电解铝气幕铸造机计算机控制系统开发
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摘要
电解铝气幕铸造机是中国铝业股份有限公司贵州分公司于1999年从加拿大o.d.t工程有限公司引进的设备。随着时代的发展,原计算机控制系统在软件和硬件技术上已经非常落后,有待升级提高。同时原计算机控制系统还存在一些问题,经常造成系统死机,致使其运行工况不稳定,产品合格率低,能耗高,热效率低,工人劳动强度大,环境污染严重。
在充分了解原计算机控制系统和气幕铸造机生产工艺的基础上,提出了原计算机控制系统不能满足生产的需要,有必要进行电解铝气幕铸造机计算机控制系统的开发。简要介绍了项目的技术背景及国内外发展水平,指出了原计算机控制系统在软件、硬件以及环境等方面存在的问题,从铝合金气幕铸造工艺和控制系统与控制算法三方面介绍了国内外研究现状。针对所存在的问题,采用的解决方法主要有：通过铸造工艺的分析,更合理地利用各种技术手段来设计铸造工艺控制系统;通过软、硬件升级,提升计算机控制系统的技术性能;引入先进的计算机技术,提高控制系统的稳定性、收敛性和鲁棒性。
简要介绍了气幕铸造机的系统组成,给出了计算机控制系统的需求、动作顺序及总体设计。在系统的硬件设计方面,详细描述了立式铸机(VDC) PLC、模具空气1系统PLC、模具空气2系统PLC及MMI(人机界面)的硬件设计。给出了模糊控制器、专家系统和PID控制器的设计及系统的控制策略。对软件开发工具RSView32、RSLinx、RSLogix 500TM及RSLogix Emulate 500TM进行了简要的介绍,并对软件开发进行了说明。本计算机控制系统具有一定的特点,通过实际应用,取得了很好的效果。
The gas curtain casting machine was fetched in Guizhou branch of Aluminum Corporation of China Limited from Canada o.d.t engineering limited company in 1999. Along with the development of the ages, the original computerization control system has fallen behind very much in software and hardware technique, and needs to upgrade and advance. The original computerization control system has some problems, usually results in the system halted, the produce process is unsteady, and the eligible rate of the production is low, high energy consumption, low thermal efficiency, heavy intensity of labor and seriously environmental pollution.
Fully understood the original computerization control system and the production craft of the gas curtain casting machine, we put forward that the original computerization control system hasn't satisfied the demand of the production, there is necessity to development the computerization control system for the molten aluminum gas curtain casting machine. Simply introduced the technique background and domestic and international development level of the item, pointed out that the original computerization control system has some problems in software, hardware and environment, and introduced the domestic and international research circumstance with the aluminum alloy gas curtain casting, the control system and the control calculation. Aim at the existing problems, we adopted the following methods primarily:through analyse the casting technics, design the casting control system adopting kinds of technique more reasonably; through upgraded the software and the hardware, we steped up the capability of the control system; lead into the advanced computer technique, increase the stability, the astringency and the robustness of the control system.
Simply introduced the makeup of the gas curtain casting machine. The needs, the action order and the total design of the computerization control system are given. Detailedly discribed the hardware design of the VDC PLC, mould air 1 system PLC, mould air 2 system PLC and MMI. The design of misty controller, expert system and PID controller are given, the control strategy of the system is also given. Simply introduced the software development tool:RSView32, RSLinx, RSLogix 500TM and RSLogix Emulate 500TM, and gave an elucidation to the software development. The computerization control system has some certain characteristics and it obtained large effect in practice.
在充分了解原计算机控制系统和气幕铸造机生产工艺的基础上,提出了原计算机控制系统不能满足生产的需要,有必要进行电解铝气幕铸造机计算机控制系统的开发。简要介绍了项目的技术背景及国内外发展水平,指出了原计算机控制系统在软件、硬件以及环境等方面存在的问题,从铝合金气幕铸造工艺和控制系统与控制算法三方面介绍了国内外研究现状。针对所存在的问题,采用的解决方法主要有：通过铸造工艺的分析,更合理地利用各种技术手段来设计铸造工艺控制系统;通过软、硬件升级,提升计算机控制系统的技术性能;引入先进的计算机技术,提高控制系统的稳定性、收敛性和鲁棒性。
简要介绍了气幕铸造机的系统组成,给出了计算机控制系统的需求、动作顺序及总体设计。在系统的硬件设计方面,详细描述了立式铸机(VDC) PLC、模具空气1系统PLC、模具空气2系统PLC及MMI(人机界面)的硬件设计。给出了模糊控制器、专家系统和PID控制器的设计及系统的控制策略。对软件开发工具RSView32、RSLinx、RSLogix 500TM及RSLogix Emulate 500TM进行了简要的介绍,并对软件开发进行了说明。本计算机控制系统具有一定的特点,通过实际应用,取得了很好的效果。
The gas curtain casting machine was fetched in Guizhou branch of Aluminum Corporation of China Limited from Canada o.d.t engineering limited company in 1999. Along with the development of the ages, the original computerization control system has fallen behind very much in software and hardware technique, and needs to upgrade and advance. The original computerization control system has some problems, usually results in the system halted, the produce process is unsteady, and the eligible rate of the production is low, high energy consumption, low thermal efficiency, heavy intensity of labor and seriously environmental pollution.
Fully understood the original computerization control system and the production craft of the gas curtain casting machine, we put forward that the original computerization control system hasn't satisfied the demand of the production, there is necessity to development the computerization control system for the molten aluminum gas curtain casting machine. Simply introduced the technique background and domestic and international development level of the item, pointed out that the original computerization control system has some problems in software, hardware and environment, and introduced the domestic and international research circumstance with the aluminum alloy gas curtain casting, the control system and the control calculation. Aim at the existing problems, we adopted the following methods primarily:through analyse the casting technics, design the casting control system adopting kinds of technique more reasonably; through upgraded the software and the hardware, we steped up the capability of the control system; lead into the advanced computer technique, increase the stability, the astringency and the robustness of the control system.
Simply introduced the makeup of the gas curtain casting machine. The needs, the action order and the total design of the computerization control system are given. Detailedly discribed the hardware design of the VDC PLC, mould air 1 system PLC, mould air 2 system PLC and MMI. The design of misty controller, expert system and PID controller are given, the control strategy of the system is also given. Simply introduced the software development tool:RSView32, RSLinx, RSLogix 500TM and RSLogix Emulate 500TM, and gave an elucidation to the software development. The computerization control system has some certain characteristics and it obtained large effect in practice.
引文
1.杨孟刚.铝及铝合金气幕铸造工艺[J],有色金属加工,2002,31(4)：33-35
2.井满清.6063铝合金铸棒生产中几种常见缺陷的分析与防止[J],铸造技术,2007,28(5)：717-719
3.张泰山等.连续铸造机计算机控制系统[J],中南矿冶学院学报,1994,25(1)：96-100
4.钟映春等.铝合金车轮低压铸造智能控制系统的研究与实践[J],机床与液压,2005(5)：107-108+118
5.孙勇.计算机模拟在铸造中的应用及其软件的开发[J],铸造设备研究,2005(2)：20-22
6.孙丽文等.铸件热应力及热裂的数值模拟研究[J],铸造设备研究,2006(3)：18-20
7.马建华.热分析技术在铸铁领域的应用[J],中国铸造装备与技术,2007(1)：20-23
8.李吉文等.PLC在铝锭连续铸造机组上的应用[J],有色设备,2004(3)：23-24
9.吴成玉等.立式半连续铝棒铸造机[J],中国铸机,1995(6)：28-29
10.康瑾.提高铝杆连铸机产量的途径[J],轻合金加工技术,1994,22(4)：10-11
11.于守信.生产铝合金锭的立式半连铸设备的新发展[J],有色金属加工1992(3)：1-5
12.袁晓东.立式半连续铸造机油路设计[J],特种铸造及有色合金,1991(3)：40-40
13.邢小军等.基于LabVIEW的分布式调压铸造计算机控制系统设计[J],制造业自动化,2004,26(3)：42-43,543
14.任天庆.铸造设备自动控制系统设计[M],北京：国防工业出版社,1990
15.李建超等.铸造铝合金圆锭温度场试验研究和数值模拟[J],特种铸造及有色合金,2006,26(6)：337-339
16.邵正荣等.铝合金铸造工艺与铸锭质量的关系[J],轻合金加工技术,2006, 34(4)：16-17
17.彭学仕等.半连续铸锭缺陷及其预防措施[J],铝加工,1994,17(2)：1-13,24
18.许音等.铝合金铸件尺寸精度主要影响因素分析[J],科技情报开发与经济,2007,17(2)：182-184
19.李魁胜.铸造工艺设计基础[M],北京：机械工业出版社,1989
20.熊艳才.铸造铝合金现状及未来发展[J],特种铸造及有色合金,1998(4)：1-5
21. o.d.t.Engineering. Operating and Maintenance Manual AIRSOL VEIL-Mould [M],1999
22. o.d.t.Engineering. Vertical Casting Machine (VDC) and Mould Station Electrical Control System [M],1999
23. Rockwell. Developing RSView Supervisory Edition Applications [M],2003
24. John Paris, Michael Matisko. DC casting station equipment and procedural modifications to allow safe aborts [J], Light Metals,2005:825-828
25. P. E. King. Design and operation of an experimental reverberatory aluminum furnace [J], Light Metals,2005:899-904
26. Li, T., King, P. E., Hassan, M., Kuwana, K. and Saito, K. An Analytical Furnace Model for Optimizing Aluminum Melting, to be presented at the TMS 2005,134th Annual Meeting & Exhibition, San Francisco, CA, Feb.2005.
27. Golchert, B. M., Zhou, C.Q., Quenette, A., Han, Q., and King, P. E., Combustion Space Modeling of an Aluminum Furnace, to be presented at the TMS 2005,134th Annual Meeting & Exhibition, San Francisco, CA, Feb.2005.
28. Li, T.X., Hassan, M., Kuwana, K., Saito, K., and King P., Performance of Secondary Aluminum Melting:Thermodynamic Analysis and Plant-Site experiments, Submitted for publication in Energy,2004.
29. D.V.Neff, "Molten Metal Pumping & Pipeline Transport in Aluminum Cast Houses," The Aluminum Association, The Aluminum Industry Energy Conservation Workshop, Washington D.C. USA,20-21 October 1987.
30. D.V.Neff, "Furnace Stirring & Melting-A Review," Sixth Australian Asian Pacific Conference on Aluminium Cast House Technology,1999.
31. Gripenberg, et al. Controlled melting of secondary aluminium in rotary furnaces, TMS Light Metals 2003
2.井满清.6063铝合金铸棒生产中几种常见缺陷的分析与防止[J],铸造技术,2007,28(5)：717-719
3.张泰山等.连续铸造机计算机控制系统[J],中南矿冶学院学报,1994,25(1)：96-100
4.钟映春等.铝合金车轮低压铸造智能控制系统的研究与实践[J],机床与液压,2005(5)：107-108+118
5.孙勇.计算机模拟在铸造中的应用及其软件的开发[J],铸造设备研究,2005(2)：20-22
6.孙丽文等.铸件热应力及热裂的数值模拟研究[J],铸造设备研究,2006(3)：18-20
7.马建华.热分析技术在铸铁领域的应用[J],中国铸造装备与技术,2007(1)：20-23
8.李吉文等.PLC在铝锭连续铸造机组上的应用[J],有色设备,2004(3)：23-24
9.吴成玉等.立式半连续铝棒铸造机[J],中国铸机,1995(6)：28-29
10.康瑾.提高铝杆连铸机产量的途径[J],轻合金加工技术,1994,22(4)：10-11
11.于守信.生产铝合金锭的立式半连铸设备的新发展[J],有色金属加工1992(3)：1-5
12.袁晓东.立式半连续铸造机油路设计[J],特种铸造及有色合金,1991(3)：40-40
13.邢小军等.基于LabVIEW的分布式调压铸造计算机控制系统设计[J],制造业自动化,2004,26(3)：42-43,543
14.任天庆.铸造设备自动控制系统设计[M],北京：国防工业出版社,1990
15.李建超等.铸造铝合金圆锭温度场试验研究和数值模拟[J],特种铸造及有色合金,2006,26(6)：337-339
16.邵正荣等.铝合金铸造工艺与铸锭质量的关系[J],轻合金加工技术,2006, 34(4)：16-17
17.彭学仕等.半连续铸锭缺陷及其预防措施[J],铝加工,1994,17(2)：1-13,24
18.许音等.铝合金铸件尺寸精度主要影响因素分析[J],科技情报开发与经济,2007,17(2)：182-184
19.李魁胜.铸造工艺设计基础[M],北京：机械工业出版社,1989
20.熊艳才.铸造铝合金现状及未来发展[J],特种铸造及有色合金,1998(4)：1-5
21. o.d.t.Engineering. Operating and Maintenance Manual AIRSOL VEIL-Mould [M],1999
22. o.d.t.Engineering. Vertical Casting Machine (VDC) and Mould Station Electrical Control System [M],1999
23. Rockwell. Developing RSView Supervisory Edition Applications [M],2003
24. John Paris, Michael Matisko. DC casting station equipment and procedural modifications to allow safe aborts [J], Light Metals,2005:825-828
25. P. E. King. Design and operation of an experimental reverberatory aluminum furnace [J], Light Metals,2005:899-904
26. Li, T., King, P. E., Hassan, M., Kuwana, K. and Saito, K. An Analytical Furnace Model for Optimizing Aluminum Melting, to be presented at the TMS 2005,134th Annual Meeting & Exhibition, San Francisco, CA, Feb.2005.
27. Golchert, B. M., Zhou, C.Q., Quenette, A., Han, Q., and King, P. E., Combustion Space Modeling of an Aluminum Furnace, to be presented at the TMS 2005,134th Annual Meeting & Exhibition, San Francisco, CA, Feb.2005.
28. Li, T.X., Hassan, M., Kuwana, K., Saito, K., and King P., Performance of Secondary Aluminum Melting:Thermodynamic Analysis and Plant-Site experiments, Submitted for publication in Energy,2004.
29. D.V.Neff, "Molten Metal Pumping & Pipeline Transport in Aluminum Cast Houses," The Aluminum Association, The Aluminum Industry Energy Conservation Workshop, Washington D.C. USA,20-21 October 1987.
30. D.V.Neff, "Furnace Stirring & Melting-A Review," Sixth Australian Asian Pacific Conference on Aluminium Cast House Technology,1999.
31. Gripenberg, et al. Controlled melting of secondary aluminium in rotary furnaces, TMS Light Metals 2003
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