The Design And Research Of Auto-pouring Control System Based On CCD Sensor

The automation of foundry is divided into two aspects: The automation of molding and pouring. Pouring is an important part in the progress of foundry produce. Now, many factories have realized the automation of molding, but pouring is operated by handicraft. Handicraft operation has many disadvantages. Worker's labor is intensity, and the work environment is bad. Work efficiency is low, and the product quantity is unsteady.The thesis presents the design method of auto-pouring, established the mathematics model of the object, put forward the method of iron level examination and then analysis, design and research to whole control system according to the characteristics of pouring cup.The thesis adopt CCD camera as sensor to exam the knage in pouring cup. The iron level is gained after computer image processing. Through subtracting between set value and iron level, deviation is attained. It is send controller and the control signal is given. Step motor change the dimension of pouring flow valve and control pouring flow. So the iron level in pouring cup is controlled.Considering the time-variety and non-linearity of pouring flow, the iron level in pouring furnace must retain stabilization. The furnace fluid level control system included three parts: the collection and transformation of fluid level, the design of control algorithm and actuator. The fluid level is exam by fluid sensor,The design of control algorithm is the main part in system design and investigation. And establishing mathematical model is the basic part in it. The thesis establishes the mathematics model according to characteristic of object and expecting target, and then designs control algorithm.For pouring cup iron level control system, three segment controls are adopted according to three mathematics model of the ideal liquid curve in pouring cup. The starting segment use open-loop control and the closing segment use PI control. Control algorithm of the second segment is most complicated, and this paper design two algorithms: PID-Smith and Fuzzy-Smith control.For pouring furnace iron level control system, this thesis presents intelligent PID control algorithm according to the non-equilibrium characteristic of object.