主权项 |
1. An apparatus for controlling pool power, pool power being defined as the total energy flux into a top ingot surface during vacuum arc remelting processes, the apparatus comprising:
a. a remelting furnace comprising a movable electrode, an electrode drive, and a programmable logic controller; b. an electrical current supply that supplies current to the electrode; c. an ingot pool located beneath the electrode, the ingot pool comprising molten metal from the electrode; d. a controller computer that communicates with the programmable logic controller using a communication protocol comprising an ethernet connection and which sends two separate and distinct controller signals over the connection from two different controllers programmed into the computer; e. a first controller that adjusts current supplied to the remelting furnace based upon a predetermined pool power reference value, the pool power reference value being defined as the sum of a total melt power entering the ingot pool as enthalpy contained in molten metal dripping from the melting electrode plus a fraction, ε, of an electrical arc power, the fraction consisting of the arc power collected by the ingot pool surface, wherein the first controller computer employs the following equation to calculate the adjusted current:I=-VCF2(RI+RGG)+(VCF2(RI+RGG))2+Ppool+αrCSΔAehsupΔ(μCSphsuphm+ɛ)(RI+RGG), wherein Ppool,ref is a pool power reference setpoint, hsup is a volume specific enthalpy at superheat temperature, VCF is a cathode fall voltage, RI is a VAR circuit resistance less an electrode gap resistance, RG is an experimentally determined electrode gap resistance parameter, G is an electrode gap, Ae is an electrode cross-sectional area, αr is a room temperature thermal diffusivity, CSΔ and CSp are material dependent constants, μ is a process efficiency, Δ is an electrode thermal boundary layer, and hm is a volume specific enthalpy at melt temperature; and f. a second controller that adjusts the remelting furnace's electrode drive speed based upon a predetermined electrode gap reference value, Gref, and a predetermined pool power reference value, Ppool,ref, wherein the adjusted electrode drive speed is calculated from the following equation:fG=ahsupAe{Ppool,ref-ɛ[(VCF)I+(RI+RGG)I2]} wherein α is a fill ratio parameter, hsup is a volume specific enthalpy at superheat temperature, ε is an arc power fraction to the pool surface, VCF is a cathode fall voltage, RI is a VAR circuit resistance less an electrode gap resistance, RG is an experimentally determined electrode gap resistance parameter, G is an electrode gap, Ae is an electrode cross-sectional area, and I is a process current. |