In recent years, the world is facing the pressure of energy shortage and environmental protection. With the rapid development of information, Internet, Internet of Things and other technologies, improving the production efficiency of energy-intensive industries and realizing the intelligent and digital energy efficiency monitoring and evaluation and optimization control system have become the focus of governments and enterprises.

         Recently, the 863 Plan advanced manufacturing technology field“ Research on digital intelligent aluminum alloy melting and casting production line and energy efficiency monitoring system” The subject has passed the technical acceptance of the expert group.

         With the support of the National 863 Plan, Tianjin Lizhong Alloy Group Co., Ltd., in cooperation with the General Institute of Mechanical Science and other scientific research institutes and enterprises, has carried out the research on the digital intelligent aluminum alloy melting and casting production line and the energy efficiency monitoring system, constructed the energy efficiency evaluation index system and the theoretical analysis model of aluminum alloy process energy efficiency suitable for the aluminum alloy melting and casting industry, and designed the melting and casting production line for the new process flow of continuous feeding and regenerative combustion A MES (Manufacturing Execution System) platform with real-time data acquisition and energy efficiency analysis functions has been built; Realized the on-line identification and composition calibration of raw materials LIBS (Laser Induced Breakdown Spectroscopy) of the production line, intelligent batching based on expert system, real-time energy efficiency monitoring of the whole process, and optimization and control of double-layer structure model prediction of air fuel ratio and flue gas oxygen content, etc. After the system optimization, the comprehensive energy efficiency of production increased by 10.13%; The one-time accuracy rate of ingredients reached 93.28%.

         This achievement has broken through the current situation of the aluminum alloy melting and casting industry with complex process, low automation and low equipment standardization, realized the three functions of online monitoring, scientific decision-making and effective control of key parameters of the melting and casting process, improved the intelligent control capability and level of the aluminum alloy melting and casting industry, significantly improved production efficiency and reduced energy consumption. At present, the results of this project have been demonstrated and applied in the 10000-ton production line of Tianjin Lizhong and Guangdong Longda.

(Source: Ministry of Science and Technology)