CN102303109B - Automatic releasing agent proportioning economizer for die casting machine - Google Patents
Automatic releasing agent proportioning economizer for die casting machine Download PDFInfo
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- CN102303109B CN102303109B CN 201110254000 CN201110254000A CN102303109B CN 102303109 B CN102303109 B CN 102303109B CN 201110254000 CN201110254000 CN 201110254000 CN 201110254000 A CN201110254000 A CN 201110254000A CN 102303109 B CN102303109 B CN 102303109B
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Abstract
The invention relates to an automatic releasing agent proportioning economizer for a die casting machine. The automatic releasing agent proportioning economizer is high in automation and control accuracy and comprises a liquid level sensor, a flow sensor, a pressure sensor, an electric energy transducer, a liquid level module, a flow module, a pressure module, an electric energy module, an original feedback system, a human machine interface (HMI) monitoring system, a communication module, an input interface, a central processing unit, a frequency transformer communication data interface, an output interface, a frequency transformer I, a frequency transformer II, a proportional valve and an external execution unit, wherein the flow sensor, the liquid level sensor and the pressure sensor are used for acquiring the flow of a raw material, the flow of water, a liquid level of a releasing agent dispensing pool and the pressure of a dispensing pump manifold in real time; the central processing unit is used for processing and regulating; and the execution unit is used for accurate execution. The automatic releasing agent proportioning economizer has the characteristics that: the raw material of a releasing agent is reduced, the production efficiency of the die casting machine is improved, electric energy is saved, pollution is reduced, automation of production management is realized, and impact on natural grid is reduced.
Description
Technical field
The present invention relates to releasing agent proportioning and batching and carry the electricity-saving appliance of automatic energy-saving control technology and automatic energy saving.
Background technology
In die casting machine mould release agent batching and the induction system, adopt the artificial mode that is in harmonious proportion the releasing agent ratio can not satisfy the demand of various foundry goods so that releasing agent is prepared burden, so that the qualification rate of die casting machine casting die is greatly affected.Simultaneously, in order to satisfy the smoothly demoulding of foundry goods, will inevitably artificially strengthen releasing agent raw material consumption.Make it to cause the waste of very large raw material and water.In addition releasing agent batching delivery pump according to maximum use amount and farthest the equipment pressure demand design, and be engraved in variation during on-the-spot machine operation, the releasing agent of demand is prepared burden also and to be changed along with the working condition of the die casting machine at scene.This just forms two-part affluence amount (the affluence amount in the rich amount of design and the use).The releasing agent matching system causes wastage of material, energy consumption increase, maintenance to strengthen many.And only use converter technique, then do not reach high-precision demand.Also can't carry out effectively energy consumption simultaneously, real time measure.
Summary of the invention
The purpose of this invention is to provide a kind of qualification rate of producing foundry goods that improves, reduce staff labor intensity, reduce releasing agent raw material use amount, reduce the use amount of water, reduce electric weight, reduce the energy-saving appliance of maintenance cost.
The present invention adopts following technical scheme to achieve these goals:
Automatic releasing agent proportioning economizer for die casting machine comprises liquid level sensor, flow sensor, pressure sensor, electric energy transmitter, liquid level module, flow module, modular pressure, power module, original system feedback, HMI monitoring system, communication module, input interface, central processing unit, inverter communication data-interface, output interface circuit, frequency converter I, frequency converter II, proportioning valve and outside performance element.
Wherein, liquid level sensor gathers the liquid level signal and inputs central processing unit by the liquid level module from input interface, flow sensor gathers flow signal Q and inputs central processing unit by flow module from input interface, pressure sensor gathers pressure signal P and inputs central processing unit by modular pressure from input interface, the signal of electric energy transmitter collection is inputted central processing unit by power module from input interface, and feedback data is inputted central processing unit by the original system feedback from input interface; Central processing unit is by output interface circuit control ratio valve.
Described HMI monitoring system communicates with the RS232 port with central processing unit with the twisted pair line connection communication module of band shielding; Central processing unit is connected with frequency converter I and frequency converter II with the RS485 port by the inverter communication data-interface and adopts standard MODBUS communications protocol to communicate;
Described frequency converter I and frequency converter II are regulated the rotating speed of connected releasing agent dosing pump and releasing agent feedstock pump according to input signal regulation output frequency; By proportioning data and data on flows, control the flow output that outside performance element proportioning valve is realized and the releasing agent raw material mates by central processing unit.
Described outside performance element comprises the execution loop that is made of breaker, reactor, wave filter, frequency converter, contactor.
The outside performance element of central processing unit control connection releasing agent dosing pump and releasing agent feedstock pump is realized interlock function with the work of power frequency mode or with conversion system work.
Advantage of the present invention is:
1, save the releasing agent raw material, because the part of the different die castings of die casting machine is different, the releasing agent raw material of use and the ratio of water are also different, before by artificial rough maximized allotment.The present invention can reach and save the releasing agent raw material more than 20%.
2, improve die casting machine production efficiency, after accurate proportioning.The fully demoulding of the foundry goods of die casting machine, and cast(ing) surface is smooth.Product qualified rate is more than 99%.
3, save electric energy, behind the use automatic releasing agent proportioning economizer for die casting machine, change the operating mode of in the past maximum pressure conveying demoulding batching.Realized automatically regulating according to on-the-spot pressure demand the running speed of delivery pump.And needing to keep the pressure with terminal constant.The energy of saving in this way is more than 35%.
4, the automation of production management puts into operation by of the present invention, except the monitoring management to self, has also realized the effective management to producing.The monitoring management of self is that the operation conditions to various components and parts in the energy-saving appliance detects inquiry in real time, realizes OBD, self-protection, fault alarm.Production management, the present invention can analyze the creation data that gathers, store, print.Mode by the webpage issue uploads to the production management center.For production and administration provides reliable analysis foundation.The raising of production efficiency and the raising of productivity effect have better been realized.And reduced maintenance cost.
5, minimizing is to the impact of national grid, and equipment reduces the impact to electrical network with startup level and smooth, that linear mode is realized equipment.
6, reduce labour intensity, the present invention changes labor operation mode in the past, by realizing that in the HMI monitoring system the accurate control of releasing agent batching be need not artificial participation.Reduce the maintenance cost of malfunction elimination time and equipment, perfect fault detect and defencive function energy-saving appliance have two position protection, height traffic protection, high-low pressure protection; Supply voltage overvoltage protection, under-voltage protection, overcurrent protection, short-circuit protection, open-phase protection are so that the operating personnel can investigate fault, handling failure fast according to the HMI monitoring system.
7, reduce pollution, the present invention has also reduced the sewage discharge after the releasing agent raw material uses when the releasing agent raw material is saved.
8, energy-saving appliance of the present invention is applied widely, is not only applicable to die casting machine mould release agent batching automatic mixing system, and is applicable to the batching of all fluids.
Description of drawings
The present invention can further specify by the non-limiting enforcement example that accompanying drawing provides.
Fig. 1 is structure chart of the present invention;
Fig. 2 is executive component of the present invention (releasing agent feed proportioning system) connection layout;
Fig. 3 is executive component of the present invention (releasing agent raw material system) connection layout;
Fig. 4 is operated from a distance figure of the present invention;
Fig. 5 is short-range operation figure of the present invention;
Fig. 6 is communication unit wiring diagram of the present invention.
The specific embodiment
Be described further below in conjunction with accompanying drawing.
Referring to Fig. 1, automatic releasing agent proportioning economizer for die casting machine comprises liquid level sensor, flow sensor, pressure sensor, electric energy transmitter, liquid level module 1, flow module 2, modular pressure 3, power module 4, original system feedback 5, HMI monitoring system 6, communication module 7, input interface 8, central processing unit 9, inverter communication data-interface 10, output interface circuit 11, frequency converter I 12, frequency converter II 13, proportioning valve 14 and outside performance element.Wherein, liquid level sensor gathers the liquid level signal and inputs central processing units 9 by liquid level module 1 from input interface 8, flow sensor gathers flow signal Q and inputs central processing units 9 by flow module 2 from input interface 8, pressure sensor gathers pressure signal P and inputs central processing units 9 by modular pressure 3 from input interface 8, from input interface 8 input central processing units 9, feedback data is inputted central processing units 9 by original system feedback 5 from input interface 8 to the signal that the electric energy transmitter gathers by power module 4; Central processing unit 9 is by output interface circuit 11 control ratio valves 14.
The twisted pair line connection communication module 7 of described HMI monitoring system 6 usefulness band shielding communicates with the RS232 port with central processing unit 9; Central processing unit 9 is connected with frequency converter I 12 and frequency converter II 13 with the RS485 port by inverter communication data-interface 10 and adopts standard MODBUS communications protocol to communicate.Described frequency converter I 12 and frequency converter II 13 are regulated the rotating speed of connected releasing agent dosing pump and releasing agent feedstock pump according to input signal regulation output frequency.By proportioning data and data on flows, by the flow output that the outside performance element proportioning valve 14 of central processing unit 9 controls is realized and the releasing agent raw material mates.
Flow sensor, liquid level sensor, pressure sensor are to the Real-time Collection of the pressure on releasing agent material flow, discharge, releasing agent dosing chamber liquid level and the dosing pump house steward, the data analysis of setting on the data of 9 pairs of collections of central processing unit and the HMI monitoring system 6, relatively reach multiple PID and calculate, mutually exchanged by service data and PLC central processing unit 9 data of inverter communication data-interface 10 with frequency converter again.Then accurately carried out according to the service data of data processing unit output by performance element.Last monitoring software and the touch-screen by the HMI monitoring system is the data that will control with economize on electricity that data are directly perceived, soft to be reflected.
PLC pulse input end I0.0 connects the pulse input signal of flow transmitter.I0.1 to I3.2 connects the digital quantity input signal of all controls.The analog input AI1 to AI7 of 4-20MA current signal is the open degree feedback signal of pressure input signal of the present invention, flow input signal, liquid level input signal and proportioning valve.In the wiring of output, digital output area is Q0.0 to Q1.8, for switching value output of the present invention, is used for start and stop, break-make, the interlocking of control system.The analog signal output scope is AQ0 to AQ3, is used for as analogue data output control releasing agent feedstock pump frequency converter II 13, releasing agent batching frequency converter I 12, feedwater proportioning valve 14.The connection of PORT COM is as follows: port one (PORT1) is used for connecting releasing agent raw material frequency converter II 13 and releasing agent batching frequency converter I 12, adopt RS485 communications protocol and physical connection line take the RS232 port as connector, carry out take PLC as main website, frequency converter is that the mode of slave station is communicated by letter; Port two (PORT2) is used for connecting HMI monitoring system 6, and both communicate with the communications protocol of RS485 and the physical connection of the twisted-pair feeder of band shielding equally.
The input of PLC, output connect form and are:
The present invention adopts mode manually or automatically when batching, during manual proportioning, keep control model or the operator scheme of original artificial batching.Automatically the time, then use model to carry out automatic blending according to a series of automatic data collection and on-the-spot mould of die casting machine.Automatic pressure, Flow-rate adjustment remain the constant of on-the-spot supply pressure.Selecting when manual, what the releasing agent dosing pump adopted is original power frequency operation mode, and operational mode is for subsequent use each other automatically, chain relation each other, and the actuating signal by digital input point I1.2 and I1.3 and I0.2 and I0.3 realizes." system reset I1.5 " input point is that the initialization after finishing as error protection and troubleshooting is used.
The present invention all realizes by the high speed communication transmission means on exchanges data.PLC central processing unit 9, frequency converter and HMI monitoring system 6 with the communication transfer mode that remote client is realized are:
Communication one is the PLC main website, and the data communication form is standard MODBUS communications protocol form.Do the communication program realization to the communication of two frequency converters at PLC central processing unit 9.The baud rate that arranges is 19.2KBPS, and releasing agent feedstock pump frequency converter is No. 1 station, and releasing agent dosing pump frequency converter is No. 2 stations.What arrange is verified as even parity check, 8 data bit, and 1 is position of rest.The PLC main website adopts broadcast mode to realize data interaction.Mainly be that fault-signal to running frequency, running current, working voltage, running time and the operation of two frequency converters reads, to the frequency that frequency converter will move, the acceleration time that move, deceleration time, frequency limits, start and stop and overload quantity carry out given.
Communication two, PLC central processing unit 9 is communicated by letter with HMI monitoring system 6, and both communication is that the mode of each other main website is carried out exchanges data.The communication connector of PLC central processing unit 9 ends is the PORT1 mouth, port be set to default setting.HMI end, the converter of RS485 RS 232 serial ports are connected to the RS232 end of computer.The traffic rate of computer terminal port must be consistent with PLC central processing unit 9 ends, adopts 9600KBP speed.Also must be set to identical connection speed and the connection serial ports of being connected on the monitor system software that adopts.
Performance element of the present invention is referring to Fig. 2, Fig. 3, and the reactor, breaker, proportioning valve, the plunger displacement pump that are connected by contactor, auxiliary reclay, isolating transformer, frequency converter upper and lower side form.Concrete connection is comprised of three parts, releasing agent feedstock pump part, releasing agent clear water proportioning valve part, releasing agent dosing pump part.Releasing agent feedstock pump frequency conversion part is by external power source A, B, C three-phase 380V ac power input end connecting breaker QF1, A.C. contactor KM1, wave filter ACL1, converter power supply input (R, S, T), inverter output terminal (U, V, W), reactor AL1, A.C. contactor KM2, frequency conversion plunger displacement pump.This part mainly realizes given to the releasing agent raw material by the flow-control to plunger displacement pump.Reach the ratio target of controlling, the control of precision is emphatically to adopt multiple PID control, uses the very high mass flowmenter of precision as the data feedback foundation.Releasing agent dosing pump part, syndeton is the same with the releasing agent feedstock pump, and just the data of feedback are pressure data.Realize the purpose of the constant voltage control of pressure.Be in order to reduce the high order current harmonics to the impact of motor in the main purpose of inverter output terminal device reactor, and reduce high frequency carrier to motor noise.And in the purpose of frequency converter upper end installing filter, mainly be to reduce harmonic wave that frequency converter produces to the interference to other equipment of the impact of electrical network and high subcarrier.Releasing agent water proportioning valve then is to realize the given of water and control by feedback releasing agent material flow and releasing agent proportion scale.This part adopts installs electromagnetic flowmeter at outlet pipe and comes water is measured and feeds back.After PLC control, its precision reaches need use standard.
Described HMI monitoring system 6 is comprised of dynamic visualization interface, comes control object directly perceived, vivid, mildly reaction reality with control object and the device distribution of simulated field, and analyzes the energy consumption of this energy-saving appliance, forms the complete energy management system of a cover.
Protection part of the present invention; the autoprotection of this energy-saving appliance; because frequency converter has multi-protective function (overcurrent, overvoltage, short circuit, phase shortage, over the ground, three-phase equilibrium protection); consisted of perfect defencive function with this; other adds the various interlockings of original control and existing energy-saving appliance; and the various protections of program software; formed the complete protection system of a cover; change etc. from the damage of the broken string of control circuit, components and parts, the pressure to control, flow, given abnormal proportion, can both be on the monitoring system the mode of voice and literal carry out alarm.Also at energy-saving appliance audible-visual annunciator is installed simultaneously.When the rank of reporting to the police reaches severity level, energy-saving appliance will automatically lock shutdown.Must etc. fault get rid of, by HMI monitoring system 6 confirm or energy-saving appliance on the SR action after, just put into operation.
Electricity principle of the present invention, energy-conservation main channel are to save rich amount.One is the static rich amount of equipment, and another is dynamically rich amount of equipment.Static rich amount is the difference of equipment allocating power and actual power demand.Dynamically the affluence amount then is the difference of the dynamic load of the required peak power power of equipment and actual motion.Integrated application of the present invention intelligent data acquisition technology, intelligent data treatment technology, PLC control technology, the parameter of electric machine from survey technology, frequency conversion control technique, man-machine conversation's technology and the economize on electricity control program.Realize dynamic prediction, adjust in advance, optimize synchronously, finally regulate the parameters such as pressure, flow, releasing agent proportioning of releasing agent feed system.The accuracy of the required releasing agent proportioning of assurance field apparatus and terminal die casting machine equipment are to the requirement of pressure, flow.
Energy-conservation minute three aspects of automatic releasing agent proportioning economizer for die casting machine, the one, the saving of releasing agent dosing pump electric energy, the 2nd, to the saving of releasing agent raw material and water, the 3rd, production, the management of this equipment component are saved.The judgment basis that electric energy is saved is active watt-hour meter to be installed or/and determine by the energy spectrometer table on the HMI monitoring system 6 at the power input of energy-saving appliance, and the parameter of saving electric weight is that the mode with power saving rate realizes.Concrete Computer Corp. is: electric weight power saving rate=(active energy of former operation active energy-electricity-saving appliance)/former operation active energy * 100%.The condition of both operations must be consistent, i.e. the time consistency that requirement puts into operation, and the produced on-site amount is identical, and the releasing agent batching pressure of field demand is identical.By Data Comparison, the power saving rate of generation is more than 35%.The comparison of releasing agent raw material and water consumption is installed water meter at the port of export of releasing agent feedstock pump, and the proportioning valve port of export on water-main is installed water meter.Contrast according to computing formula and the service condition of saving electric weight respectively, save the ratio of releasing agent feed ratio and saving water all more than 25%.Automation control by energy-saving appliance has reduced staff's labour intensity, has improved efficient and quality that on-the-spot die casting machine is produced, and data storage and data analysis by monitoring system have improved the efficient of whole production management or/and the production management mode.
The beneficial effect that this practicality invention reaches has:
Realize the automatic mixing of releasing agent raw material and water, water and releasing agent feed proportioning scope are in 1:1 to 150:1 water high accuracy batching, and accuracy error is ± 1.
The selection of power frequency/frequency conversion has realized that energy-saving appliance and original controller form for subsequent use, chain each other each other.
Have perfect defencive function, have the protections such as short-circuit protection, overload protection, ground protection, lightning protection, open-phase protection, route protection.
Automatically adjust output according to site technique ruuning situation, realize that optimization is energy-conservation.
Energy-saving appliance applied widely except the suitable mold release agent proportioning, also is applicable to the place of all fluids batchings.Just select different at sensor with corresponding pid parameter and fuzzy control Mathematical Modeling.
What the present invention adopted is the sensor signal distributed collection, the mode that focuses on.Realized the reliable collection of all data and reliably crossed.Collection signal has guaranteed true collection and the long-distance transmissions of data all by the photoelectricity isolation.
The present invention is take PLC as control core, removes by correspondence to control frequency converter and proportioning valve.Realize the exchanges data of Fast synchronization.Satisfy control accuracy and technological requirement.
Man-machine interface and long distance control system have formed reliable man-machine conversation, and corresponding technique can in time be adjusted.The mode that simultaneously corresponding data communication device is crossed WEB is published to remote client.For management provides reliable information platform.
The present invention relates to the optimization of the quality of power supply, can improve the plant capacity factor.Make it original power factor 0.6 is brought up to more than 0.95.Reduced to a great extent the cable line loss.Also improved simultaneously the meritorious use capacity of transformer.Energy-saving appliance is by installing reactor and wave filter, thoroughly changed the harmful effect of harmonics of inverter, High-frequency Interference.Make it to reach below the national grid harmonic wave setting.
Claims (3)
1. an automatic releasing agent proportioning economizer for die casting machine is characterized in that: comprise liquid level sensor, flow sensor, pressure sensor, the electric energy transmitter, and corresponding liquid level module (1), flow module (2), modular pressure (3), power module (4), original system feedback (5), HMI monitoring system (6), communication module (7), input interface (8), central processing unit (9), inverter communication data-interface (10), output interface circuit (11), frequency converter I (12), frequency converter II (13), proportioning valve (14) and outside performance element;
Wherein, liquid level sensor gathers the liquid level signal and inputs central processing unit (9) by liquid level module (1) from input interface (8), flow sensor gathers flow signal Q and inputs central processing unit (9) by flow module (2) from input interface (8), pressure sensor gathers pressure signal P and inputs central processing unit (9) by modular pressure (3) from input interface (8), from input interface (8) input central processing unit (9), feedback data is inputted central processing unit (9) by original system feedback (5) from input interface (8) to the signal that the electric energy transmitter gathers by power module (4); Central processing unit (9) is by output interface circuit (11) control ratio valve (14);
Described HMI monitoring system (6) communicates with the RS232 port with central processing unit (9) with the twisted pair line connection communication module (7) of band shielding; Central processing unit (9) is connected with frequency converter I (12) and frequency converter II (13) with the RS485 port by inverter communication data-interface (10) and adopts standard MODBUS communications protocol to communicate;
Described frequency converter I (12) and frequency converter II (13) are regulated the rotating speed of connected releasing agent dosing pump and releasing agent feedstock pump according to input signal regulation output frequency; By proportioning data and data on flows, by the flow output of central processing unit (9) the outside performance element of control and proportioning valve (14) realization and releasing agent raw material coupling.
2. described automatic releasing agent proportioning economizer for die casting machine according to claim 1, it is characterized in that: described outside performance element comprises the execution loop that is made of breaker, reactor, wave filter, frequency converter, contactor.
3. described automatic releasing agent proportioning economizer for die casting machine according to claim 1, it is characterized in that: the described outside performance element of central processing unit (9) control is with the work of power frequency mode or with conversion system work.
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| Application Number | Priority Date | Filing Date | Title |
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| CN 201110254000 CN102303109B (en) | 2011-08-31 | 2011-08-31 | Automatic releasing agent proportioning economizer for die casting machine |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 201110254000 CN102303109B (en) | 2011-08-31 | 2011-08-31 | Automatic releasing agent proportioning economizer for die casting machine |
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| CN102303109A CN102303109A (en) | 2012-01-04 |
| CN102303109B true CN102303109B (en) | 2013-01-23 |
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Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN105081268A (en) * | 2015-08-20 | 2015-11-25 | 温州乐控节能科技有限公司 | Power source system of die-casting machine |
| CN109677702A (en) * | 2019-01-07 | 2019-04-26 | 凯迈(洛阳)机电有限公司 | Packing machine communication control system and its control method |
| CN112169678B (en) * | 2020-09-10 | 2022-04-05 | 广东鸿图南通压铸有限公司 | Intelligent proportioning system of remote monitoring and controlling of die casting |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN2584320Y (en) * | 2002-12-07 | 2003-11-05 | 灌南压铸机有限公司 | Die casting machine with automatic diagnostic system |
| DE50312004D1 (en) * | 2003-08-25 | 2009-11-19 | Fondarex Sa | Method for vacuum pressure or injection molding |
| JP4866083B2 (en) * | 2005-12-26 | 2012-02-01 | 東芝機械株式会社 | Method and apparatus for spraying mold release agent in die casting machine |
| CN201629732U (en) * | 2010-04-07 | 2010-11-10 | 株洲南车时代电气股份有限公司 | Real-time data acquisition and pulse distribution system of general frequency converter |
| CN202239559U (en) * | 2011-08-31 | 2012-05-30 | 重庆溢希恩真节能电力设备有限公司 | Novel automatic proportioning energy saver for die casting machine mould release agent |
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