The present invention relates to a temperature probe for the automated measurement of the temperature of a fusion furnace. Further, the present invention relates to a temperature measurement and control process of the temperature of a fusion furnace by means of the temperature probe according to the invention.
More generally, the system developed for automated measurement of temperature can generally be used for the thermal field survey within any fusion furnace (of the resistive or inductive type), e.g. used for the production of superalloy components having directional (DS)/monocrystalline (SX) grain structure by the lost wax precision casting process.
More specifically, the present invention relates to a temperature probe to be used in high vacuum furnaces for production, by means of the lost wax precision casting process (investment casting) of superalloy components with a DS/SX grain structure for aerospace, naval and industrial turbines.
At the state of the art, as shown in
The production process (or cast process) of components with DS/SX grain structure is mainly based on the setting of a high in modulus (of 101 to 102° C./cm, with specific values for each category of components), and clearly set in direction (unidirectional, along the gravitational axis, coinciding with the principal axis of the component), spatial thermal gradient during the superalloy solidification phase by means of:
If the furnace is not provided with control thermocouples inside the hot chamber, a periodic inspection of the thermal field must be carried out to monitor the stability of the cast process and correct the temperature where necessary.
The thermal field verification procedure involves measuring the temperature along the main axis of the furnace during the simulation of a cast at a predetermined depth in the thermal chamber 3 with respect to the probe datum fixed on the valve 10 positioned between the thermal chamber 3 and the melting chamber 1. The measurements are made by means of manual insertion, within the thermal chamber 3 (in the absence of the ceramic shell 6 to keep free the axial zone of the furnace) through the melting chamber 1 and the pouring tube 2 of a type “B” thermocouple probe temperature, more generally for high temperatures. Said operation of temperature probe insertion must be carried out in a relatively short time and in such a way as to accurately position the thermocouple at set depths within the thermal chamber, for a precise evaluation of the thermal field.
Getting a balancing between short time and accuracy of temperature measurement is difficult to achieve by manual operation.
It is an object of the present invention that of carrying out the measurement and control process of the temperature inside the thermal chamber of a fusion furnace for the production of components in superalloy with DS/SX grain by the lost wax precision casting process in a short time and getting accurate measurements.
It is specific object of the present invention a measurement process of the thermal field of a fusion furnace, in particular for the production of superalloy components with directional (DS)/monocrystalline (SX) grain structure by a lost wax precision casting process, by means of a system for the control and the measurement of the temperature inside of a fusion furnace, said fusion furnace comprising a melting chamber, a thermal chamber in connection with said melting chamber, and an extraction chamber in connection with said thermal chamber, a valve interposed between said two melting and thermal chambers, said system comprising a temperature probe for the measurement of the thermal field in said fusion furnace, said temperature probe comprising a thermocouple for high temperatures, a support element for the positioning of the temperature probe in the melting chamber of the furnace, displacement and measurement means of the position of the thermocouple for the displacement and the measurement of the position of the thermocouple inside of the thermal chamber of the furnace, a control device apt to activate and control said displacement and measurement means for the execution of control programs of said probe, said process providing the following sequential steps:
wherein the program to execute or the selected program provides the following steps:
Preferably, according to the invention, the drive phase of the probe by means of said control device can provide
Still according to the invention, said control device can comprise a programmable logic controller or PLC, a driver, a touch-screen interface for the control and the monitoring of the procedure by an operator, and control push-buttons, said PLC can be connected by connection means, preferably in Ethernet/IP net, with the control system of the furnace, so as to be able to communicate the displacement positions of the probe and the information related to the control programs in execution, and after the phase of insertion of the probe, is provided the phase of:
Always according to the invention, said zero position or probe datum can correspond to the lower limit of the valve in correspondence of the thermal chamber.
Furthermore according to the invention, the data acquired from said PLC and sent to said control system of the furnace can be stored in the database of the company Manufactory Execution System (MES), and the measured temperature and the correspondent position of the thermocouple are archived in the database of the company MES.
Further, according to the invention, a program to execute can be the program for the switch on of the furnace that provides after step d) the following step:
Alternatively, according to the invention, the selected program or program to be executed can be the control and adjustment program of the temperature of the furnace that provides after step d) the following steps:
Furthermore, according to the invention, the selected program can be the turn-off program of the furnace that provides the following steps:
Always according to the invention, said interface zone between the thermal chamber and the extraction chamber of the furnace can be equivalent to a depth approximately of 23″ inside of the thermal chamber with respect to said zero position or probe datum.
In particular, according to the invention, said preset depth can correspond to approximately 14″ inside of the thermal chamber of the furnace with respect to said zero position or probe datum.
Finally according to the invention, the preferred temperature at said preset depth can be comprised between +3° C. and −3° C. with respect to the nominal temperature of the furnace, the temperature of attention at said preset depth can be comprised between +3° C. and +20° C. or −3° C. and −20° C. with respect to the nominal temperature of the furnace, and the temperature not accepted at said preset depth is higher than +20° C. and lower than −20° C. with respect to the nominal temperature of the furnace.
Further it is an object of the present invention, a system for the control and the measurement of the temperature inside of a fusion furnace, in particular for the production of superalloy components with directional (DS)/monocrystalline (SX) grain structure by a lost wax precision casting process, said fusion furnace comprising a melting chamber, a thermal chamber in connection with said melting chamber, and an extraction chamber in connection with said thermal chamber, a valve interposed between said two melting and thermal chambers, said system comprising a temperature probe for the measurement of the thermal field in said fusion furnace, said temperature probe comprising a thermocouple for high temperatures, a support element for the positioning of the temperature probe in the melting chamber of the furnace, displacement and measurement means of the position of the thermocouple for the displacement and the measurement of the position of the thermocouple inside the thermal chamber of the furnace, a control device apt to activate and control said displacement and measurement means for the execution of control programs of said probe and a control device of said probe for the execution of the control programs of said probe by means of the process described in the above.
Preferably according to the invention, said support element of said probe can be a flange.
Still according to the invention, said thermocouple can be of “B” type.
Always according to the invention, said thermocouple can be housed inside a tube, preferably made of alumina.
Furthermore according to the invention, said displacement and measurement means of the position of the probe can comprise a motor with high precision encoder apt to measure the position of the thermocouple inside the thermal chamber of the furnace.
Further according to the invention, said displacement and measurement means of the position of the probe can comprise means for the transmission of the rotational motion with reduction of the number of turns, in particular an angular reducer.
Preferably according to the invention, said displacement and measurement means of the position of the probe can comprise means for the translation of said thermocouple, in particular a linear belt guide.
Finally according to the invention, said probe can comprise a graded bar, arranged in correspondence of the thermocouple, and said thermocouple can provide a pointer, preferably an arrow, in order to visually assess, by means of the sliding of said pointer with respect to said graded bar, of the correct displacement of said thermocouple inside of the furnace.
The invention will be now described in an illustrative but not limitative way, with particular reference to the drawings of the enclosed figures, wherein:
Making reference to
The temperature probe 12 according to the invention mainly comprises a thermocouple 13 for high temperatures, in particular of “B” type, preferably housed within a tube 60, preferably comprised of alumina, a support element 5 of the probe 12, particularly a flange 5, for positioning the temperature probe 12 in the melting chamber 1, means for actuating and handling the thermocouple 13, in particular a motor with high precision encoder 46, an angular reducer 54 capable of transmitting rotational motion with a reduction in the number of revolutions and minimizing the dimensions, and a linear belt guide 9 for the displacement of the thermocouple 13. The control device of the temperature probe 12 comprises a programmable logic controller (or PLC) 15, a driver 16, a touch-screen interface 19 for controlling and monitoring the procedure by an operator, and control buttons 20.
The movement of the thermocouple 13 is motorized, the positioning depth inside the thermal chamber 3 is accurately measured by means of the high precision encoder 46. In addition, the probe 12 may include a graded bar 8, positioned aside the thermocouple 13, ensuring the possibility to even visually assess, by sliding an arrow indicator 35 connected to the thermocouple 13, the correct displacement within the furnace, as foreseen in the set measurement program.
The temperature measurement procedure by thermocouple 13 is managed automatically by means of the control and monitoring system managed by a dedicated software or program.
The touch-screen interface 19 allows the operator to control the whole procedure.
The automatic probe 12 is fully integrated with the furnace automation platform: PLC 15 of the probe 12 is connected to the Eterneth/IP network with the furnace control architecture so that it can communicate the motor displacement positions and the information provided of the carried out procedure. Other means of connection, such as any one-to-one communication or link bus, may be eventually provided. Real-time data acquired are stored in the company's Manufactory Execution System (MES) database. By company MES it is meant a centralized IT system with management and control role of the company production, providing, among other functions, also the direct connection to machineries for dispatching production programs and corresponding recording of the machine process parameters for monitoring and traceability of the production itself.
The control program and its thermal probe operator interface for automatic control of the verification procedure of the thermal field within furnace thermal chamber 3 provides a number of programs for carrying out various control procedures including those necessary for switch on/off of the furnace and for periodic control and adjustment during the production, of the furnace temperature.
The process according to the invention for the measurement of the thermal field of a fusion furnace, particularly for the production of superalloy components with directional (DS)/monocrystalline (SX) grain structure by means of the lost wax precision casting process by the automated probe 12 according to the invention basically provides the following steps, on the basis of the set control program:
Specifically, the program for switching on the furnace, as shown in
During the production process, the program for controlling and regulating the furnace temperature shown in
If, after step a), the measured temperature TM corresponds to the TX value for this depth, the procedure is successfully completed.
Finally, the furnace's shutdown program, shown in
The furnace shutdown program according to the invention comprises the following steps:
In the foregoing, preferred embodiments of the present invention have been described and variants have been suggested, but it is to be understood that those skilled in the art will be able to introduce modifications and changes without departing for the scope as defined by the claims enclosed.
Number | Date | Country | Kind |
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102016000057262 | Jun 2016 | IT | national |
Filing Document | Filing Date | Country | Kind |
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PCT/IT2017/000109 | 5/31/2017 | WO | 00 |