Breakthrough in Energy Efficiency Monitoring and Optimized Control Technology for Aluminum Alloy Casting Industry in China

In recent years, the world is facing energy shortages and environmental protection pressures. With the rapid development of information, Internet, and Internet of Things technologies, the production efficiency of high-energy-consuming industries has been increased, and the energy efficiency monitoring, evaluation, and optimization control systems have become intelligent. Digitalization has become the focus of attention of governments and companies in various countries.

Recently, the project of “Digital Intelligent Aluminum Alloy Casting Production Line and Energy Efficiency Monitoring System” in the advanced manufacturing technology of the 863 Program passed the technical acceptance of the expert group.

Under the support of the National 863 Program, Tianjin Lizhong Alloy Group Co., Ltd. cooperated with the General Research Institute of Machinery Science and other scientific research institutes and enterprises to carry out research on digital intelligent aluminum alloy casting production lines and energy efficiency monitoring systems, and constructed suitable aluminum. The energy efficiency evaluation index system of the alloy casting industry and the theoretical analysis model of the aluminum alloy process energy efficiency were designed for a continuous casting and regenerative combustion process, and a MES (Manufacturing Execution System) with real-time data acquisition and energy efficiency analysis functions was designed. Manufacturing Enterprise Production Process Execution System) platform; realized raw material LIBS (Laser-Induced Breakdown Spectroscopy, laser elemental spectroscopy) online identification and component calibration, intelligent ingredient based on expert system, real-time energy efficiency monitoring of the whole process, air-fuel ratio With the two-layer structure model predicting and optimizing the control of the oxygen content of the flue gas, the overall energy efficiency of the production has been improved by 10.13% after the system optimization; the batch one-time hit rate reached 93.28%.

This achievement has broken through the current status of complex industrial aluminum alloy casting process, low degree of automation, and low level of standardization of equipment, realizing the three major functions of on-line monitoring, scientific decision-making and effective regulation of the key parameters of the casting process, and enhancing the intelligence of the aluminum alloy casting industry. The ability and level of control have significantly increased production efficiency and reduced energy consumption. At present, the results of this project have been demonstrated in Tianjin Lizhong and Guangdong Longda.