The data and signal acquisition of key equipment shall be carried out according to the characteristics of iron mold sand casting process, mainly including molding, box closing, box opening, cleaning, pouring and iron mold conveying. According to the requirements of different station equipment, select the sensor that can meet the requirements of the performance test of iron mold sand casting process parameters.
1. Modeling station equipment data and signal acquisition
The analog signal data that the molding station equipment needs to collect include: mold temperature, iron mold temperature, heating mold circuit current and voltage, heating mold power, iron mold sand coating and shooting pressure, etc; The digital signal data to be collected include: the sand shooting time of the iron-coated sand mold, the solidification time of the iron-coated sand layer, the sand volume of the coated sand storage, and the oil pressure of the hydraulic station. For temperature data acquisition, PT100 temperature control instrument with multi-section temperature control, high temperature control accuracy, and various types of sensors shall be selected to meet the requirements of contact temperature measurement for covering mold and non-contact temperature measurement for iron mold; Three-phase intelligent digital display multi-function electric instrument is selected for data acquisition of heating mold current, voltage and power to realize the display, acquisition, transmission and measurement of voltage, current and power. The digital signal acquisition and selection instruments include resistance rotation level gauge, proximity switch, time relay, oil pressure gauge signal, etc. The anti-rotation level gauge accurately warns the sand volume of the sand silo; The proximity switch avoids the interference of dust and sundries on the site, and has good reliability; The time relay records the sand shooting time and curing time, which can realize the timing of starting the input signal and completing the output signal; The sand injection pressure sensor uses a diffused silicon pressure transmitter to convert the gas pressure into a standard electrical signal and input it to the PLC control module.
2. Data and signal acquisition of pouring station equipment
The data and signals collected by the pouring station equipment include the current actual position, current speed, actual acceleration time, actual deceleration time, molten iron pouring time, pouring temperature, molten iron weight, torque value of lock box torque wrench, unloading time of iron lock box, current and historical number of pouring boxes, etc. In order to ensure the accuracy of molten iron pouring position, the servo drive control track-change push cylinder is selected to push the pouring trolley, and the encoder with accurate detection position is selected to collect the equipment operation data. Due to the unsafe wiring and inconvenient operation in the pouring area, the data acquisition of molten iron temperature, weight of molten iron, torque value of lock box torque wrench and other data are all using wireless measuring instruments. The sensors and testers synchronously transmit the collected data to the wall-mounted large-screen display through wireless transmission technology and record the data.
3. Data and signal acquisition of unpacking station equipment
The signals and data collected by the unpacking machine station equipment include: hydraulic station pressure, starting time, track deceleration time, iron mold temperature before unpacking, iron mold sand casting temperature after unpacking, iron mold waiting for unpacking time, unpacking machine operation time, current and historical unpacking number, etc.
Data acquisition and signal instruments include pressure gauge, time relay, temperature control meter and proximity switch. The intelligent temperature controller is selected for temperature data acquisition, and the sensor is non-contact measurement, which can not only feed back the upper and lower limits of temperature, but also give an alarm beyond the temperature range; Select the time relay for the time record of the iron mold to be unpacked. The relay has the function of inputting the signal for the start of the timing and outputting the signal for the completion of the timing to remind the operator of the end of the unpacking time waiting and start the unpacking of the iron mold sand casting.
4. Cleaning station equipment data and signal acquisition
The data and signal acquisition of the cleaning station equipment include: the temperature of 6 temperature measuring points at different positions of the upper and lower iron types, the pressure of the water cooling system, the pressure of natural gas, the water spraying time of 4 nozzles at different positions of the upper and lower iron types, the heating time of the upper and lower iron types, the ignition recording time of the upper and lower iron types, the operation time of the axial flow fan, the number of water cooling (heating) tanks of the current day and the history, and the operation time of the water cooling system. The pressure gauge adopts shock-proof magnetic-assisted electric contact pressure gauge, which outputs signal feedback when the pressure is too high or too low; The temperature sensor uses non-contact and anti-interference infrared temperature sensor, which can detect the temperature reliably.