| In the manufacturing process of anode,the quality of anode was affected by the sloshing of molten copper caused by casting wheel during operation.Therefore,it is significant to study the casting wheel structure characteristics and servo system for improving the quality of anode.The structure of the wheel was studied,and the external drive of the wheel was changed to the internal drive to enhance the stability of the wheel.The radial beam of the wheel is designed,simulated and optimized to thicken the thickness of the fixed support plate.At the same time,the stiffened plate is designed to make the stress concentration deviate from the dangerous area and enhance the strength and rigidity of the overall structure of the wheel.Through the analysis of the sloshing of molten copper,the motion characters of the wheel were studied.The two-dimensional model of molten copper in the mold was established by ICEM CFD,and the mesh of the model was divided.Using VOF(volume function of fluid)method and UDF(user defined function),the sloshing of molten copper in different motion models was studied.When the temperature of molten copper is 1200℃,the maximum amplitude of liquid surface sloshing is 4mm,and the maximum acceleration of molten copper is 0.056 m/~2.According to the obtained maximum acceleration of molten copper,the motion model of anode mold was established:S-type motion model.After the wheel drive mode was changed to internal drive,the dual servo motor was used to drive,and the dual servo clearance system was studied.Based on Siemens CPU 1515T-2PN,a dual servo master-slave synchronous clearance control strategy was established,a torque compensation controller was designed,and the torque change of the wheel during operation was analysed.The virtual prototype of the wheel was built in Adams,and the dynamic simulation analysis was carried out for the method of directional torque compensation and constant offset torque compensation.The comparison with the angular acceleration and angular velocity of the wheel under the model of clearance compensation was made,which verified the practicability of the model in the operation of the wheel.In Adams,the wheel driving gear and the central gear were parameterized.The radius R1 of the driving gear and the radius R2 of the central gear were designed as constraint variables.The maximum value of the absolute value of the angular acceleration of the wheel was set as the objective function,which isΣ=|Σ(R1,R2)|.Through the experimental design function of Adams,the optimal design of the wheel was carried out.Finally,the radius of driving gear R1 and central gear R2,R1=80mm,R2=550mm,with the minimum sloshing amplitude of the wheel under the constraint conditions are obtained.The free message was established by SCOUT to exchange data with the free message in the TIA.The TIA could read the current data and torque data of the servo motor,and realize the application of the torque compensation controller in the dual servo master-slave synchronous clearance control strategy.The experiment platform of double servo control system was built and the experiment is completed.The casting system of double wheel anode is designed,and the equipment is installed and debugged in the factory.The burr number of anode produced by the new equipment is about 20%less than that produced by the old equipment,and the average edge is reduced by 1.8mm,which improves the quality of anode. |
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