阅读说明：本技术 电子束恒熔速冶炼控制系统 (Electron beam constant melting speed smelting control system ) 是由 皮坤 巫乔顺 杨开 刘洪具 沈志彦 于 2020-12-18 设计创作，主要内容包括：本发明涉及一种电子束恒熔速冶炼控制系统,属于电子束熔炼技术领域。该系统包括推料装置、熔炼冷床、拉锭系统、高能电子束枪、电子枪驱动服务器、工业高清摄像机、视频处理服务器、中央控制系统和行程测量装置；推料装置设有两个,分别熔炼冷床左右两侧,拉锭系统位于熔炼冷床下方,高能电子束枪位于熔炼冷床正上方；推料装置和拉锭系统上均安装有行程测量装置；本发明实现了电子束熔炼时的自动恒速稳定熔炼控制,能提升熔炼效率,减少人工误操作概率,提高产品品质,易于推广应用。(The invention relates to an electron beam constant melting speed smelting control system, and belongs to the technical field of electron beam smelting. The system comprises a material pushing device, a smelting cooling bed, an ingot pulling system, a high-energy electron beam gun, an electron gun driving server, an industrial high-definition camera, a video processing server, a central control system and a stroke measuring device; the two material pushing devices are respectively arranged at the left side and the right side of the smelting cooling bed, the ingot pulling system is positioned below the smelting cooling bed, and the high-energy electron beam gun is positioned right above the smelting cooling bed; stroke measuring devices are arranged on the pushing device and the ingot pulling system; the invention realizes the automatic constant-speed stable smelting control during the electron beam smelting, can improve the smelting efficiency, reduce the probability of manual misoperation, improve the product quality and is easy to popularize and apply.)

1. The electron beam constant melting speed smelting control system is characterized by comprising a material pushing device (1), a melting cold bed (2), an ingot pulling system (3), a high-energy electron beam gun (4), an electron gun driving server (5), an industrial high-definition camera (6), a video processing server (7), a central control system (8) and a stroke measuring device (9);

the two material pushing devices (1) are respectively arranged at the left side and the right side of the smelting cooling bed (2), the ingot pulling system (3) is positioned below the smelting cooling bed (2), and the high-energy electron beam gun (4) is positioned right above the smelting cooling bed (2);

stroke measuring devices (9) are respectively arranged on the pushing device (1) and the ingot pulling system (3); the stroke measuring device (9) is used for acquiring stroke and speed;

the industrial high-definition camera (6) is used for monitoring the smelting condition in the smelting furnace in real time;

the electron gun driving server (5) is connected with the high-energy electron beam gun (4) through a high-voltage power supply (10) and is used for driving the high-energy electron beam gun (4) to work;

the video processing server (7) is respectively connected with the electron gun driving server (5), the industrial high-definition camera (6) and the central control system (8), the video processing server (7) compares and analyzes the collected video images in the smelting chamber with a basic image model prestored in the smelting chamber, and respectively sends instruction signals to the electron gun driving server (5) and the central control system (8) according to comparison results, and the smelting power of the high-energy electron beam gun (4) is controlled by controlling the electron gun driving server (5); the central control system (8) controls the feeding speed of the material pushing device (1) and the ingot pulling speed of the ingot pulling system (3) through the received instruction signals;

the stroke measuring device (9) is connected with the central control system (8); the central control system (8) is connected with a high-voltage power supply (10);

the stroke measuring device (9) sends stroke and speed data of the pushing device (1) and the ingot pulling system (3) to the central control system (8), and the central control system (8) is used for judging whether to interrupt the high-voltage power supply (10) to stop smelting of the high-energy electron beam gun according to the sent stroke and speed data.

2. The electron beam constant melting speed smelting control system according to claim 1, characterized in that an industrial high-definition camera (6) is installed on an observation window outside the smelting furnace.

3. The electron beam constant melting speed smelting control system according to claim 1, wherein the central control system (8) is a PLC.

Technical Field

The invention belongs to the technical field of electron beam smelting, and particularly relates to an electron beam constant smelting speed smelting control system.

Background

When the electron beam cold hearth furnace is used for smelting metal materials, the electron gun emits high-energy electron beams to scan the molten metal materials, the power of each electron gun needs to be continuously adjusted, and meanwhile, the feeding device and the ingot pulling system are driven to complete the smelting process.

At present, when electron beams are smelted, the power of each electron gun is adjusted by rotating a knob after the smelting state in a furnace is observed manually, field operators need to operate frequently, misoperation is easily caused due to fatigue and the like when the electron beams are smelted for a long time or in night shifts, equipment is damaged if the electron beams are not operated frequently, and accidents of fire or explosion can be caused if the electron beams are stopped if the electron beams are not operated frequently, so that casualties are caused.

In the current electron beam smelting process, an operator needs to observe information such as liquid level height and material smelting position in a furnace on site and then feeds back the information and instructs personnel in a central control room to drive a material pushing device and an ingot pulling system, so that delay and error possibility exist in information transmission, and the efficiency is low.

Meanwhile, in the conventional smelting of the electron beam cold hearth furnace, due to the influence of factors such as feeding speed, smelting speed, ingot pulling speed and the like, the problem that the solidification rate of solution flowing out is not constant exists, so that the surface of a finished product of a product has a very obvious fault phenomenon, and the quality of the product is influenced.

In addition, the electron beam cold hearth furnace has severe environmental conditions on the production and smelting site, and has great noise pollution on the site, and dust, partial impurity gas and the like volatilized in the smelting process are harmful to the health of site operators.

Therefore, how to overcome the defects of the prior art is a problem to be solved urgently in the technical field of electron beam melting at present.

Disclosure of Invention

The invention aims to overcome the defects in the prior art and provides an electron beam constant melting speed smelting control system.

In order to achieve the purpose, the technical scheme adopted by the invention is as follows:

the electron beam constant melting speed smelting control system comprises a material pushing device, a melting cold bed, an ingot pulling system, a high-energy electron beam gun, an electron gun driving server, an industrial high-definition camera, a video processing server, a central control system and a stroke measuring device;

the two material pushing devices are respectively arranged at the left side and the right side of the smelting cooling bed, the ingot pulling system is positioned below the smelting cooling bed, and the high-energy electron beam gun is positioned right above the smelting cooling bed;

stroke measuring devices are arranged on the pushing device and the ingot pulling system; the stroke measuring device is used for acquiring stroke and speed;

the industrial high-definition camera is used for monitoring the smelting condition in the smelting furnace in real time;

the electron gun driving server is connected with the high-energy electron beam gun through a high-voltage power supply and is used for driving the high-energy electron beam gun to work;

the video processing server is respectively connected with the electron gun driving server, the industrial high-definition camera and the central control system, carries out comparison analysis on the collected video image in the smelting chamber and a basic image model prestored in the smelting chamber, respectively sends instruction signals to the electron gun driving server and the central control system according to comparison results, and controls the smelting power of the high-energy electron beam gun by controlling the electron gun driving server; the central control system controls the feeding speed of the material pushing device and the ingot pulling speed of the ingot pulling system through the received instruction signals;

the travel measuring device is connected with the central control system; the central control system is connected with the high-voltage power supply;

the stroke measuring device sends stroke and speed data of the material pushing device and the ingot pulling system to the central control system, and the central control system is used for judging whether to interrupt the high-voltage power supply to stop smelting of the high-energy electron beam gun according to the sent stroke and speed data.

Further, preferably, the industrial high-definition camera is mounted on an observation window outside the smelting furnace.

Further, preferably, the central control system is a PLC.

The video processing server is responsible for analyzing the information collected by the industrial high-definition camera and mainly collects the liquid level height of the molten liquid. The invention adopts a video image analysis and comparison technology to establish a basic image model, and carries out data comparison and analysis on the received video image information and the image model stored by the video processing server.

The metal materials propelled from the left side and the right side are melted by high-energy electron beams emitted by a high-energy electron beam gun above the smelting cold bed and then flow into the smelting cold bed, and the molten liquid level reaches a certain height and then flows into an ingot pulling system below. The material pushing device adopts variable-frequency stepless speed regulation to execute an instruction issued by a central control system so as to control the feeding speed at two sides to be matched with the smelting rate. The ingot pulling system always keeps operating at a relatively constant speed on the premise of stable outflow speed of the molten liquid.

The electron gun driving server adjusts the power of the electron beam by adjusting the current of the high-energy electron beam gun, so as to achieve the purpose of controlling the material smelting speed.

The invention preferably uses a pulse measuring sensor to measure and record the speed of the material pushing device and the ingot pulling system.

Compared with the prior art, the invention has the beneficial effects that:

the invention introduces a video analysis technology, the material pushing speed and the power of an electron gun influence the liquid level height of a solution, and the video analysis is carried out on the liquid level height of a molten liquid and then the liquid level height is fed back to an electron gun driving server and a central control system to adjust the material pushing speed, the ingot pulling speed and the power of the electron gun, so as to form a closed-loop control system; the molten metal is kept in a constant-speed outflow state.

The central control system and the electronic gun driving server automatically adjust the power of the electronic gun and the pushing and ingot pulling speeds according to the data instruction after the video processing server analyzes the melt liquid level, so that the liquid level of the solution is controlled to keep a certain height. Constant melting speed smelting is realized on the basis of automatic ingot pulling, so that the ingot pulling speed is basically constant, and the finished product quality of the product is improved.

The electron beam constant melting speed smelting control system disclosed by the invention can automatically adjust the whole smelting process according to video analysis, so that full-automatic smelting at a constant speed is realized. The product quality can be improved, the production efficiency is improved, the production time is shortened, the field personnel allocation and accident risk are reduced, and direct or indirect economic benefits are brought to enterprises.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.

FIG. 1 is a schematic structural diagram of an electron beam smelting control system according to the present invention;

in the figure, 1, a material pushing device; 2. a smelting cold bed; 3. an ingot pulling system; 4. a high-energy electron beam gun; 5. an electron gun driving server; 6. an industrial high definition camera; 7. a video processing server; 8. a central control system; 9. a stroke measuring device; 10. a high voltage power supply; wherein the arrow is the data or signal transmission direction.

Detailed Description

The present invention will be described in further detail with reference to examples.

It will be appreciated by those skilled in the art that the following examples are illustrative of the invention only and should not be taken as limiting the scope of the invention. The examples do not specify particular techniques or conditions, and are performed according to the techniques or conditions described in the literature in the art or according to the product specifications. The materials or equipment used are not indicated by manufacturers, and all are conventional products available by purchase.

It will be appreciated by those skilled in the art that the following examples are illustrative of the invention only and should not be taken as limiting the scope of the invention. The specific techniques, connections, conditions, or the like, which are not specified in the examples, are performed according to the techniques, connections, conditions, or the like described in the literature in the art or according to the product specification. The materials, instruments or equipment are not indicated by manufacturers, and all the materials, instruments or equipment are conventional products which can be obtained by purchasing.

As used herein, the singular forms "a", "an", "the" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. It will be understood that when an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may also be present. Further, "connected" as used herein may include wirelessly connected. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

In the description of the present invention, "a plurality" means two or more unless otherwise specified. The terms "inner," "upper," "lower," and the like, refer to an orientation or a state relationship based on that shown in the drawings, which is for convenience in describing and simplifying the description, and do not indicate or imply that the referenced device or element must have a particular orientation, be constructed and operated in a particular orientation, and thus should not be construed as limiting the invention.

In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "provided" are to be construed broadly, e.g., as being fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; may be directly connected or indirectly connected through an intermediate. To those of ordinary skill in the art, the specific meanings of the above terms in the present invention are understood according to specific situations.

It will be understood by those skilled in the art that, unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the prior art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

As shown in fig. 1, the electron beam constant melting speed smelting control system comprises a material pushing device 1, a smelting cooling bed 2, an ingot pulling system 3, a high-energy electron beam gun 4, an electron gun driving server 5, an industrial high-definition camera 6, a video processing server 7, a central control system 8 and a stroke measuring device 9;

the two material pushing devices 1 are respectively arranged at the left side and the right side of the smelting cooling bed 2, the ingot pulling system 3 is positioned below the smelting cooling bed 2, and the high-energy electron beam gun 4 is positioned right above the smelting cooling bed 2;

stroke measuring devices 9 are respectively arranged on the pushing device 1 and the ingot pulling system 3; the stroke measuring device 9 is used for acquiring stroke and speed;

the industrial high-definition camera 6 is used for monitoring the smelting condition in the smelting furnace in real time;

the electron gun driving server 5 is connected with the high-energy electron beam gun 4 through a high-voltage power supply 10 and is used for driving the high-energy electron beam gun 4 to work;

the video processing server 7 is respectively connected with the electron gun driving server 5, the industrial high-definition camera 6 and the central control system 8, the video processing server 7 compares and analyzes the collected video images in the smelting chamber with a basic image model prestored in the smelting chamber, and respectively sends instruction signals to the electron gun driving server 5 and the central control system 8 according to the comparison result, so that the smelting power of the high-energy electron beam gun 4 is controlled by controlling the electron gun driving server 5; the central control system 8 controls the feeding speed of the pushing device 1 and the ingot pulling speed of the ingot pulling system 3 through the received instruction signals;

the stroke measuring device 9 is connected with the central control system 8; the central control system 8 is connected with a high-voltage power supply 10;

the stroke measuring device 9 sends stroke and speed data of the material pushing device 1 and the ingot pulling system 3 to the central control system 8, and the central control system 8 is used for judging whether to interrupt the high-voltage power supply 10 to stop smelting of the high-energy electron beam gun according to the sent stroke and speed data.

Preferably, the industrial high-definition camera 6 is mounted on an observation window outside the smelting furnace.

Preferably, the central control system 8 is a PLC.

The system structure comprises a plurality of industrial high-definition cameras 6, and video image signals are recorded and collected in real time through the industrial high-definition cameras 6; the video processing server 7 analyzes and processes the collected video images in the smelting chamber, mainly melt liquid level information, and finally outputs instruction signals; the instruction signals are respectively sent to the electron gun driving server 5 and the central control system 8, the electron gun driving server 5 automatically adjusts the smelting power of the high-energy electron beam gun 4 after receiving the instruction signals, and the central control system 8 adjusts the feeding speed of the pushing devices 1 on the two sides and the ingot pulling speed of the ingot pulling system 3 after receiving the instruction signals; meanwhile, the stroke measuring device 9 returns the data of the pushed material and the pulled ingot to the central control system 8, so that the smelting speed and the feeding speed of the whole system keep a constant speed, and the constant smelting speed smelting control is realized.

During installation and construction, the system comprises the following specific steps:

the method comprises the following steps of firstly, installing an industrial high-definition camera 6 on an observation window outside a smelting furnace, and observing the smelting state in the furnace to acquire image video signals of the smelting liquid level in the furnace.

Secondly, stroke devices and limiting devices are arranged on the pushing device 1 and the ingot pulling system 3, and stroke and position interlocking protection is formed; and then, installing a stroke measuring device 9 on the pushing device 1 and the ingot pulling system 3 for acquiring speed and stroke data of feeding and ingot pulling.

The melt liquid level image information in the furnace is collected by an industrial high-definition camera 6, transmitted to a video image processing server 7 for analysis and processing, and analyzed and judged by combining stroke position data such as the pushing speed of the pushing device 1, the pushing speed of the ingot pulling system 3 and the like and a limit state, and then sent to an electronic gun driving server 5 and a central control system 8 to control the smelting speed of the whole system to be kept constant.

The electron gun driving server 5 adjusts the power of each high-energy electron beam gun by modifying the current of the high-voltage power supply 10 according to the instruction sent by the received video image processing server 7, thereby adjusting the smelting speed.

The central control system 8 starts to send execution commands to the pushing device 1 and the ingot pulling system 3 according to the instruction sent by the video image processing server 7, so as to adjust the feeding speed of the pushing device 1 and the ingot pulling speed of the ingot pulling system 3 to be matched with the smelting speed of the high-energy electron beam gun 4, and thus the whole production process of feeding, smelting and ingot pulling is always kept at a constant speed.

The stroke positions and the limit states of the pushing device 1 and the ingot pulling system 3 are returned to the central control system 8 in real time through the stroke measuring device 9, and the central control system 8 judges whether to interrupt the high-voltage power supply 10 to stop the smelting of the high-energy electron beam gun according to the received stroke positions and the limit states, so that the safety interlocking protection of the smelting process is formed.

The foregoing shows and describes the general principles, essential features, and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.