阅读说明：本技术 一种基于多传感器技术的熔铸铝水防溢漏系统装置 (Fusion cast molten aluminum anti-overflow system device based on multi-sensor technology ) 是由 李玉军 周国斌 焦尚彬 梁琨 张青 杜京航 于 2021-09-03 设计创作，主要内容包括：本发明公开了一种基于多传感器技术的熔铸铝水防溢漏系统装置,包括支架,支架上安装驱动机构、传感器阵列,驱动机构包括电机、滑动托板、封堵头；传感器阵列的信号线及电源线经过升降压模块后与ARM主控器连接；ARM主控器和LCD显示屏通过信号线通讯连接,LCD显示屏将ARM主控器处理好的各项数据显示在LCD显示屏上；电机通过导线与ARM主控器连接,ARM主控器电源和外部供电连接,传感器阵列用信号线连接AC/DC转换模块后电性连接ARM主控器,传感器阵列有呈对称状分布在驱动机构下方的支架上；采用了多个传感器,可有效测量出铝口铝水温度、铝水流量,板载温度及封堵杆位移情况等各项参数,实现对铝水流量的实时监控；能够对出铝口铝水流量进行预测和预警。(The invention discloses a fusion casting molten aluminum anti-overflow leakage system device based on a multi-sensor technology, which comprises a bracket, wherein a driving mechanism and a sensor array are arranged on the bracket, and the driving mechanism comprises a motor, a sliding supporting plate and a blocking head; the signal line and the power line of the sensor array are connected with the ARM main controller after passing through the buck-boost module; the ARM main controller is in communication connection with the LCD display screen through a signal line, and the LCD display screen displays various data processed by the ARM main controller on the LCD display screen; the motor is connected with the ARM main controller through a wire, a power supply of the ARM main controller is connected with an external power supply, the sensor array is electrically connected with the ARM main controller after being connected with the AC/DC conversion module through a signal wire, and the sensor array is symmetrically distributed on the bracket below the driving mechanism; by adopting a plurality of sensors, the aluminum water temperature of the aluminum port, the aluminum water flow, the onboard temperature, the displacement condition of the plugging rod and other parameters can be effectively measured, and the aluminum water flow can be monitored in real time; can predict and early warn the aluminum water flow of the aluminum outlet.)

1. A fusion cast molten aluminum anti-overflow leakage system device based on a multi-sensor technology is characterized by comprising a support (6), wherein a driving mechanism (1) and a sensor array (3) are installed on the support (6), and the driving mechanism (1) comprises a motor (2), a sliding supporting plate and a blocking head; an output shaft of the motor (2) is connected with a driving lead screw of the sliding support plate, the sliding support plate is driven to slide back and forth on the driving lead screw, and the sliding support plate is fixedly connected with the blocking head (7) and drives the blocking head (7) to move back and forth to complete the opening and blocking of an aluminum outlet; the signal wire and the power wire of the sensor array (3) are connected with the ARM main controller (4) after passing through the buck-boost module;

the ARM main controller (4) is in communication connection with the LCD display screen (5) through a signal line, and the LCD display screen (5) displays various data processed by the ARM main controller (4) on the LCD display screen (5); the motor (2) is connected with the ARM main controller (4) through a wire, a power supply of the ARM main controller (4) is connected with an external power supply, and the sensor array (3) is electrically connected with the ARM main controller (4) after being connected with the AC/DC conversion module through a signal line; the sensor array (3) is symmetrically distributed on the bracket (6) below the driving mechanism (1);

the system also comprises a human-computer interaction unit; the man-machine interaction unit is communicated with the LCD display screen (5) through the RS232 communication module, and displays the temperature of the molten aluminum, the flow of the molten aluminum and the onboard temperature measured by the measured sensor array (3) in real time.

2. The molten aluminum water anti-overflow leakage system device based on multi-sensor technology as claimed in claim 1, wherein: the sensor array (3) comprises a temperature sensor, a flow sensor and a proximity inductive switch; the sensor array (3) comprises a temperature sensor, a flow sensor and a proximity inductive switch which are all connected with the ARM main controller (4).

3. The molten aluminum water anti-overflow leakage system device based on multi-sensor technology as claimed in claim 1, wherein: the sensor array (3) is powered by the converted direct current; the A/D analog-to-digital converter is used as a signal analog quantity acquisition unit.

4. The molten aluminum anti-overflow and leakage system device based on multi-sensor technology of claim 2, wherein the ARM controller is further electrically connected with the A/D digital-to-analog converter, the data memory, the LCD screen, the JTAG, the indicator light and the key.

5. The molten aluminum water anti-overflow and leakage system device based on multi-sensor technology as claimed in claim 4, wherein the data storage is any one of SPI _ FLASH word bank memory and EEPROM power-down data storage.

6. A detection method of a fusion casting aluminum water anti-overflow leakage system device based on a multi-sensor technology is characterized by comprising the following steps:

step A, when a motor (2) of a driving mechanism (1) works, a plugging rod is driven to move back and forth to complete the opening and plugging of an aluminum outlet; the motor is connected with the ARM main controller (4) through a wire and is controlled by the ARM main controller (4); the sensor array realizes the omnibearing monitoring of the aluminum outlet;

b, a temperature sensor detects the temperature of the aluminum liquid and converts the temperature value into a voltage value; the flow sensor detects the flow of the aluminum water at the aluminum port;

step C, converting the analog quantity into digital quantity by the A/D converter, and storing the data by the data memory;

d, the ARM controller (4) performs data fusion on the converted data, performs data processing on the aspect of algorithm on a program, and finally performs data display on each parameter information through an LCD display screen (5);

step E, when emergency situations such as water cut-off and power failure occur, a program triggers an alarm function, an ARM main controller transfers a motor and drives a traction device to complete the locking and plugging processes of a plugging head (7), and molten aluminum is prevented from leaking;

and F, after the emergency situation is relieved, a signal is sent to the ARM controller (4) through a key to drive the blocking head (7) to move backwards, the original position is recovered under the guidance of the inductive switch sensor, and the LCD display screen (5) is communicated to display the information of each parameter, so that the real-time online monitoring of the aluminum outlet is realized.

Technical Field

The invention relates to the technical field of sensor detection, in particular to a fusion casting molten aluminum water anti-overflow leakage system device based on a multi-sensor technology.

Background

At present, the modernization construction of our country is developed rapidly, the modernization of the national defense industry and the development of the civil industry, especially the transportation industry, are all independent of aluminum bars, the demand of the domestic market is huge, the international market also has a large gap, and in the process of aluminum bar production, the problem of melt-cast molten aluminum overflow leakage prevention is the most important problem, if the problem is not dealt with in time, the cast bar can not be cooled, the cast bar is broken, a large amount of aluminum is leaked, the production fails, even a large amount of aluminum is leaked into a well, a large amount of steam is generated to hurt operators, and serious safety accidents are caused. In recent years, explosion of aluminum plants occurs frequently, and most of the reasons are caused by aluminum leakage and failure in timely blockage of an aluminum outlet. Liquid aluminum is filled in the furnace, once aluminum leaks, high-temperature aluminum liquid leaks out rapidly, personnel cannot approach the place where the aluminum liquid arrives, and manual work cannot effectively leak the leakage; however, many aluminum factories are rarely or even not equipped with automatic plugging devices, if an aluminum leakage accident that cannot be blocked manually occurs, a major accident is likely to happen, and a fusion-cast aluminum water anti-overflow leakage system device is rarely reported. Therefore, it is necessary to design an automatic plugging device to solve the above problems.

The overflow and leakage prevention of the molten aluminum is mainly realized by manually pushing and plugging waste rocks by workers at present so as to achieve the purpose of overflow and leakage prevention. At the present stage, the operation mode has great dependence on workers and consumes a great deal of manpower and material resources. The operation mechanism not only increases operation links, but also is easily interfered by external factors, and each parameter is judged only by manual experience, so that long-time stable operation is difficult to realize. Other semi-automatic plugging devices only depend on electric power to drive the plugging device to realize simple switching, and have no specific parameter quantitative display and human-computer interaction functions. The casting molten aluminum anti-overflow system device is relatively simple in structure, has the advantages that the multi-sensor can measure parameters such as the power supply condition of an aluminum port, the temperature of molten aluminum, the flow of molten aluminum and the onboard temperature, is easy to calibrate, has a good human-computer interaction interface, improves monitoring efficiency and precision, guarantees production safety, and has the characteristics of stable operation, safety and reliability.

Disclosure of Invention

Technical problem to be solved

Aiming at the defects of the prior art, the invention provides a fusion casting aluminum water anti-overflow leakage system device based on a multi-sensor technology. With aluminium liquid flow detection, aluminium liquid temperature detection, device position detection combines, flow sensor can detect the flow size of aluminium water, temperature sensor can detect the aluminium water temperature, whether proximity sensing switch detects the shutoff pole and reachs the assigned position, whether MCU detection device power supply is normal, thereby realize the current-limiting control to the aluminium water flow, the excessive hourglass problem of aluminium water is solved to the efficient, it is strong to have the feasibility, the precision is high, reduce the incident that manual work received the interference of external factor and caused, practice thrift cost and safe and reliable's characteristics.

(II) technical scheme

In order to achieve the purpose, the invention provides the following technical scheme: a fusion casting molten aluminum anti-overflow leakage system device based on a multi-sensor technology comprises a support, wherein a driving mechanism and a sensor array are installed on the support, and the driving mechanism comprises a motor, a sliding supporting plate and a plugging head; the output shaft of the motor is connected with a driving lead screw of the sliding support plate, the sliding support plate is driven to slide back and forth on the driving lead screw, and the sliding support plate is fixedly connected with the blocking head and drives the blocking head to move back and forth to complete the opening and blocking of the aluminum outlet; the signal wire and the power wire of the sensor array are connected with the ARM main controller after passing through the buck-boost module;

the ARM main controller is in communication connection with the LCD display screen through a signal line, and the LCD display screen displays various data processed by the ARM main controller on the LCD display screen; the motor is connected with the ARM main controller through a wire, a power supply of the ARM main controller is connected with an external power supply, the sensor array is electrically connected with the ARM main controller after being connected with the AC/DC conversion module through a signal wire, and the sensor array is symmetrically distributed on the bracket below the driving mechanism;

the system also comprises a human-computer interaction unit; the man-machine interaction unit is communicated with the LCD display screen through the RS232 communication module, and displays the aluminum liquid temperature, the aluminum liquid flow and the onboard temperature measured by the measured sensor array in real time.

Preferably, the sensor array comprises a temperature sensor, a flow sensor and a proximity inductive switch; the sensor array comprises a temperature sensor, a flow sensor and a proximity inductive switch which are all connected with the ARM main controller. The ARM master controller adopts STM32F103 series chips.

Preferably, the sensor array is powered by the converted direct current; the A/D analog-to-digital converter is used as a signal analog quantity acquisition unit.

Preferably, the ARM controller is further electrically connected with the A/D digital-to-analog converter, the data memory, the LCD screen, the JTAG, the indicator light and the key.

Preferably, the data memory adopts any one memory of an SPI _ FLASH word bank memory and an EEPROM power-down data memory.

(III) advantageous effects

The invention provides a fusion casting molten aluminum anti-overflow leakage system device based on a multi-sensor technology. The method has the following beneficial effects:

the device of the invention has the advantages that: because the multi-sensor multi-data real-time parallel processing of the flow-temperature-proximity inductive switch and the like is adopted, the monitoring on the environment and the flow of the aluminum outlet is more accurate; the STM32F103 series chip is adopted, and has 12-bit analog-to-digital conversion ADC, the maximum conversion rate is 1Mhz, namely the conversion time is 1us, the trouble of signal conversion is avoided, and the measurement precision is high; the composite multidirectional polling detection structure is adopted, so that the detection of all parts of the aluminum outlet is efficiently realized, and the detection comprehensiveness and the detection efficiency are greatly improved.

The method has the advantages that: a plurality of sensors are adopted, so that various parameters such as the aluminum water temperature of an aluminum port, the aluminum water flow, the onboard temperature, the displacement condition of a plugging rod and the like are effectively measured, the parameters are vividly displayed on a display screen interface, and the real-time monitoring of the aluminum water flow is realized; can predict and early warn the aluminum water flow of the aluminum outlet.

Drawings

FIG. 1 is a side view of the occlusion rod actuation mechanism of the present invention.

Fig. 2 is a top view of the plugging rod driving mechanism of the present invention.

FIG. 3 is a schematic block diagram of an ARM controller according to the present invention.

FIG. 4 is a block diagram of the detection method of the present invention.

FIG. 5 is a software flow diagram of the present invention.

FIG. 6 is a flow chart of the detection method of the present invention.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

As shown in fig. 1 to 6, the present invention provides a technical solution: a fusion casting molten aluminum anti-overflow leakage system device based on a multi-sensor technology comprises a support 6, wherein a driving mechanism 1 and a sensor array 3 are installed on the support 6, and the driving mechanism 1 comprises a motor 2, a sliding supporting plate and a plugging head; an output shaft of the motor 2 is connected with a driving lead screw of the sliding support plate, the sliding support plate is driven to slide back and forth on the driving lead screw, the sliding support plate is fixedly connected with a blocking head 7 and drives the blocking head 7 to move back and forth to complete the opening and blocking of an aluminum outlet; the signal wire and the power wire of the sensor array 3 are connected with the ARM main controller 4 after passing through the buck-boost module;

the ARM main controller 4 is in communication connection with the LCD display screen 5 through a signal line, and the LCD display screen 5 displays various data processed by the ARM main controller 4 on the LCD display screen 5; the motor 2 is connected with an ARM main controller 4 through a wire, a power supply of the ARM main controller 4 is connected with an external power supply, the sensor array 3 is electrically connected with the ARM main controller 4 after being connected with the AC/DC conversion module through a signal wire, and the sensor array 3 is symmetrically distributed on a bracket 6 below the driving mechanism 1;

the system also comprises a human-computer interaction unit; the man-machine interaction unit is communicated with the LCD display screen 5 through the RS232 communication module, and displays the aluminum liquid temperature, the aluminum liquid flow and the onboard temperature measured by the measured sensor array 3 in real time.

Further, the sensor array 3 comprises a temperature sensor, a flow sensor and a proximity inductive switch; the sensor array 3 comprises a temperature sensor, a flow sensor and a proximity inductive switch which are all connected with the ARM main controller 4.

Further, the sensor array 3 is powered by the converted direct current; the A/D analog-to-digital converter is used as a signal analog quantity acquisition unit.

Furthermore, the ARM controller is electrically connected with the A/D digital-to-analog converter, the data memory, the LCD screen, the JTAG, the indicator light and the keys.

Furthermore, the data memory adopts any one memory of an SPI _ FLASH word bank memory and an EEPROM power-down data memory.

A detection method of a fusion casting aluminum water anti-overflow leakage system device based on a multi-sensor technology comprises the following steps:

step A, when a motor 2 of a driving mechanism 1 works, a plugging rod is driven to move back and forth to complete the opening and plugging of an aluminum outlet; the motor is connected with the ARM main controller 4 through a wire and is controlled by the ARM main controller 4; the sensor array realizes the omnibearing monitoring of the aluminum outlet.

B, a temperature sensor detects the temperature of the aluminum liquid and converts the temperature value into a voltage value; the flow sensor detects the flow of the aluminum water at the aluminum port;

step C, converting the analog quantity into digital quantity by the A/D converter, and storing the data by the data memory;

d, the ARM controller 4 performs data fusion on the converted data, performs data processing on the aspect of algorithm on a program, and finally performs data display on each parameter information through the LCD display screen 5;

step E, when emergency situations such as water cut-off and power failure occur, a program triggers an alarm function, an ARM main controller transfers a motor and drives a traction device to complete the locking and plugging processes of a plugging head 7, and molten aluminum is prevented from leaking;

and F, after the emergency situation is relieved, a signal is sent to the ARM controller 4 through a key to drive the plugging head 7 to move backwards, the normal position is recovered under the guidance of the inductive switch sensor, the LCD screen 5 is communicated to display the information of each parameter, and the real-time online monitoring of the aluminum outlet is realized.

1) The overflow prevention of the molten aluminum water is realized by adopting the motor to drive, and the plug is ensured to have enough pressure to block the flow port. The driving mechanism 1 is set to be a hollow structure, a cable on a production line penetrates through the middle of the device, the sensor arrays 3 are symmetrically distributed below the driving mechanism 1, and the sensor arrays 3 comprise: the power supply and signal outgoing lines in the aluminum liquid temperature sensor, the onboard temperature sensor, the flow sensor and the proximity inductive switch are connected with the ARM main controller 4 after passing through the voltage boosting and reducing module, and the external power supply and signal line is connected to the ARM main controller 4 through the AC/DC conversion module;

2) the sensor array is powered by +12V, the power line and the signal line are connected with the ARM core control board through the buck-boost module, the power source anode, the power source ground, the signal anode and the signal ground respectively correspond to an interface, and the staggered arrangement mode is adopted, so that the signals of the power line and the signal line are not interfered with each other.

4) The whole composite multidirectional polling detection structure realizes a sensor array and comprehensive and efficient detection of an aluminum outlet, and the overall structural schematic diagram is shown in fig. 1 and fig. 2.

When the aluminum outlet leaks aluminum, the plugging device needs to be started emergently. The whole device is powered on and initialized firstly, when a sensor detects aluminum leakage, the motor 2 can push the plugging rod to move forwards along the sliding rail through the traction device and drive the plugging head 7 to perform plugging, whether the plugging head is in place or not can be judged in the process that the plugging head 7 descends and is plugged, a signal close to the induction switch can be obtained after the plugging is in place, the ARM main controller 4 sends a working stopping signal to the motor 2 and relieves an alarm, and at the moment, the plugging is successful, and the plugging system stops running.

When the plugging head 7 is required to be lifted without plugging, the ARM main controller 4 sends a signal to the motor 2, the traction device pushes the plugging rod to move backwards along the sliding rail, the proximity inductive switch on the plugging device can feed back a displacement signal in the backward moving process, when the backward moving signal is obtained, the ARM main controller 4 sends a work stopping signal to the motor 2, at the moment, the traction device pushes the plugging rod to successfully move backwards, and the plugging system stops running.

When the flow and the displacement are subjected to two-dimensional static calibration, a plurality of groups of experiments are firstly carried out, and a relation curve of displacement and flow change is drawn. And obtaining a linear coefficient according to the calibration data.

Through the signal conditioning circuit, firstly the rectification is carried out through the full-wave bridge circuit, then the signal filtering is carried out through the RC low-pass filter circuit, then the signal following is carried out through the LM324 operational amplifier, the original signal is strengthened, the signal amplification is carried out through the in-phase amplifying circuit, the digital-analog isolation is carried out through the optical coupling isolation circuit, and finally the standard direct-current voltage signal is obtained. During A/D conversion, the A/D conversion module firstly carries out sampling and holding on an analog signal, the holding time is entered after the sampling is finished, the voltage analog quantity is converted into a digital quantity in the holding time, and the conversion result is displayed in a certain coding form.

The ARM master 4 is STM32, and the ADC is a 12-bit successive approximation type analog-digital converter. It has 18 channels and can measure 16 external and 2 internal signal sources. The a/D conversion of each channel may be performed in a single, continuous, scanning, or discontinuous mode. The result of ADC can be stored in 16-bit data register in left alignment or right alignment mode, and the stored data is processed in STM32 single chip microcomputer.

As shown in fig. 3, it is a system block diagram of the whole ARM controller 4, and at the same time, a corresponding algorithm is added in terms of data processing:

1) nonlinear correction algorithm: the least square method is utilized to fit the hydraulic pressure and traction device pushing displacement curve during static calibration, and the input and output tend to be in a proportional relation through the square sum of the minimized error and the optimal function matching of the searched data, so that the influence caused by nonlinearity is eliminated.

2) Combining whale algorithm with ARMA water pressure prediction model: the model combining the whale optimization algorithm and the autoregressive moving average model (ARMA) for researching the time sequence makes up the disadvantage of inaccurate fixed order of the ARMA model by utilizing the advantages of simple operation principle of the whale optimization algorithm, high operability, less required human intervention parameters, rapid convergence, strong global search capability and the like, so that the prediction of the overall model on the time sequence is more accurate, and the data is more reliable. The historical aluminum water pressure data of the time series relation are integrated, so that the aluminum water flow data value in the future time period is predicted, and the aluminum water is prevented from overflowing and leaking.

3) The laser displacement sensor nonlinear error modeling and compensation based on the multiple regression algorithm comprises the steps of firstly installing a plugging rod driving mechanism on a standard displacement table, measuring the plugging rod by using a laser displacement sensor, reading the output of the laser displacement sensor and calculating a nonlinear error when the plugging rod moves to different known standard displacement positions, further establishing a mathematical model between the nonlinear error and the output of the sensor through measured data, calculating the nonlinear error of the sensor in different outputs according to the model, and compensating the output error. The core of the nonlinear error compensation lies in an accurate nonlinear error model, the nonlinear error of the laser displacement sensor needs to be modeled by means of calibration, and the essence of the calibration is also statistical analysis of nonlinear error measurement data. The essence of the multivariate regression algorithm is to construct a polynomial model structure, and adjust the model parameters according to the direct measurement data of the input and output variables, so that the residual square sum of the model on the measurement data reaches a small enough degree. Through the processing, the displacement pushed by the plugging rod driving device can be more accurate.

Liquid crystal display: the power supply condition, the aluminum water flow, the aluminum water temperature, the displacement of the plugging rod and other information are displayed in a graphic and character mode, and the offline checking is facilitated.

The alarm function is as follows: an output water pump pressure threshold value and a device voltage and current threshold value are set, and when the numerical value output by the sensor exceeds the threshold value in the emergency of water and power failure, the alarm function is realized by the flickering of the LED lamp and the sounding of the buzzer in the alarm circuit.

It is noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other identical elements in a process, method, article, or apparatus that comprises the element.

Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.