Semenko A. Development of energy and resources saving principles to control of working parameters of casting magnetodynamic installations

The dissertation is devoted to the solution of important scientific task, which is increasing with efficiency of multifunctional casting magnetodynamic equipment by continuous control of its control parameters and of the basic technological processes. The methods of studying the work of of magnetodynamic installation (MDI) for aluminum alloys and determination of rational power parameters of its electromagnetic systems has been developed and experimentally confirmed. On the basis of the use of the integrated weighing system (IWS), original methods were developed using engineering calculations, mathematical and physical modeling, field experiments, studies of the complex of electromagnetic force interactions in MSU during the preparation and casting of aluminum alloys. In this work, ponderomotor electromagnetic force interactions in MDI for aluminum alloys were established and experimentally confirmed, dynamics of change of thermal and hydrodynamic characteristics of MDI in different modes of operation and related parameters of foundry technological processes were investigated. This made it possible to estimate the ratio between the components of the generated electromagnetic energy, which are efficiently consumed (thermal (65-80%) and hydrodynamic component (8-11%)) or lost irreversibly for various reasons (for example, reaction with the design of MDI, which is 5-6 % of total energy generated). This makes it possible to take into account the design features of both individual aggregates and the whole device in the future when creating new magnetodynamic aggregates. The measured ponderomotor interactions are converted into effective electromagnetic force, which creates pressure and liquid metal head. The effective electromagnetic force was calculated for generation of electromagnetic pressure up the level of 30-35 kPa, which is 10-20% higher than the passport data of the existing series of MDI. It is 23.55-31.84 N. The basic electrical parameters of electromagnetic systems of magnetodynamic installation MDN-6A-0,63M for casting of aluminum alloys are calculated and the power of thermal losses in MDI was determined. Experimentally determined: the rate of change of the melt temperature in the range of the control system (710-730 ºС); the parameters of heating of the melt by one inductor, two inductors are set and at their alternate switching on; MDI thermal losses in the "holding mode" of the melt weighing 133.5 kg amounted to P = 21,92 kW. It became possible to replace the discrete control of MDI electromagnetic systems for the analog, which will significantly reduce the energy consumption in the casting. Experimental model surveys were carried out on the physical model of MDI with a mass dispensing inclined chute. The rational interval of the ratio of the mass of the cast portion of the metal and the instantaneous value of the mass flow rate during its casting (2.20-2.25) and the corresponding interval of the supply voltage of the electromagnet of MDI were determined in order to minimize the influence of the ripple of the jet on the metering accuracy by reducing their amplitude. The dosage error does not exceed 1.5% by weight of the dose when pouring small portions of the melt (weight 1.5-3 kg). Principal approaches have been developed and original technical solutions for the automatic control system for continuous casting of metallic melts based on the created two-chamber magnetodynamic tundish ladle have been proposed.