Abstract
In this paper, we study an advanced pouring control system using a tilting-ladle-type automatic pouring machine. In such a machine, it is difficult to precisely pour the molten metal into the pouring basin of the mold, as the outflow from the ladle can be indirectly controlled by controlling its tilt. Therefore, model-based pouring control systems have been developed as a part of conventional studies to solve this problem. In the results of a recent study, the efficacy of a pouring flow rate control system based on differential flatness has been verified, by performing a simulation. In this study, we apply the flow rate control system based on differential flatness to a tilting-ladle-type automatic pouring machine, using experiments to verify the efficacy of the flow rate control system in suppressing any disturbances. In these experiments, the tracking performance using the developed flow rate control system was better than the performance obtained using a conventional feed-forward-type flow rate control system.
Highlights
In the casting industry, the pouring process creates a dangerous working environment, involving high-temperature molten metal
The supervisory control of an automatic pouring system with a fan-shaped ladle was proposed, in order to perform multiple tasks: To ensure that the liquid in the pouring basin was maintained at a constant level; that the total quantity of the liquid that was poured into the mold was achieved precisely at the target quantity; and that sloshing of the liquid in the ladle was suppressed [10]; in this approach, flow rate control was achieved using feed-forward control based on the inverse pouring model
The tracking performances of the reference trajectories were improved by applying the flow rate control based on differential flatness to the automatic pouring machine
Summary
The pouring process creates a dangerous working environment, involving high-temperature molten metal. The supervisory control of an automatic pouring system with a fan-shaped ladle was proposed, in order to perform multiple tasks: To ensure that the liquid in the pouring basin was maintained at a constant level; that the total quantity of the liquid that was poured into the mold was achieved precisely at the target quantity; and that sloshing of the liquid in the ladle was suppressed [10]; in this approach, flow rate control was achieved using feed-forward control based on the inverse pouring model. In this study, pouring flow rate control based on differential flatness is implemented for a tilting-ladle-type automatic pouring machine, and the efficacy of flow rate control is verified through experiments. During the implementation of the flow rate control, an extended Kalman filter based on the pouring model is applied for estimating the state variables of the automatic pouring machine, and these variables are used to achieve flow rate control.
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