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铝带坯铸轧机流槽液面自动控制系统
当铸轧速度、铝液温度和铸轧辊冷却强度一定的条件下，前箱液位直接影响铸轧带坯的厚度。同时为了保证铸轧过程的连续性，当铸轧速度变化时，所需金属流量应稳定在一定的范围内。为保证前箱中的液位稳定，目前国内通常采用二级控制：第一级控制保温炉流口处流槽中的液位；第二级控制前箱中的液位。保温炉流口处液位控制主要通过人工观察前箱液位后，手动调整保温炉流口塞杆；这种方法存在一个问题，就是塞杆动作幅度大，铝液速度变化快，造成液面冲击大，液位不稳定。由此引起板表面虎皮纹，晶粒粗大等质量问题。同时也大大制约了轧机的速度。严重时还有可能引起断流，溢流，断板等生产事故。
When the casting rolling speed, the temperature of the aluminum liquid and the cooling strength of the roll are certain, the liquid level of the front box directly affects the thickness of the cast rolling strip. At the same time, in order to ensure continuous casting rolling process, when the casting speed changes, the required metal flow should be stable in a certain range. In order to ensure the stable liquid level in the tank before, at present domestic commonly used two level control level: first level control of holding furnace outlet flow in launder; second level control box in front. The liquid level control at the outlet of the holding furnace is mainly through manual observation of the liquid level of the front box, and manually adjusting the plug of the outlet of the heat preservation furnace. There is a problem in this method, that is, the action range of the plug rod is large and the velocity of the aluminum liquid changes rapidly, causing the liquid surface to impact large and the liquid level unstable. This causes the surface of the surface of the plate, the coarse grain and so on. At the same time, it also greatly restricts the speed of the rolling mill. In serious cases, it may also cause accidents such as disconnection, overflow, broken plate and so on.
液面自动控制系统基本控制原理
Basic control principle of liquid surface automatic control system
铝带坯铸轧机保温炉流口处流槽液面升降的位移量，通过浸于铝液中的浮子将信号传递出来，此机械信号再通过杠杆以一定的传递比传递到差动变压器式位移传感器上，位移传感器将位移的机械变量转变为直流电压，传送到PLC控制器，PLC控制系统模块将电压参数转变为开关量，控制直流伺服电机启、停及正、反转，然后再通过机械装置带动保温炉口塞杆做直线运动，改变保温炉出流口的面积，从而改变铝液的流出量，保证了流槽液面在一定范围内的恒定。
Aluminum strip casting rolling mill furnace insulation displacement flow outlet groove liquid level, by immersion in liquid aluminum will float out signal transmission, the signal through the mechanical lever with a certain transmission ratio is transferred to the differential transformer displacement sensor, displacement sensor, mechanical variable displacement into a DC voltage to the transmission PLC controller, PLC control system module voltage parameters into the switch quantity control of DC servo motor start and stop and reverse, then driven by a mechanical device insulation mouth plug rod linear movement, change the furnace outlet area, thus changing the outflow of liquid aluminum, ensure the constant liquid level in the tank in a certain range.
优点：采用直流伺服电机作为驱动机构的自动控流装置控制铝带坯铸轧机保温炉流口处流槽中的液面,不但使液面控制进度大大提高，有助于提高产品质量，而且降低了劳动强度，提高了生产效率。
Advantages: automatic control of DC servo motor as the driving mechanism of the flow control device of aluminum strip casting rolling mill furnace flow at the mouth of the groove, not only make the level control progress is greatly improved, helps to improve the product quality and reduce the labor intensity, improve the production efficiency.
应用技巧：
Application skills:
一．保证自动控流器的安装合理
1. Ensure that the installation of the automatic flow control device is reasonable
一、位移杠杆传感器
One, displacement lever sensor
位移传感器由杠杆、配重块、浮漂、支点四部分组成，为了保证杠杆在工作中的精度和灵敏度，安装前制作好浮漂，根据浮漂和配重块的比重以及杠杆支点的比例（传递比），保证安装后浮漂空载（无铝液浮力）时杠杆为水平。
The displacement sensor is composed of a lever, counterweight, float, the fulcrum is composed of four parts, in order to ensure the accuracy and sensitivity of the lever in the work, before the installation of production according to the float, float and counter weight proportion and the proportion of the fulcrum (transfer ratio), ensure the installation after the float empty load (no aluminum liquid lever for buoyancy) the level of.
安装及调节要领：
Key points for installation and adjustment:
1、杠杆与浮漂连接处灵活，保证浮漂垂直于地面；
1. The link between the lever and float is flexible, so that the float is perpendicular to the ground.
2、 杠杆支点刀口绝对灵敏；
2, the lever pivot is absolutely sensitive.
3、 调节杠杆配重块位置，保证杠杆绝对水平（浮漂空载没有铝液浮力的情况下）；
3, adjust the position of the lever weight block to ensure the absolute lever of the lever (floating and empty load without aluminum liquid buoyancy).
4、 不可随意调整杠杆支点的位置，保证杠杆支点靠近浮漂一端，以此保证铝液液面以较小的波动引起杠杆限位感应器端较大的反馈值。（一般情况下，液面波动精度控制在±1mm。）；
4, do not arbitrarily adjust the position of the lever fulcrum, ensure that the lever fulcrum is close to one end of the floater, so as to ensure that the liquid level of the aluminum liquid causes a larger feedback value of the lever limit inductor end with a smaller fluctuation. (in general, the accuracy of liquid surface fluctuation is controlled in 1mm.) ;
5、生产过程中根据实际需要的流槽液位高度通过浮漂调节孔调节铝液浮漂的高度，以保证位移杠杆传感器的水平。
5, in the production process according to the actual needs of the high level trough through the float adjusting hole regulating liquid aluminum float height, to ensure that the horizontal displacement lever sensor.
二、 直流伺服电机驱动机构的自动控流装置
Two, automatic current control device of DC servo motor drive mechanism
安装及调整要领：
Key points for installation and adjustment:
1、 自动控流钎塞杆长度制作合理，保证塞杆安装后控流钎传动杠杆1与地面保持相对垂直。
1. The length of the automatic flow control rod is reasonable, and it is ensured that the control flow drill lever 1 is relatively vertical to the ground after the plug is installed.
2、 伺服电机感应限位2应该尽可能缩小间距，并且相对靠近轨道中线4。
2, the induction limit 2 of the servo motor should reduce the distance as much as possible, and be relatively close to the middle line 4 of the track.
3、 保证装置各部位活动联结点的足够润滑和灵活性。
3, ensure sufficient lubrication and flexibility of the joint point of each part of the device.
二. 自动控流最终实现的目标：液位长时间保持稳定，降低液位自动调节的频次和幅度，保证液位控制±1mm的波动范围。
Two, the goal of automatic flow control is to keep the liquid level stable for a long time, reduce the frequency and amplitude of automatic adjustment of liquid level, and ensure the fluctuation range of level control + 1mm.
结语：古人说：工欲善其事，必先利其器。这是管理的基本境界。企业的“器”，大处说就是工艺装备。要做到“利其器”，企业应该把握住两个方面，一个是让工艺装备更加先进，另一个就是让工艺装备更能发挥其应有潜力。工艺装备的先进性除了设计建设的先进性，更重要还在于使用维护的先进性，不断革新完善的先进性，以及人机之间的适应先进性和管理组织的先进性。其次，工艺装备的潜力也需要我们认真考察。比如，控制系统优化的潜力，以及相关的产品质量的潜力、产品规格的潜力、节能增效的潜力等等。我厂新投产产线工艺装备设计多处于国际水平或国内领先水平，我们能不能保持这种先进性，并让这种先进性的潜力充分释放出来，甚至即使现有落后的设备也要发挥其成本潜力和特有功用，这些问题就是生产系统所面临的重要研究课题。”
Conclusion: the ancients said: "good desire for work" is the first thing to do. This is the basic realm of management. "Enterprise", the Department is processing equipment. In order to achieve "profit making device", enterprises should grasp two aspects, one is to make technology and equipment more advanced, and the other is to make process equipment better able to play its potential. In addition to the advanced nature of design and construction, the advanced nature of technology and equipment is also more important than the advanced nature of maintenance, constantly improving and improving the advanced nature and the advanced nature of management organization. Secondly, the potential of technological equipment needs to be carefully examined. For example, the potential of the control system optimization, the potential of the product quality, the potential of the product specifications, the potential of energy saving and increasing efficiency and so on. I plant the production of new production line technology and equipment design at the international level and the leading domestic level, we can maintain the advanced nature of this, and let the advanced potential fully released, even if the existing equipment backward should also play its unique function and potential cost, this problem is an important research topic facing production system the."
自动之所以称之为“自动”必有其科学性和先进性，由手动到自动是社会及科技的进步，而抵触或放弃自动使用手动在很大程度上来说是对经验主义的过分依赖和操作技能的局限性所致，手动操作的诸多不利因素导致液面流槽控制的大起大落，既劳力伤神又导致产品质量的不可控性，要想实现产品质量稳定，必先研究保证保温流口铝液的涓涓细流，进而实现铝途人生的精彩。
Automatic call "automatic" must have its scientific and advanced, from manual to automatic is the society and the progress of science and technology, and the conflict or abandon the limitations caused by using automatic manual is largely dependent on empiricism and operation skills, many adverse factors of manual operation in liquid trough control can lead to change radically, but labor is not controllable product quality, in order to achieve the stable product quality, must ensure the thermal flow of molten aluminum on trickle, and then realize the wonderful life of aluminum.
When the casting rolling speed, the temperature of the aluminum liquid and the cooling strength of the roll are certain, the liquid level of the front box directly affects the thickness of the cast rolling strip. At the same time, in order to ensure continuous casting rolling process, when the casting speed changes, the required metal flow should be stable in a certain range. In order to ensure the stable liquid level in the tank before, at present domestic commonly used two level control level: first level control of holding furnace outlet flow in launder; second level control box in front. The liquid level control at the outlet of the holding furnace is mainly through manual observation of the liquid level of the front box, and manually adjusting the plug of the outlet of the heat preservation furnace. There is a problem in this method, that is, the action range of the plug rod is large and the velocity of the aluminum liquid changes rapidly, causing the liquid surface to impact large and the liquid level unstable. This causes the surface of the surface of the plate, the coarse grain and so on. At the same time, it also greatly restricts the speed of the rolling mill. In serious cases, it may also cause accidents such as disconnection, overflow, broken plate and so on.
液面自动控制系统基本控制原理
Basic control principle of liquid surface automatic control system
铝带坯铸轧机保温炉流口处流槽液面升降的位移量，通过浸于铝液中的浮子将信号传递出来，此机械信号再通过杠杆以一定的传递比传递到差动变压器式位移传感器上，位移传感器将位移的机械变量转变为直流电压，传送到PLC控制器，PLC控制系统模块将电压参数转变为开关量，控制直流伺服电机启、停及正、反转，然后再通过机械装置带动保温炉口塞杆做直线运动，改变保温炉出流口的面积，从而改变铝液的流出量，保证了流槽液面在一定范围内的恒定。
Aluminum strip casting rolling mill furnace insulation displacement flow outlet groove liquid level, by immersion in liquid aluminum will float out signal transmission, the signal through the mechanical lever with a certain transmission ratio is transferred to the differential transformer displacement sensor, displacement sensor, mechanical variable displacement into a DC voltage to the transmission PLC controller, PLC control system module voltage parameters into the switch quantity control of DC servo motor start and stop and reverse, then driven by a mechanical device insulation mouth plug rod linear movement, change the furnace outlet area, thus changing the outflow of liquid aluminum, ensure the constant liquid level in the tank in a certain range.
优点：采用直流伺服电机作为驱动机构的自动控流装置控制铝带坯铸轧机保温炉流口处流槽中的液面,不但使液面控制进度大大提高，有助于提高产品质量，而且降低了劳动强度，提高了生产效率。
Advantages: automatic control of DC servo motor as the driving mechanism of the flow control device of aluminum strip casting rolling mill furnace flow at the mouth of the groove, not only make the level control progress is greatly improved, helps to improve the product quality and reduce the labor intensity, improve the production efficiency.
应用技巧：
Application skills:
一．保证自动控流器的安装合理
1. Ensure that the installation of the automatic flow control device is reasonable
一、位移杠杆传感器
One, displacement lever sensor
位移传感器由杠杆、配重块、浮漂、支点四部分组成，为了保证杠杆在工作中的精度和灵敏度，安装前制作好浮漂，根据浮漂和配重块的比重以及杠杆支点的比例（传递比），保证安装后浮漂空载（无铝液浮力）时杠杆为水平。
The displacement sensor is composed of a lever, counterweight, float, the fulcrum is composed of four parts, in order to ensure the accuracy and sensitivity of the lever in the work, before the installation of production according to the float, float and counter weight proportion and the proportion of the fulcrum (transfer ratio), ensure the installation after the float empty load (no aluminum liquid lever for buoyancy) the level of.
安装及调节要领：
Key points for installation and adjustment:
1、杠杆与浮漂连接处灵活，保证浮漂垂直于地面；
1. The link between the lever and float is flexible, so that the float is perpendicular to the ground.
2、 杠杆支点刀口绝对灵敏；
2, the lever pivot is absolutely sensitive.
3、 调节杠杆配重块位置，保证杠杆绝对水平（浮漂空载没有铝液浮力的情况下）；
3, adjust the position of the lever weight block to ensure the absolute lever of the lever (floating and empty load without aluminum liquid buoyancy).
4、 不可随意调整杠杆支点的位置，保证杠杆支点靠近浮漂一端，以此保证铝液液面以较小的波动引起杠杆限位感应器端较大的反馈值。（一般情况下，液面波动精度控制在±1mm。）；
4, do not arbitrarily adjust the position of the lever fulcrum, ensure that the lever fulcrum is close to one end of the floater, so as to ensure that the liquid level of the aluminum liquid causes a larger feedback value of the lever limit inductor end with a smaller fluctuation. (in general, the accuracy of liquid surface fluctuation is controlled in 1mm.) ;
5、生产过程中根据实际需要的流槽液位高度通过浮漂调节孔调节铝液浮漂的高度，以保证位移杠杆传感器的水平。
5, in the production process according to the actual needs of the high level trough through the float adjusting hole regulating liquid aluminum float height, to ensure that the horizontal displacement lever sensor.
二、 直流伺服电机驱动机构的自动控流装置
Two, automatic current control device of DC servo motor drive mechanism
安装及调整要领：
Key points for installation and adjustment:
1、 自动控流钎塞杆长度制作合理，保证塞杆安装后控流钎传动杠杆1与地面保持相对垂直。
1. The length of the automatic flow control rod is reasonable, and it is ensured that the control flow drill lever 1 is relatively vertical to the ground after the plug is installed.
2、 伺服电机感应限位2应该尽可能缩小间距，并且相对靠近轨道中线4。
2, the induction limit 2 of the servo motor should reduce the distance as much as possible, and be relatively close to the middle line 4 of the track.
3、 保证装置各部位活动联结点的足够润滑和灵活性。
3, ensure sufficient lubrication and flexibility of the joint point of each part of the device.
二. 自动控流最终实现的目标：液位长时间保持稳定，降低液位自动调节的频次和幅度，保证液位控制±1mm的波动范围。
Two, the goal of automatic flow control is to keep the liquid level stable for a long time, reduce the frequency and amplitude of automatic adjustment of liquid level, and ensure the fluctuation range of level control + 1mm.
结语：古人说：工欲善其事，必先利其器。这是管理的基本境界。企业的“器”，大处说就是工艺装备。要做到“利其器”，企业应该把握住两个方面，一个是让工艺装备更加先进，另一个就是让工艺装备更能发挥其应有潜力。工艺装备的先进性除了设计建设的先进性，更重要还在于使用维护的先进性，不断革新完善的先进性，以及人机之间的适应先进性和管理组织的先进性。其次，工艺装备的潜力也需要我们认真考察。比如，控制系统优化的潜力，以及相关的产品质量的潜力、产品规格的潜力、节能增效的潜力等等。我厂新投产产线工艺装备设计多处于国际水平或国内领先水平，我们能不能保持这种先进性，并让这种先进性的潜力充分释放出来，甚至即使现有落后的设备也要发挥其成本潜力和特有功用，这些问题就是生产系统所面临的重要研究课题。”
Conclusion: the ancients said: "good desire for work" is the first thing to do. This is the basic realm of management. "Enterprise", the Department is processing equipment. In order to achieve "profit making device", enterprises should grasp two aspects, one is to make technology and equipment more advanced, and the other is to make process equipment better able to play its potential. In addition to the advanced nature of design and construction, the advanced nature of technology and equipment is also more important than the advanced nature of maintenance, constantly improving and improving the advanced nature and the advanced nature of management organization. Secondly, the potential of technological equipment needs to be carefully examined. For example, the potential of the control system optimization, the potential of the product quality, the potential of the product specifications, the potential of energy saving and increasing efficiency and so on. I plant the production of new production line technology and equipment design at the international level and the leading domestic level, we can maintain the advanced nature of this, and let the advanced potential fully released, even if the existing equipment backward should also play its unique function and potential cost, this problem is an important research topic facing production system the."
自动之所以称之为“自动”必有其科学性和先进性，由手动到自动是社会及科技的进步，而抵触或放弃自动使用手动在很大程度上来说是对经验主义的过分依赖和操作技能的局限性所致，手动操作的诸多不利因素导致液面流槽控制的大起大落，既劳力伤神又导致产品质量的不可控性，要想实现产品质量稳定，必先研究保证保温流口铝液的涓涓细流，进而实现铝途人生的精彩。
Automatic call "automatic" must have its scientific and advanced, from manual to automatic is the society and the progress of science and technology, and the conflict or abandon the limitations caused by using automatic manual is largely dependent on empiricism and operation skills, many adverse factors of manual operation in liquid trough control can lead to change radically, but labor is not controllable product quality, in order to achieve the stable product quality, must ensure the thermal flow of molten aluminum on trickle, and then realize the wonderful life of aluminum.
