消失模自动浇铸过程监控系统设计

针对自动浇铸过程中生产效率低、数字化程度低、浇铸信息不完善等问题,设计了一种基于组态技术以及PLC技术的浇铸监控系统;该系统以MCGS组态软件作为监控系统开发平台,对分布式网络下PLC采集的设备运行状态和处理后的数据进行深层次地解析,实现了对浇铸过程的实时监控;采用无线AP Client的网络架构搭建了底层移动设备间的数据传输通道,保证了系统能够快速且稳定地完成数据采集以及设备的运行控制,实现了浇铸监控系统的实时信息显示、历史数据查询等功能;该系统已经应用于消失模铸造车间,极大提高了车间的数字化程度,利用射频识别技术(RFID)实现了浇铸工位定位,当读写次数达4 000～8 000,RFID的准确率为100％;以浇铸100 kg的变速箱体为例,平均耗时低于35 s,每包铁水用时累积节约180 s,提高了生产效率.

Design of Monitoring System for Automatic Casting Process of Lost Foam

According to the problems of low production efficiency, low digitization and imperfect casting information in the automatic casting process, a casting monitoring system based on configuration technology and PLC technology was designed. MCGS configuration software is used as the development platform of the monitoring system. The running status of the equipment and the processed data collected by PLC under the distributed network are analyzed in depth, and the real-time monitoring of the casting process is realized. The wireless AP client network architecture is used to build the data transmission channel between the underlying mobile devices, which ensures that the system can quickly and stably complete the data acquisition and equipment operation control, and realizes the real-time information display, historical data query and other functions of the casting monitoring system. The system has been applied to the lost foam casting workshop, which greatly improves the informatization degree of the workshop and production efficiency.The positioning of casting station is realized by using radio frequency identification technology (RFID). When the reading and writing times reach 4000-8000, the accuracy rate of RFID is 100%. Taking the casting of 100kg gearbox as an example, the average time consumption is less than 35S, and the accumulated time saving of each pack of molten iron is 180s, which improves the production efficiency.