Innovative design of automatic casting process for continuous casting ladle based on TRIZ theory
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摘要: 基于TRIZ理论，建立了连铸钢包开浇系统的功能模型，通过因果链原因分析法，确定了产生问题的关键原因；充分应用技术冲突、物理冲突、物质-场模型以及效应等工具对连铸钢包开浇工艺进行了改进，产生了8种创新解。针对某厂80 t钢包具体情况，通过方案对比优选出最佳方案，即采用真空复合滑板控流结构。实施后取得了良好的效果，钢包自动开浇率达到97%以上，虽然与采用传统的引流砂开浇工艺的自开率基本持平，但是降低了钢中大颗粒夹杂物产生量，有效解决了传统引流砂开浇工艺带来的引流砂污染钢液的顽疾。Abstract: Based on TRIZ theory, the function model of ladle pouring system had been established, and the key causes of the problem had been determined by causal chain analysis. By fully applying the tools of technical conflict, physical conflict, material-field model and effect, the start-up process of continuous casting ladle was improved, eight kinds of innovative solutions were produced, and the optimal scheme was determined by scheme comparison. The scheme adopts vacuum composite flow control skateboard and achieves good process effect. The automatic casting rate of the ladle can reach more than 97%. Although it is basically the same as the self-opening rate of the traditional drainage sand casting process, the new scheme can reduce the amount of large particle inclusions in the steel and effectively solve the drainage sand pollution caused by the traditional drainage sand casting process.
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Key words:
- continuous casting /
- ladle /
- automatic pouring /
- skateboard /
- TRIZ theory
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图 4 方案2：通过引入一种外部物质改善系统功能
Figure 4. Scheme 2： Improving system functionality by introducing an external substance
图 7 方案4：通过引入电磁加热改善系统功能
Figure 7. Scheme 4： Improving system function by introducing electromagnetic heating
图 8 方案5：通过将静态热场替换成动态机械场改善系统功能
Figure 8. Scheme 5：Improve system functionality by replacing static thermal fields with dynamic mechanical fields
表 1 方案比选
Table 1. Scheme comparison results
编号 方案详情 A B C D 方案评价 方案1 增加滑板厚度 10 10 10 5 8.5 方案2 低熔点高密度的液体金属“防凝剂” 8 9 9 7 8.2 方案3 低熔点高密度金属防凝剂回收循环利用 8 8 8 7 7.7 方案4 通过对水口内钢水（S1）增加电磁加热（S改进的超系统）来调节钢水温度，防止冷凝 6 6 7 6 6.3 方案5 将钢包底部原有的底吹氩透气塞与钢包下滑板组合在一起，形成包底吹氩和滑动水口一体化设计，通过下滑板上嵌入的透气塞向钢水上水口内吹入氩，使得钢包上水口内低温钢水与钢包内高温钢水实现机械混合，将原有的静态热能场替换成机械场，从而改善系统功能 9 9 8 7 8.1 方案6 下滑板镶嵌石棉板等保温材料 9 9 10 8 9 方案7 内部中空结构的下滑板 9 9 10 9 9.3 方案8 内部真空结构的下滑板 9 9 10 10 9.6 
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