Centrifugal Casting Technology for Cylinder Liner Based on Data Fusion Technology

Transcription

1 07 d Iteratoal Coferece o Iformato Techology ad Idutral Automato (ICITIA 07) ISBN: Cetrfugal Catg Techology for Cylder Ler Baed o Data Fuo Techology Haju Wag ad Qgy Me ABSTRACT The qualty ad fucto of cetrfugal catg of cylder ler depeded o the chage regulato of flow ad temperature. The tellget equpmet reearched. The tructure ad prcple of cetrfugal catg troduced, the craft by multple temperature aalyzed. The temperature formato of mult eor collected baed o the adaptve weghtg model. The temperature cotrol ytem deged. The temperature of bearg houe ad mould ad pdle are bee motored. The qualty of cylder ler hghly mproved by ug the temperature cotrol ytem. The harde of cylder ler blak creaed from 0.6 to.3. INTRODUCTION Productve effcecy ad product qualty of teral combuto ege cylder ler ca be mproved by ug cetrfugal catg techology whch automatc cotrol the catg proce[~]. It oe of the key techologe for hgh qualty ad hgh effcecy producto of cylder ler to cotrol the proce parameter cetrfugal catg of cylder ler. The temperature a mportat techcal parameter of cetrfugal catg of cylder ler, whch ha decve effect o urface ad teral qualty of catg, the other craft preco, the fal qualty of cylder ler. Meauremet ad cotrol of hgh preco temperature become the key techology of the cetrfugal catg qualty cotrollg[3~4]. Iformato fuo techology the core techology of hgh preco temperature Haju Wag, GKN Zhogyua Cylder ler Compay Lmted, Hea, Cha. Qgy Me, Luoyag Ittute of Scece ad Techology, Hea, Cha.

2 meauremet, whch tegrate a varety of related formato, ad carre o the compreheve proceg to the formato. Thereby the deco formato wth hgher accuracy obtaed. TECHNOLOGY BACKGROUND 0-Stato Cetrfugal Catg Mache 0-Stato cetrfugal catg mache clude catg, coolg, tme, materal, cleag, door, prayg, dryg tato, a how a Fgure. Sgle Cetrfugal Catg Mache 0-Stato cetrfugal catg mache compoed by gle cetrfugal catg mache to cat the cylder ler. Sgle cetrfugal catg mache maly compoed of catg cover, mold, flywheel, ma haft, balace block flage, balace block, bearg eat ad other part, a how a Fgure.Whe the cetrfugal catg, the temperature at the ed of ma haft ear the mold ca reach to 0. The eceve temperature varato retrct the adjutmet of the bearg ed play. Fgure. Scheme of tato of 0-Stato cetrfugal catg mache. 3

3 - catg cover;-mold;3-flywheel; 4-ma haft;5- balace block flage; 6- balace block;7-bearg eat aembly Fgure. Cotructo of gle cetrfugal catg mache. Fgure 3. Water coolg bearg eat. The hgh temperature ca reduce the load capacty of bearg, lead to uplaed outage or load heddg operato of mache, creae the vbrato of the catg proce, eve emerge the rotatg tall ad urge, th horte the ervce lfe of mache. I order to eure the cotuou operato of the equpmet, mprove the effcecy ad relablty, t ha bee mproved to upport of the tradtoal ldg bearg. The ma haft ad bearg eat are deged (Fgure 3) to ue water coolg cotrol ad the bearg eat tegrated deg at top ad ed of catg mache. The mamum temperature of the bearg cotrolled at 35, o that the heat load of the bearg reduced. The tegrated deg of the bearg eat ot oly mprove the rgdty of catg mache, but alo be mached tegral at oce. It eure the er hole proper algmet of top ad ed bearg eat, reduce the vbrato of the cetrfugal catg mache at hgh peed rotato, ad greatly mprove the bearg lfe ad the preco of the catg mache. Catg Temperature of Lqud Iro Catg temperature of lqud ro of 0-Stato cetrfugal catg mache 400~450,tappg temperature 500~530. If the pourg temperature of lqud ro too low, the fludty of lqud ro poor, the cluo are odzed, the amout of ucto large, ad the rejecto rate of catg creaed. Temperature of Coatg ad Mold Temperature I order to make the catg mold uloadg ealy, prevet the catg ro to be chlled, reduce the mpact of lqud metal o metal type ad the peak temperature of the metal type, obta the deal catg urface, creae the fracto force wth the lqud ro, decreae the tme whe the lqud ro acheve the p velocty of catg mold. The cetrfugal catg mold eed pray pat. 4

4 The reult how that the approprate mold temperature ca reduce the urface defect of catg ad eure the catg performace. If the mold temperature tme too low, o that the heat lackg, t lead to low evaporato of water the pat eve the pheomeo of flow ad heap, the wall adheo ot trog, ad the pat ot uform ad hardly dry. If the mold temperature tme too hgh, o that the evaporato of water the pat mghtly, t wll make the pat powder upprg, lot ad plah durg catg, t dffcult to form a uform coatg ad adheo weak betwee coatg ad wall, reult that coatg wahed out by lqud ro ealy. Table how the referece rage of catg preheatg temperature ad workg temperature of cat ro alloy cylder ler. I addto, uder the hgher mold temperature, the coolg effect of the catg mold weak, ad the lqud metal rema lqud tate whe t move alog the aal drecto of the mold, utl the metal lqud reache the two ecto of the catg mold, t beg to oldfy. Whe the mold temperature low, the coolg effect of the mold large, the frt metal lqud ha ot fully reached the ed of the mold ha bee oldfed, reultg the pheomeo of water ad wrkled k. However, whe the mold temperature relatvely hgh, the catg the radal drecto from the outer wall to reduce the temperature gradet of the er wall, the wall thcke of catg drecto o the er wall ad the outer wall of the bdrectoal oldfcato hrkage the mddle layer tefed lat perod of oldfcato wll further epad. The qualty of the mold alo good, but the hgh temperature of the mold wll drectly lead to the oldfcato of the radal drecto of the oldfcato of the catg tefed, thu creag the ze of the hole, order to olve th cotradcto, ca be ued to pray water. That to ay, pourg hgh mold temperature, after pourg fhed, order to creae the coolg rate of catg from the outer wall to the er wall of the pray coolg water the oldfcato proce of catg the coolg mold, thereby mprovg the catg wall to the er wall of the coolg rate, mprove catg urface qualty, ad reduce the hrkage of purpoe. TABLE. CASTING TEMPERATURE. Cylder ler type Preheatg temperature/ Workg temperature/ Agrcultural mache ege, automoble ege cylder ler 00~50 00~300 Shp ege cylder ler 50~300 50~350 5

5 DATA FUSION TECHNOLOGY The Fudametal ad Proce of Data Fuo Data fuo algorthm alo amed a mult-eor data fuo algorthm. It prcple[3] to model the ytem ad objectve by effectve uage of the pecto formato obtaed by eor, mot of all, proceg the redudacy or complemetary formato patotemporal doma, wth effectve role. Data fuo techology baed o the depedet pecto formato acqured by varou eor, ad the help obta more formatve data by advaced algorthm. By th proce, t ca make good ue of the advatage of mult-eor ytem to mprove t effectvee, to elmate the lmtato of gle or few eor. Therefore, more effectvee ca be acheved tha that of ubytem dvdually. The bac proce of the Data fuo of the mult-eor ytem how a Fgure4. Egeerg techcal parameter gal are frtly trated to electrcal gal by the eor, ad the are trated to dgtal data by A/D wtcher. Net, the dgtalzed electrcal gal wll be proceed to elmate the dturbg ad oe data deleto, low frequecy fltrato, moothg, averagg algorthm. Feature etracto the coducted to the ueful formato of prelmary proceed data. Fally, the formato calculated by the data fuo algorthm to obta the fuo reult. I the proce of ege cylder ler catg, the temperature a mportat techcal parameter. The meauremet of catg temperature, bearg temperature ad lqud ro temperature are coducted by oe et of eor, whch cot of 8 eor. Much hgher accuracy of temperature ca be acheved by fuo proce of the meauremet data. At the ame tme, the cylder ler catg cotrol ytem ued to motor ad fuo the bearg vbrato ad the ma haft revoluto, ad to cotrol the rotato peed ad temperature of bearg. The cotrol of each parameter wll be eplaed aother paper. Idetfcato ad Deleto of The Abormal Sgal Abormal gal are evtable the temperature data acqured by the computer due to ome evtable varou dturbg. I the temperature meauremet of the ball mll ma bearg, the followg role are appled to determe the effectvee of the vector[5], the abormal data ad eecute deleto accordg to the prcple of t. Seor ytem for the ma bearg temperature meauremet A/D Preproceg Feature etracto Data fuo Reult Fgure 4. Data fuo proce. 6

6 For the temperature gal acqured by the eor,,,,, f k upcou value, average value ca be calculated by deletg the k. If there o upcou value, the average ad tadard devato ca be obtaed drectly. k () v k The tadard devato of the tet value(the calculato ot cluded k ) k v () The, accordg to the gve eor umber ad the otable level α, the K(,α) ca be obtaed from the t table. k(, ) The f k,k take a the abormal value, ad hould be deleted. Otherwe, the value ot abormal ad hould be kept. I mot occao, the abormal value are the mamum or mmum value. Therefore, order to reduce the calculato cot of the computer, the mamum ad mmum value hould be calculated frtly, ad the determe f they are the abormal value. Accordg to the effectvee judge calculato, effectvee vector defed a S=[,,, ]T. Where, for the effectve data, the (=,,,) equal to. Otherwe for the abormal data, the equal to zero. Self-adaptve Weghted Fuo of The Temperature Meauremet The elf-adaptve fuo algorthm how a Fgure 5. At the codto of abormal data deleto, the weght vector W(=,,,) troduced to mark the meauremet accuracy accordg to mmal prcple of the two order etracto value of the error. Baed o the acqured data, the optmal ga factor ca be obtaed by the adaptve calculato. The the optmal y value ca be obtaed by the fuo calculato. W W W y Fgure 5. Algorthm of the elf-adaptve data fuo. 7

7 Set the temperature value collected by temperature eor are depedet of each other, t the ubaed etmate of X temperature to be meaured; the varace of temperature eor are,,, ; the ga factor are W,W,,W, o the ga factor of fuo value y hould be atfed: W y (3) W (4) Error of Ma Square : ] ) )( ( ) ( [ ] [, j j j j j WW y W E E Y X (5) Where, X=[,,,]T,Y=[y,y,,y]T,there are member vector Y. Sce the,,, are depedet from each other, ad are the o-error etmato of the real value, E[(-)(-j)]=0 ( j; =,,,; j=,,, ). The ca be obtaed: W W E ] ) ( [ (=,,,) (6) From the eq.6, the the two order fucto of the ga factor of the effectve data. Therefore, mut have the mmum value. The value ca be calculated ealy. By ug the mult-fucto etrema calculato approach, the ga factor whe the error of the ma quare reache the mmum etrema ca be obtaed: W * (=,,,) (7) Here, the correpodg mmum error of the ma quare : W m (8) The calculato of the mea quare devato ca be foud the referece [4]. 8

8 Temperature Meauremet Tet of Water-cooled Bearg Seat I th paper, 8 N-Cr/N-S armoured thermocouple ytem bult up to carry out the temperature meauremet of the ball mll ma bearg. The meauremet data how a TABLE. The beleve level of the 8 eor were et to be 0.5. By the t tet, the effectvee vector ca be calculated S=[,,,,,,,]T. Therefore, all the meauremet data are effectve. Ad the, by eq. 3 ad eq. 6, the etmated value ad quare could be obtaed to be ad repectvely. Whle by the averagg calculato, the value are ad It obvouly the accuracy mproved largely by the mplemetato of the fuo algorthm. AUTOMATIC TEMPERATURE CONTROL I the proce of cetrfugal catg, the temperature ad vbrato accelerato of the bearg eat dcate the workg codto of the cetrfugal catg mache. Mold temperature, alloy oluto temperature ad ma haft revoluto of cetrfugal catg mache have a decve effect o the catg qualty of cylder ler. Therefore, t hould be motored o the vbrato accelerato of the bearg eat, the temperature of the alloy oluto, the bearg eat temperature of the cetrfugal catg mache, the catg temperature ad the rotato peed of the ma haft. Sytem Frame Deg The motorg ytem ucleu of cetrfugal catg mache clude: TABLE. Epermetal reult ad data fuo aaly of the temperature meauremet. Meauremet data / Average devato Ga factor W

9 Cetrfugal catg mache Seor Actuator Sgal modulated Sgal acquto devce PLC(oftware) Iteractve devce Fgure 6. Scheme of proce cotrol ytem. eor, gal codtog equpmet, data acquto equpmet, PLC (cludg oftware), drver, actuator, teractve devce ad other compoet, a how Fgure6. The phycal parameter are tramtted to electrcal gal by eor, the the electrcal gal are modulated by codtog equpmet, fally put gal acquto devce. After PLC treatmet, the output could ue to prt, dplay, oud ad lght alarm or provded utable output power for actuator by the drver. Hece the actuator complete the operato to realze the ytem cotrol (uch a water pray to cotrol the mold temperature). PLC ad t motorg ytem oftware cotrol, detecto ad dplay the ytem parameter. Mold Temperature Cotrol of Cetrfugal Catg Mache The cotrol prcple of cetrfugal catg mache mold temperature how Fgure 7. Accordg to the cylder ler parameter put, PLC et the mold cotrol temperature automatc whch hould compare wth the real-tme detecto mold temperature gal from the eor. So that, t cotrol mold pray ytem workg codto ad real- tme mold cotrol, provdg the utable rate ad tme of prayg. Catg Cylder Ler Uder The Mold Temperature Cotrol Fgure 8 ad Fgure 9 how the fracture appearace of catg at the mold temperature 400 ad 00. Compared wth the two fgure, t ca be ee that wth the decreag the mold temperature, the hrkage hole the catg decreae obvouly. Fgure0 ad Fgure llutrate the urface morphology of the catg uder the codto of two kd of mold temperature. At hgh 30

10 Settg mold temperature PLC Mold pray ytem Mold Temperature meauremet Fgure 7. Cotrol prcple of the mold temperature. Fgure 8. The hrkage the catg ecto at 400 mold temperature. Fgure 9. The hrkage the catg ecto at 00 mold temperature. Fgure 0. The urface charactertc of catg at 400 mold temperature. Fgure. The urface charactertc of catg at 00 mold temperature. mold catg uder the codto of two kd of mold temperature. At hgh mold temperature, the urface of catg moothly a how Fgure 0. I cotract, the urface of catg appeared grave wrkled k pheomeo at low temperature a how Fgure. The reult how that at the hgh mold temperature, the catg ha better urface qualty, ad the lower mold temperature ca reduce the hrkage of the catg. The reult that at the hgher mold temperature, the coolg effect of the catg mold weak, ad the lqud metal rema lqud tate whe t move alog the aal drecto of the mold, utl the metal lqud reache the two ecto of the catg mold, t beg to oldfy. Whe the mold temperature low, the coolg effect of the mold large, the frt metal lqud ha ot fully reached the ed of the mold ha bee oldfed, reultg the pheomeo of 3

11 water ad wrkled k. However, whe the mold temperature relatvely hgh, the catg the radal drecto from the outer wall to reduce the temperature gradet of the er wall, the wall thcke of catg drecto o the er wall ad the outer wall of the bdrectoal oldfcato hrkage the mddle layer tefed lat perod of oldfcato wll further epad. The qualty of the mold good, but the hgh temperature of the mold wll drectly lead to the oldfcato of the catg alog the radal drecto tefy, thu creae the ze of the hole. I other word, durg the catg proce of the cylder ler, the mold temperature ad the rate of coolg from the outer to the er hould be cotrolled for the purpoe of mprovg the qualty of catg urface ad the decreag the ze of the hole. Whe ug the mold temperature cotrol ytem for cylder ler catg proceg, the harde of a cylder ler CPK mproved from 0.6 to.3. CONCLUSION AND TECHNOLOGY DISCUSSION Due to the lack of hgh temperature mechacal properte of the catg materal, the room temperature mechacal properte of the catg ca be take a the ba of the catg deg; becaue of the hortage of the hghet temperature data permtted by mold materal, t ot attach mportace to the rk caued by the over hgh mold temperature durg the rotato. Take more atteto to preheatg temperature cotrol ca mprove the producto qualty of cylder ler catg. ACKNOWLEDGMENT The author are grateful to Natural Scece Foudato of Hea Educatoal Commttee for ther facal upport for th project. REFERENCES. Xu Yaozeg, Du Zhehua, Sog Xudg. Numercal Smulato o Flow ad Temperature Fled Cetrfugal Catg Soldfcato Proce[J]. Hot Workg Techology, 0, 4(): Wu Log, Gao Hao, A Zja. Reearch o Cetrfugal Catg Soldfcato Numercal Smulato of Cylder Ler[J]. Foudry, 04, 63(): Cro M, Percleou K, Croft T N, et al. Computatoal modelg of mold fllg ad related free-urface flow hape catg: a overvew of the challege volved[j]. Metal. Mater. Tra. B. 006,(37): Gao Hao. Reearch o the Itellget Mult-poto Cetrfugal Catg Mache of Automotve Cylder Catg[J]. Iteral Combuto Ege & Part/Iter Comb Eg Part, 04,(): Zhag Temao, Dg Jaguo. Epermet Deg ad Data Proceg[M]. BeJg: Bejg Laguage ad Culture Uverty Pre,