target alignment judgment, and adjusting the PLC delay trigger time of the current alignment judgment to the PLC delay trigger time of the target alignment judgment.
2. The method for aligning aluminum ingot in aluminum ingot continuous casting production line according to claim 1, wherein the step of calculating the PLC delay trigger time for obtaining the target alignment judgment is as follows: Acquiring a current basic delay, a risk coupling coefficient and a system reliability coefficient; dynamically determining an additional delay amount within a preset maximum allowable additional delay range according to a system reliability coefficient and a risk coupling coefficient; Adding the basic delay and the additional delay amount to obtain the PLC delay triggering time for target alignment judgment; When the system reliability coefficient is high, the adaptive adjustment is carried out within the maximum allowable additional delay range according to the size of the risk coupling coefficient.
3. The method for aligning an aluminum ingot in an aluminum ingot continuous casting production line according to claim 2, wherein the step of calculating and acquiring the system reliability coefficient is: Acquiring the debounce time of a current sensor signal, the standard deviation of multi-sensor readings and the response time deviation of an actuating mechanism; normalizing the debounce time of the sensor signal by a negative exponential decay function, and calculating a signal stability factor, wherein the signal stability factor decreases along with the increase of the debounce time; carrying out ratio processing on the current multi-sensor reading standard deviation and the maximum allowable standard deviation, and taking the complement of the ratio as a multi-sensor consistency factor; Calculating the response reliability factor of the actuating mechanism according to the ratio of the response time deviation of the actuating mechanism to the maximum allowable deviation through a linear decay function, wherein the response reliability factor of the actuating mechanism decreases along with the increase of the deviation; And taking the minimum value of the signal stability factor, the multi-sensor consistency factor and the actuator response reliability factor as a system reliability coefficient.
4. The method for aligning aluminum ingots in an aluminum ingot continuous casting production line as claimed in claim 2, wherein the step of calculating and obtaining risk coupling coefficients is as follows: acquiring a current motion instability coefficient, a surface slip coefficient, an aluminum ingot vibration amplitude and an aluminum ingot mass; Performing ratio processing on the current vibration amplitude of the aluminum ingot and the reference vibration amplitude to obtain an index of the vibration amplitude of the aluminum ingot; Carrying out maximum-minimum normalization treatment on the current aluminum ingot quality to obtain an aluminum ingot quality index; combining the motion instability coefficient with the quality index of the aluminum ingot to form a motion risk component; Combining the surface slip coefficient with the aluminum ingot vibration amplitude index to form a surface risk component; Performing weighted square sum fusion operation on the motion risk component and the surface risk component, and performing evolution processing on an operation result to obtain a risk coupling coefficient in a range of 0 to 1; The risk coupling coefficient is 0, which indicates that the risk of multi-factor coupling is lowest, and the risk coupling coefficient is 1, which indicates that the risk of multi-factor coupling is highest.
5. The method for aligning an aluminum ingot in an aluminum ingot continuous casting line according to claim 4, wherein the step of calculating and acquiring a motion instability coefficient is: Acquiring the instantaneous speed and the instantaneous acceleration of the current production line and the attitude and angular speed of an aluminum ingot; performing ratio processing on the instantaneous speed of the current production line and the maximum speed of the production line design to obtain an instantaneous speed index of the production line; Calculating an instantaneous acceleration index of the production line through a hyperbolic tangent function according to the ratio of the instantaneous acceleration to the reference acceleration, wherein the instantaneous acceleration index of the production line monotonically increases and tends to be saturated along with the increase of the instantaneous acceleration; calculating an aluminum ingot attitude angular velocity index through an exponential decay type complementary function according to the ratio of the current aluminum ingot attitude angular velocity to the reference angular velocity, wherein the aluminum ingot attitude angular velocity index monotonically increases and tends to be saturated along with the increase of the angular velocity; And carrying out weighted summation on the instantaneous speed index of the production line and the instantaneous acceleration index of the production line, modulating the weight of the instantaneous acceleration index item of the production line by the attitude and angular speed index of the aluminum ingot to amplify the unstable effect of the instantaneous acceleration of the production line by the attitude and angular speed of the aluminum ingot, and carrying out amplitude limiting treatment on the weighted summation result to obtain the motion unstable coefficient between 0 and 1.
6. The method for aligning an aluminum ingot in an aluminum ingot continuous casting line according to claim 4, wherein the step of calculating the obtained surface slip coefficient is: acquiring the bottom surface temperature of the current aluminum ingot, the thickness of the residual water film of cooling water and the spraying amount of a release agent; The bottom surface temperature and the release agent spraying amount of the current aluminum ingot are respectively processed in a ratio to the maximum allowable temperature and the maximum allowable release agent spraying amount of the bottom surface of the aluminum ingot, and after the upper limit of the limiting ratio of the min function is 1, a bottom surface temperature index and a release agent spraying amount index are obtained; Calculating a cooling water residual water film thickness index according to the ratio of the cooling water residual water film thickness to the critical water film thickness through a square function, wherein the cooling water residual water film thickness index increases along with the increase of the cooling water residual water film thickness; Superposing and fusing the thickness index of the residual water film of the cooling water and the spraying quantity index of the release agent to obtain a comprehensive lubrication factor; the bottom surface temperature index amplifies the comprehensive lubrication factor and obtains a surface slip coefficient, and the surface slip coefficient monotonically increases along with the increase of the bottom surface temperature index, the cooling water residual water film thickness index and the release agent spraying amount index.
7. An aluminum ingot alignment device used in an aluminum ingot continuous casting production line is characterized by comprising a memory, a control unit and a control unit, wherein the memory is used for storing a computer program; A processor for carrying out the steps of the aluminium ingot alignment method for use in an aluminium ingot continuous casting line as claimed in any one of claims 1 to 6 when executing a computer program.

Description

Aluminum ingot alignment device and method for aluminum ingot continuous casting production line Technical Field The invention belongs to an automatic control technology for aluminum ingot continuous casting production, and particularly relates to an aluminum ingot alignment device and method for an aluminum ingot continuous casting production line. Background The aluminum ingot continuous casting production line is used as a core link of aluminum smelting processing, and the geometric regularity and the surface quality of the produced aluminum ingot directly determine the implementation effect of the subsequent transportation, storage and deep processing technology. In the continuous casting process, after the high-temperature molten aluminum is cooled and molded by a crystallizer, the high-temperature molten aluminum is required to be transferred to a stacking or weighing station through a conveying mechanism. In actual production, the aluminum ingot is often subjected to position deviation due to multiple dynamic factors, namely motion inertia unbalance is caused by instantaneous speed fluctuation and acceleration change during the operation of a production line, the rotation effect caused by the attitude angular speed of the aluminum ingot aggravates attitude torsion, and meanwhile, the friction characteristics of a conveying interface are obviously changed under the combined action of uneven temperature distribution of the bottom surface of the aluminum ingot, water film thickness change formed by cooling water residues and release agent spraying quantity difference. In addition, the vibration amplitude and the mass difference of the aluminum ingot further amplify the motion instability, and the problems of sensor signal jitter, multi-sensor reading discreteness, actuating mechanism response time deviation and the like in a control system are solved, so that the state change of the aluminum ingot is difficult to accurately capture by a traditional alignment mechanism. Two types of alignment control strategies are commonly adopted in the current industry. The first type is based on a triggering mode of a fixed delay or position sensor, and the alignment mechanism is started only according to a preset time point or a fixed position signal, so that real-time motion characteristics such as continuous change of production line speed, dynamic fluctuation of acceleration, attitude and angular speed of an aluminum ingot and the like can not be sensed. The second type of control method introducing simple sensor feedback can monitor single parameters such as the overtemperature or the speed overthreshold of the aluminum ingot, but has the fundamental defects that control logic is isolated to treat each influencing factor, a coupling relation model between the bottom surface temperature, the water film thickness and the release agent spraying amount cannot be established, the comprehensive influence on the surface slip risk is ignored, and meanwhile the amplification effect of the vibration amplitude and the mass of the aluminum ingot on the motion inertia risk is ignored, so that risk assessment distortion is caused. More importantly, the existing scheme lacks a quantitative evaluation mechanism for the reliability of the control system, and cannot dynamically correct control parameters according to the debounce time of sensor signals, the standard deviation of readings and the response deviation of an actuating mechanism. Therefore, under complex working conditions such as fluctuation of aluminum liquid cooling speed, change of environmental temperature and humidity or ageing of equipment, the phenomenon of advancing or lagging frequently occurs when the aluminum ingot is triggered, so that the interlocking problems such as aluminum ingot stacking deflection, bundling structure failure, weighing data misalignment and the like are caused, and the collision of a conveying mechanism or the unplanned shutdown of a production line is caused when the problem is serious, so that the overall production efficiency and the product consistency are restricted. In view of the above, there is a need in the art for improvements. Disclosure of Invention The embodiment of the invention aims to provide an aluminum ingot alignment device and method for an aluminum ingot continuous casting production line, and aims to solve the problems. The aluminum ingot alignment method for the aluminum ingot continuous casting production line comprises the steps of calculating and obtaining a motion instability coefficient based on the instantaneous speed and the instantaneous acceleration of the production line and the attitude angular speed of the aluminum ingot, calculating and obtaining a surface slip coefficient based on the bottom surface temperature of the aluminum ingot, the residual water film thickness of cooling water and the spraying amount of a release agent, calculating and obtaining a risk coupling coefficient based on the motio