An intelligent operation simulation method for an aluminum casting manufacturing process based on digital twinning

Abstract

The application discloses an aluminum casting manufacturing process intelligent operation simulation method based on digital twinning, comprising the following steps: acquiring equipment and its layout and runtime sequence of an aluminum liquid supply process of the aluminum casting manufacturing process; setting a first simulation rule according to state parameters of the equipment of the aluminum liquid supply process and an updating rule thereof; setting a second simulation rule according to a collaborative working process of an aluminum alloy melting furnace, an aluminum liquid transfer component and an aluminum liquid holding furnace; taking process parameters and a production plan of the aluminum liquid supply process as input parameters and taking state parameter sequences of the equipment of each aluminum liquid supply process in a production process as output parameters; when an abnormal event occurs in the aluminum casting manufacturing process, acquiring actual state parameters of the equipment of the aluminum liquid supply process, and adjusting the first simulation rule and the second simulation rule by comparing the actual state parameters of the equipment of the aluminum liquid supply process with simulation state parameters. The method is suitable for precise simulation of operation of the aluminum liquid supply process of the aluminum casting manufacturing process.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing technology for aluminum alloy castings, and in particular to an intelligent operation simulation method for the manufacturing process of aluminum castings based on digital twins. Background Technology

[0002] China is currently the world's largest producer and consumer of aluminum alloy castings (hereinafter referred to as aluminum castings). Its aluminum casting manufacturing industry is characterized by three major features: large scale, continuously growing demand, and high energy consumption and emissions from manufacturing processes. As a key area for energy conservation and carbon reduction, the aluminum casting manufacturing industry is undergoing transformation and upgrading towards automation, digitalization, and intelligence. Some leading aluminum casting manufacturers have already completed upgrades to automated production lines and digital management systems; however, they still lack research on intelligent decision-making methods such as intelligent low-carbon operation optimization based on digitalization and informatization, resulting in a relative lack of intelligent applications for quality improvement, efficiency enhancement, and carbon reduction. The aluminum liquid supply process in aluminum casting manufacturing includes aluminum alloy melting and holding, aluminum liquid refining, aluminum liquid distribution, aluminum liquid holding, and quantitative aluminum liquid pouring, characterized by both continuous and discrete mixing. The aluminum liquid supply process is the most critical link in the intelligent operation of the aluminum alloy casting process, accounting for approximately 60% of the total energy consumption and 70% of the total carbon emissions in aluminum casting manufacturing. Optimizing the operation of the aluminum liquid supply process can save approximately 10% to 20% of energy consumption, which can bring considerable economic value. Therefore, optimizing the operation of the molten aluminum supply process is key to the intelligent and low-carbon operation of the aluminum casting manufacturing process.

[0003] The operation of the aluminum liquid supply process is affected by multiple factors such as the control logic of the equipment, flexible production rules, and dynamic events in the production process. It is difficult to model it using mathematical or formal description methods, and simulation is required. In addition, when dynamic events occur in the production process, it is necessary to assess the impact of the dynamic events in a timely manner and formulate accurate response strategies. These behaviors all need to be based on simulation. How to conduct intelligent operation simulation of the aluminum liquid supply process is a practical need for intelligent and low-carbon operation in aluminum casting manufacturing process. In response to the simulation needs of the aluminum liquid supply process, Chinese patent with publication number CN113111540A - Energy-saving optimization method for the integration of melting, delivery and heat preservation parameters for aluminum die casting - proposes a simulation method for the aluminum liquid supply process based on discrete event simulation. However, this simulation method has some shortcomings, including: (1) This method is an offline simulation method and cannot perform dynamic simulation based on real-time data; (2) This method can simulate the normal production process, but cannot simulate the process after an abnormal production event occurs.

[0004] Digital twin production lines and workshops are crucial components of future factories and smart factories. Some leading foundry companies are building digital twin production lines for aluminum alloy casting manufacturing, which will create a new environment for intelligent and low-carbon operation optimization. Digital twin production lines provide real-time data and accurate models for intelligent operation simulation, making them an important enabling technology for intelligent operation simulation. Some scholars have already conducted research on simulation methods based on digital twins. For example, Zhao Rongli proposed an offline simulation method and system for digital twin production lines, which includes a simulation operation module, an event management module, a simulation model management module, and a data statistics module (An Offline Simulation Method and System for Digital Twin Production Lines: CN115544766A). However, current digital twin-based simulation methods are difficult to apply to intelligent operation simulation of aluminum casting manufacturing processes. Further research is needed to overcome key technological challenges and develop new simulation methods to support intelligent and low-carbon operation optimization. Summary of the Invention

[0005] The purpose of this invention is to provide an intelligent simulation method for the manufacturing process of aluminum castings based on digital twins. This invention can decouple the complex control logic of multiple devices in the production process, the flexible coordination rules between multiple devices, and the influence relationships of abnormal events in the production process, supporting accurate simulation of the operation of the aluminum liquid supply process.

[0006] The technical solution of this invention: an intelligent operation simulation method for aluminum casting manufacturing process based on digital twins, comprising the following steps:

[0007] The equipment, layout, and operation sequence of the aluminum liquid supply process in the aluminum casting manufacturing process are obtained; the equipment in the aluminum liquid supply process includes an aluminum alloy melting furnace, an aluminum liquid degasser, an aluminum liquid transfer component, an aluminum liquid holding furnace, and a quantitative casting machine;

[0008] The first simulation rule is set based on the status parameters and update rules of the equipment in the aluminum liquid supply process;

[0009] The second simulation rule is set based on the collaborative working process of the aluminum alloy melting furnace, the aluminum liquid transfer component, and the aluminum liquid holding furnace;

[0010] The process parameters and production plan of the aluminum liquid supply process are used as input parameters, and the sequence of status parameters of the equipment in each aluminum liquid supply process during the production process is used as output parameters.

[0011] When an abnormal event occurs in the aluminum casting manufacturing process, the actual state parameters of the equipment in the aluminum liquid supply process are obtained. By comparing the actual state parameters of the equipment in the aluminum liquid supply process with the simulation state parameters, the first simulation rule and the second simulation rule are adjusted.

[0012] Furthermore, the equipment, its layout, and operating sequence for the aluminum molten metal supply process in the aluminum casting manufacturing process include:

[0013] The layout refers to the relative positions of the equipment in each aluminum liquid supply process within the workshop;

[0014] The aforementioned operational sequence refers to the process of equipment operation and mutual coordination in the aluminum liquid supply process, including: the aluminum alloy melting furnace melts the aluminum alloy to obtain aluminum liquid, which is then transported to the aluminum liquid degasser through the aluminum liquid transfer component to degas the aluminum liquid, the degassed aluminum liquid is then transported to the aluminum liquid holding furnace through the aluminum liquid transfer component and liquid is added to the aluminum liquid holding furnace, the aluminum liquid holding furnace holds the aluminum liquid at a certain temperature, and the quantitative casting machine takes liquid from the aluminum liquid holding furnace and casts it.

[0015] Furthermore, the setting of the first simulation rule based on the state parameters and update rules of the equipment in the aluminum liquid supply process includes:

[0016] Set the state parameters and update rules for the aluminum alloy melting furnace, including:

[0017] The status parameters of the aluminum alloy melting furnace include: the status of the melting burner, which is either standby or working, the melting speed, and the amount of aluminum liquid held at the temperature.

[0018] The update rules for the status parameters of the aluminum alloy melting furnace include: when the melting burner is in operation, the aluminum liquid holding amount is updated according to the melting rate; after the aluminum alloy melting furnace discharges liquid, the aluminum liquid holding amount is updated to the difference between the original aluminum liquid holding amount and the discharge amount.

[0019] The update rules for the status of the melting burner in the aluminum alloy melting furnace include: when the aluminum liquid holding temperature exceeds the upper limit of the holding temperature, the melting burner will be in standby mode until the aluminum liquid holding temperature falls below the lower limit of the holding temperature, at which point the melting burner will be in working mode.

[0020] Set the status parameters of the aluminum liquid degasser: The status parameters of the aluminum liquid degasser include the total degassing time and the time already degassed;

[0021] Define the status parameters and update rules for the molten aluminum transfer component, including:

[0022] The status parameters of the aluminum liquid transfer component include: the amount of aluminum liquid transported by the aluminum liquid transfer component, the number of the target aluminum liquid holding furnace, the amount of liquid added to each target aluminum liquid holding furnace, the order of adding liquid to each target aluminum liquid holding furnace, the current position and moving speed, and the running time.

[0023] The status parameter update rules for the molten aluminum transfer component include: updating the position of the molten aluminum transfer component based on its moving speed, running route, and running time during molten aluminum transfer; updating the amount of molten aluminum transported by the molten aluminum transfer component after the aluminum alloy melting furnace adds molten aluminum to the molten aluminum transfer component to be the sum of the original amount of molten aluminum transported by the molten aluminum transfer component and the amount added; and updating the amount of molten aluminum transported by the molten aluminum transfer component after the molten aluminum transfer component adds molten aluminum to the molten aluminum holding furnace to be the difference between the original amount of molten aluminum transported by the molten aluminum transfer component and the amount added.

[0024] Set the status parameters and update rules for the aluminum liquid holding furnace, including:

[0025] The status parameters of the aluminum liquid holding furnace include: the amount of aluminum liquid in the aluminum liquid holding furnace;

[0026] The update actions for the status parameters of the aluminum liquid holding furnace include: when the aluminum liquid transfer component adds liquid to the aluminum liquid holding furnace, the aluminum liquid volume of the aluminum liquid holding furnace is updated to the sum of the original aluminum liquid volume and the added liquid volume; when the quantitative casting machine takes liquid from the aluminum liquid holding furnace, the aluminum liquid volume of the aluminum liquid holding furnace is updated to the difference between the original aluminum liquid volume and the taken liquid volume.

[0027] The status parameters of the quantitative casting machine are set, including: the status of the quantitative casting machine, wherein the status of the quantitative casting machine is standby or working, the quantitative casting volume, the quantitative casting interval, and the time until the next quantitative casting.

[0028] Furthermore, the second simulation rule set based on the collaborative working process of the aluminum alloy melting furnace, the aluminum liquid transfer component, and the aluminum liquid holding furnace includes:

[0029] The coordination rules for the aluminum alloy melting furnace include: when the aluminum casting manufacturing process ends, the aluminum liquid holding amount in the aluminum alloy melting furnace is the lower limit of the holding amount; when the amount of aluminum liquid melted in the aluminum alloy melting furnace meets the amount of aluminum liquid required by the production plan, the melting burner will be in standby mode and will not be updated to working mode.

[0030] The coordination rules for the aluminum liquid holding furnace include: when the amount of aluminum liquid in the holding furnace is lower than or equal to the lower limit of the holding capacity, the holding furnace needs to be replenished with aluminum liquid by the aluminum liquid transfer component. The amount of aluminum liquid added is the difference between the upper limit of the holding capacity and the original amount of aluminum liquid in the holding furnace at the time of replenishment; when the amount of aluminum liquid in the holding furnace is lower than the amount of aluminum liquid that the quantitative casting machine can normally take, the quantitative casting machine is updated to standby mode until the amount of aluminum liquid required for the holding capacity is met, at which point the quantitative casting machine is updated to working mode; when the planned production of the aluminum casting process ends, the amount of aluminum liquid in the holding furnace is the lower limit of the holding capacity.

[0031] The coordination rules for the molten aluminum transfer component include: the time for the molten aluminum transfer component to take molten aluminum from the aluminum alloy melting furnace is equal to the time required to add molten aluminum to the aluminum holding furnace minus the degassing time of the molten aluminum and the transportation time from the aluminum alloy melting furnace to the aluminum holding furnace; the amount of molten aluminum taken by the molten aluminum transfer component from the aluminum alloy melting furnace is the difference between the upper limit of the molten aluminum supplied to the aluminum holding furnace and the original amount of molten aluminum in the aluminum holding furnace at the time of addition; if the amount of molten aluminum taken is greater than the maximum capacity of the molten aluminum transfer component, then the maximum capacity is taken. Aluminum liquid volume; when the liquid taking time of any two or more aluminum liquid transfer components is less than the threshold for combined liquid taking and transportation, and the total aluminum liquid volume they need is less than or equal to the maximum capacity of the aluminum liquid transfer component, then one aluminum liquid transfer component can be used to transport and supply multiple aluminum liquid holding furnaces simultaneously; when the aluminum liquid transfer component takes liquid from the aluminum alloy melting furnace, if the aluminum liquid volume of the aluminum alloy melting furnace is insufficient to meet the required aluminum liquid volume, then the liquid taking volume is the difference between the aluminum liquid volume of the aluminum alloy melting furnace and the lower limit of the aluminum liquid volume of the aluminum alloy melting furnace.

[0032] Furthermore, the input parameters are: the melting rate of the aluminum alloy melting furnace, the upper and lower limits of the heat preservation amount of the aluminum alloy melting furnace, the upper and lower limits of the heat preservation amount of the aluminum liquid holding furnace, the amount of liquid that the quantitative casting machine can normally extract, the threshold for combining liquid extraction and transportation, the maximum capacity of the aluminum liquid transportation component, the number of products to be produced, and the quantitative casting amount and quantitative casting interval of the quantitative casting machine.

[0033] Furthermore, the output parameters are: the working status change sequence of the melting burner of the aluminum alloy melting furnace, the melting speed change sequence of the aluminum alloy melting furnace, the aluminum liquid volume change sequence of the aluminum alloy melting furnace, the aluminum liquid volume change sequence of each aluminum liquid holding furnace, the number of times each aluminum liquid holding furnace is added, and the duration of production stoppage for each quantitative casting machine.

[0034] Furthermore, the abnormal events that occur during the aluminum casting manufacturing process include: emergency order insertion, fluctuations in yield rate, production suspension, execution deviations, and / or equipment performance degradation.

[0035] Furthermore, the intelligent operation simulation method for aluminum casting manufacturing process based on digital twins also includes:

[0036] Select the actual production order to obtain the actual status parameter sequence of the equipment for each aluminum liquid supply process during actual production;

[0037] Using the actual process parameters and production plan of the aluminum liquid supply process corresponding to the actual production order as input parameters, intelligent operation simulation of the aluminum casting manufacturing process is carried out, and the simulation status parameter sequence of the equipment of each aluminum liquid supply process is output.

[0038] The actual state parameter sequence is compared with the simulated state parameter sequence to determine whether the difference between each state parameter sequence is less than the error threshold.

[0039] When the difference between the state parameter sequences is greater than the error threshold, the first and second simulation rules are adjusted for iterative optimization until the difference between the state parameter sequences is less than the error threshold.

[0040] An electronic device includes a memory and a processor, the memory being coupled to the processor; wherein the memory is used to store program data, and the processor is used to execute the program data to implement the above-described intelligent operation simulation method for aluminum casting manufacturing process based on digital twin.

[0041] A computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the above-described intelligent operation simulation method for aluminum casting manufacturing process based on digital twins.

[0042] Compared with the prior art, the beneficial effects of the present invention are:

[0043] 1. This invention proposes a simulation method for the aluminum liquid supply process in aluminum casting manufacturing based on digital twins. This method decouples the complex control logic of multiple devices in the production process, the flexible coordination rules between devices, and the impact relationships of abnormal events in the production process, supporting accurate simulation of the aluminum liquid supply process. Furthermore, this invention supports real-time adjustment of simulation rules and parameters during the simulation process, achieving intelligent operational simulation.

[0044] 2. The method proposed in this invention is an important enabling technology for digital twin models of aluminum alloy casting manufacturing lines. It can be effectively integrated with digital twin production line models, and can support the simulation of operating parameters of the aluminum liquid supply process and the evaluation of the impact of abnormal events in the production process on the operation of the aluminum liquid supply process, thereby supporting the intelligent and low-carbon operation of the aluminum casting manufacturing process. Attached Figure Description

[0045] Figure 1 This is a schematic diagram of the implementation process of the present invention.

[0046] Figure 2 The simulation results of the aluminum liquid supply process in the die-casting workshop are shown in the figure.

[0047] Figure 3 This is a schematic diagram of an electronic device. Detailed Implementation

[0048] The present invention will be further described below with reference to the accompanying drawings and embodiments, but this should not be construed as limiting the present invention.

[0049] This invention provides an intelligent operation simulation method for aluminum casting manufacturing process based on digital twins, such as... Figure 1 As shown, it includes the following steps.

[0050] (1) Obtain the equipment, layout, and operation sequence of the aluminum liquid supply process in the aluminum casting manufacturing process;

[0051] The equipment for the aluminum molten metal supply process includes an aluminum alloy melting furnace, an aluminum molten metal degasser, an aluminum molten metal transfer component, an aluminum molten metal holding furnace, and a quantitative casting machine. The aluminum molten metal transfer component includes: transport equipment and aluminum molten metal transport packages. The layout refers to the relative positions of the equipment in each aluminum molten metal supply process within the workshop. The operational sequence refers to the process of the equipment in the aluminum molten metal supply process operating and coordinating with each other, including: the aluminum alloy melting furnace melting aluminum alloy to obtain aluminum molten metal, transporting the aluminum molten metal to the aluminum molten metal degasser through the aluminum molten metal transfer component for degassing, transporting the degassed aluminum molten metal to the aluminum molten metal holding furnace through the aluminum molten metal transfer component and adding liquid to the aluminum molten metal holding furnace, the aluminum molten metal holding furnace holding the aluminum molten metal at a certain temperature, and the quantitative casting machine taking liquid from the aluminum molten metal holding furnace and casting it.

[0052] (2) Set the first simulation rule based on the status parameters and update rules of the equipment in the aluminum liquid supply process;

[0053] The status parameters of the aluminum alloy melting furnace include: the status of the melting burner (standby or working), melting speed, and aluminum liquid holding capacity. The update rules for the status parameters of the aluminum alloy melting furnace include: when the melting burner is in working condition, the aluminum liquid holding capacity is updated according to the melting speed; after the aluminum alloy melting furnace discharges liquid, the aluminum liquid holding capacity is updated to the difference between the original aluminum liquid holding capacity and the discharge volume.

[0054] The update rules for the status of the melting burner in the aluminum alloy melting furnace include: when the aluminum liquid holding temperature exceeds the upper limit of the holding temperature, the melting burner will be in standby mode until the aluminum liquid holding temperature falls below the lower limit of the holding temperature, at which point the melting burner will be in working mode.

[0055] Set the status parameters of the aluminum liquid degasser: The status parameters of the aluminum liquid degasser include the total degassing time and the time already degassed;

[0056] The status parameters of the molten aluminum transfer component include: the amount of molten aluminum transported by the component, the number of the target molten aluminum holding furnace, the amount of molten aluminum added to each target holding furnace, the order of adding molten aluminum to each target holding furnace, the current position and moving speed, and the elapsed running time. The update rules for the status parameters of the molten aluminum transfer component include: updating the position of the component based on its moving speed, route, and running time while transporting molten aluminum; updating the amount of molten aluminum transported by the component after the aluminum alloy melting furnace adds molten aluminum to the component, making it the sum of the original amount transported and the added amount; and updating the amount of molten aluminum transported by the component after adding molten aluminum to the holding furnace, making it the difference between the original amount transported and the added amount.

[0057] The status parameters of the aluminum liquid holding furnace include: the amount of aluminum liquid in the furnace; the update actions of the status parameters of the aluminum liquid holding furnace include: when the aluminum liquid transfer component adds liquid to the aluminum liquid holding furnace, the amount of aluminum liquid in the furnace is updated to the sum of the original amount of aluminum liquid in the furnace and the amount added; when the quantitative casting machine takes liquid from the aluminum liquid holding furnace, the amount of aluminum liquid in the furnace is updated to the difference between the original amount of aluminum liquid in the furnace and the amount taken.

[0058] The status parameters of the quantitative casting machine are set, including: the status of the quantitative casting machine, wherein the status of the quantitative casting machine is standby or working, the quantitative casting volume, the quantitative casting interval, and the time until the next quantitative casting; the status update rules of the quantitative casting machine include: according to the quantitative casting interval, the quantitative casting machine takes a quantitative amount of aluminum liquid from the aluminum liquid holding furnace and pours it into the casting machine.

[0059] (3) Set the second simulation rules based on the collaborative working process of the aluminum alloy melting furnace, aluminum liquid transfer components and aluminum liquid holding furnace;

[0060] The coordination rules for the aluminum alloy melting furnace include: when the aluminum casting manufacturing process ends, the aluminum liquid holding amount in the aluminum alloy melting furnace is the lower limit of the holding amount; when the amount of aluminum liquid melted in the aluminum alloy melting furnace meets the amount of aluminum liquid required by the production plan, the melting burner will be in standby mode and will not be updated to working mode.

[0061] The coordination rules for the aluminum liquid holding furnace include: when the amount of aluminum liquid in the holding furnace is lower than or equal to the lower limit of the holding capacity, the holding furnace needs to be replenished with aluminum liquid by the aluminum liquid transfer component. The amount of aluminum liquid added is the upper limit of the holding capacity minus the original amount of aluminum liquid in the holding furnace at the time of replenishment; when the amount of aluminum liquid in the holding furnace is lower than the amount of aluminum liquid that the quantitative casting machine can normally take, the quantitative casting machine is updated to standby mode until the amount of aluminum liquid required for the holding capacity is met, at which point the quantitative casting machine is updated to working mode; when the planned production of the aluminum casting process ends, the amount of aluminum liquid in the holding furnace is the lower limit of the holding capacity.

[0062] The coordination rules for the molten aluminum transfer component include: the time for the molten aluminum transfer component to take molten aluminum from the aluminum alloy melting furnace is equal to the time required to add molten aluminum to the aluminum holding furnace, minus the degassing time of the molten aluminum and the transportation time from the aluminum alloy melting furnace to the aluminum holding furnace; the amount of molten aluminum taken by the molten aluminum transfer component from the aluminum alloy melting furnace is equal to the upper limit of the molten aluminum supplied to the aluminum holding furnace, minus the original amount of molten aluminum in the aluminum holding furnace at the time of addition; if the amount of molten aluminum taken is greater than the maximum capacity of the molten aluminum transfer component, then the maximum capacity is taken. Aluminum liquid volume; when the liquid taking time of any two or more aluminum liquid transfer components is less than the threshold for combined liquid taking and transportation, and the total aluminum liquid volume they need is less than or equal to the maximum capacity of the aluminum liquid transfer component, then one aluminum liquid transfer component can be used to transport and supply multiple aluminum liquid holding furnaces simultaneously; when the aluminum liquid transfer component takes liquid from the aluminum alloy melting furnace, if the aluminum liquid volume of the aluminum alloy melting furnace is insufficient to meet the required aluminum liquid volume, then the liquid taking volume is the difference between the aluminum liquid volume of the aluminum alloy melting furnace and the lower limit of the aluminum liquid volume of the aluminum alloy melting furnace.

[0063] (4) The process parameters and production plan of the aluminum liquid supply process are used as input parameters, and the sequence of state parameters of the equipment in each aluminum liquid supply process during the production process is used as output parameters.

[0064] Input parameters include: melting rate of aluminum alloy melting furnace, upper and lower limits of heat preservation of aluminum alloy melting furnace, upper and lower limits of heat preservation of aluminum liquid holding furnace, amount of liquid that the quantitative casting machine can normally take, threshold for combining liquid taking and transportation, maximum capacity of aluminum liquid transportation components, number of products to be produced, quantitative casting machine's quantitative casting amount and quantitative casting interval.

[0065] The output parameters include: the working status change curve of the melting burner of the aluminum alloy melting furnace, the melting speed change curve, the aluminum liquid volume change curve of the holding zone of the aluminum alloy melting furnace, the aluminum liquid volume change curve of each aluminum liquid holding furnace, the number of times each aluminum liquid holding furnace is added, and the duration of production stoppage for each quantitative casting machine.

[0066] (5) When an abnormal event occurs in the aluminum casting manufacturing process, the actual state parameters of the equipment in the aluminum liquid supply process are obtained. By comparing the actual state parameters of the equipment in the aluminum liquid supply process with the simulation state parameters, the first simulation rule and the second simulation rule are adjusted. The specific steps are as follows:

[0067] When an abnormal event occurs in the aluminum casting manufacturing process, the actual status parameters of each piece of equipment in the aluminum liquid supply process at the time of the abnormal event are immediately obtained from the constructed digital twin aluminum casting production line model. The abnormal events include: emergency order insertion, yield fluctuation, production suspension, execution deviation and / or equipment performance degradation.

[0068] Compare the actual state parameters with the simulated state parameters, adjust the first and second simulation rules, update the input parameters, and start the next round of simulation with the actual state parameters and the updated input parameters as the starting point.

[0069] Furthermore, the method of the present invention also includes: verifying the effectiveness of the intelligent operation simulation method for aluminum casting manufacturing process, the steps of which are as follows:

[0070] Select the actual production order and obtain the actual status parameter curves of the equipment in each aluminum liquid supply process during actual production.

[0071] Using the actual process parameters and production plan of the aluminum liquid supply process corresponding to the actual production order as input parameters, intelligent operation simulation of the aluminum casting manufacturing process is carried out, and the simulation status parameter curves of the equipment of each aluminum liquid supply process are output.

[0072] The actual state parameter sequence is compared with the simulated state parameter curve to determine whether the difference between each state parameter curve is less than the error threshold; in this example, the error threshold is set to 3%.

[0073] When the difference between the state parameter sequences is greater than the error threshold of 3%, the first and second simulation rules are adjusted for iterative optimization until the difference between the state parameter curves is less than the error threshold of 3%.

[0074] Example 1

[0075] The following describes the implementation of the present invention using an aluminum liquid supply process in an aluminum alloy die-casting production process as an example. The aluminum liquid supply process in this example includes a melting furnace, three aluminum liquid transport components, three holding furnaces, and a quantitative casting machine. The specific steps are as follows:

[0076] Step (1): On-site investigation and collection of case studies on the equipment, layout, and operation sequence of the aluminum liquid supply process in the die casting workshop, including the melting speed range of the melting furnace (700kg / h to 2000kg / h), the minimum and maximum amount of aluminum liquid in the heat preservation zone (2000kg and 6000kg), the maximum transport capacity of the aluminum liquid transport component (800kg), the minimum and maximum heat preservation capacity of the heat preservation furnace (200kg and 500kg), the distance and route of the aluminum liquid transport component from the aluminum alloy melting furnace to each aluminum liquid heat preservation furnace (250m, 300m, 280m), the transport speed of the aluminum liquid transport component (70m / min), the normal liquid volume of the quantitative pouring machine (200kg), the production plan (3 different products, 500 pieces each), the quantitative pouring time interval and quantitative pouring volume (70s and 4kg, 80s and 5kg, 90s and 6kg);

[0077] Step (2): Set the first simulation rule based on the status parameters and update rules of the equipment in the aluminum liquid supply process;

[0078] Step (3): Set the second simulation rules based on the collaborative working process of the aluminum alloy melting furnace, aluminum liquid transfer components, and aluminum liquid holding furnace;

[0079] Step (4): Using [melting speed, lower limit of molten aluminum in melting furnace, upper limit of molten aluminum in melting furnace, lower limit of molten aluminum in holding furnace 1, lower limit of molten aluminum in holding furnace 2, lower limit of molten aluminum in holding furnace 3, upper limit of molten aluminum in holding furnace 1, upper limit of molten aluminum in holding furnace 2, upper limit of molten aluminum in holding furnace 3] (take [1844, 2243, 2989, 256, 220, 203, 469, 471, 477]), [melting speed, lower limit of molten aluminum in melting furnace, upper limit of molten aluminum in melting furnace, lower limit of molten aluminum in holding furnace 1 ... 1, upper limit of molten aluminum in holding furnace 3] (take [1844, 2243, 2989, 256, 220, 203, 469, 471, 477] (take [1844, 2243, 2989, 256, 220, 203, 469, 471, 477] (take [1844, 2243, 2989, 256, The following parameters are used as input parameters for the simulation: [lower limit of aluminum liquid in holding furnace 2, upper limit of aluminum liquid in holding furnace 1, upper limit of aluminum liquid in holding furnace 2] (taken as [1852, 4568, 5997, 206, 220, 426, 451]), and [melting speed, lower limit of aluminum liquid in melting furnace, upper limit of aluminum liquid in melting furnace, lower limit of aluminum liquid in holding furnace 1, upper limit of aluminum liquid in holding furnace 1] (taken as [2000, 2000, 4378, 308, 500]). The simulation results are as follows: Figure 2 As shown, Figure 2 The table lists the aluminum liquid volume variation curves for the aluminum alloy melting furnace and the aluminum liquid volume variation curves for the three aluminum liquid holding furnaces.

[0080] Step (5): Compare the simulation results with the actual data recorded by the digital twin system of the production line. The differences between the curves of each state parameter are less than the error threshold of 3%, which meets the requirements of production operation optimization.

[0081] Accordingly, this application also provides an electronic device, comprising: one or more processors; a memory for storing one or more programs; and when the one or more programs are executed by the one or more processors, causing the one or more processors to implement the intelligent operation simulation method for aluminum casting manufacturing process based on digital twins as described in the embodiments. Figure 3 The diagram shown is a hardware structure diagram of any device with data processing capabilities for the intelligent operation simulation method for aluminum casting manufacturing process based on digital twins provided in this embodiment of the invention, except for... Figure 3 In addition to the processor, memory, and network interface shown, any data processing device in this embodiment may also include other hardware depending on the actual function of the data processing device, which will not be described in detail here.

[0082] Accordingly, this application also provides a computer-readable storage medium storing computer instructions, which, when executed by a processor, implement the intelligent operation simulation method for aluminum casting manufacturing process based on digital twins as described in Embodiment 1. The computer-readable storage medium can be an internal storage unit of any data processing device as described in any of the foregoing embodiments, such as a hard disk or memory. The computer-readable storage medium can also be an external storage device, such as a plug-in hard disk, smart memory card, SD card, flash memory card, etc., equipped on the device. Further, the computer-readable storage medium can include both internal storage units of any data processing device and external storage devices. The computer-readable storage medium is used to store the computer program and other programs and data required by the data processing device, and can also be used to temporarily store data that has been output or will be output.

[0083] The above description of the embodiments is provided to enable those skilled in the art to understand and apply the present invention. Those skilled in the art can readily make various modifications to the above embodiments and apply the general principles described herein to other embodiments without creative effort. Therefore, the present invention is not limited to the above embodiments, and any improvements and modifications made to the present invention by those skilled in the art based on the disclosure thereof should be within the scope of protection of the present invention.

Claims

1. A digital twin-based intelligent simulation method for aluminum casting manufacturing process, comprising the following steps: The equipment, layout, and operation sequence of the aluminum liquid supply process in the aluminum casting manufacturing process are obtained; the equipment in the aluminum liquid supply process includes an aluminum alloy melting furnace, an aluminum liquid degasser, an aluminum liquid transfer component, an aluminum liquid holding furnace, and a quantitative casting machine; The first simulation rule is set based on the status parameters and update rules of the equipment in the aluminum liquid supply process; The second simulation rule is set based on the collaborative working process of the aluminum alloy melting furnace, the aluminum liquid transfer component, and the aluminum liquid holding furnace; The process parameters and production plan of the aluminum liquid supply process are used as input parameters, and the sequence of status parameters of the equipment in each aluminum liquid supply process during the production process is used as output parameters. When an abnormal event occurs in the aluminum casting manufacturing process, the actual state parameters of the equipment in the aluminum liquid supply process are obtained. By comparing the actual state parameters of the equipment in the aluminum liquid supply process with the simulation state parameters, the first simulation rule and the second simulation rule are adjusted. The first simulation rule is set based on the status parameters and update rules of the equipment in the aluminum liquid supply process, including: Set the state parameters and update rules for the aluminum alloy melting furnace, including: The status parameters of the aluminum alloy melting furnace include: the status of the melting burner, which is either standby or working, the melting speed, and the amount of aluminum liquid held at the temperature. The update rules for the status parameters of the aluminum alloy melting furnace include: when the melting burner is in operation, the aluminum liquid holding amount is updated according to the melting rate; after the aluminum alloy melting furnace discharges liquid, the aluminum liquid holding amount is updated to the difference between the original aluminum liquid holding amount and the discharge amount. The update rules for the status of the melting burner in the aluminum alloy melting furnace include: when the aluminum liquid holding temperature exceeds the upper limit of the holding temperature, the melting burner will be in standby mode until the aluminum liquid holding temperature falls below the lower limit of the holding temperature, at which point the melting burner will be in working mode. Set the status parameters of the aluminum liquid degasser: The status parameters of the aluminum liquid degasser include the total degassing time and the time already degassed; Define the status parameters and update rules for the molten aluminum transfer component, including: The status parameters of the aluminum liquid transfer component include: the amount of aluminum liquid transported by the aluminum liquid transfer component, the number of the target aluminum liquid holding furnace, the amount of liquid added to each target aluminum liquid holding furnace, the order of adding liquid to each target aluminum liquid holding furnace, the current position and moving speed, and the running time. The status parameter update rules for the molten aluminum transfer component include: updating the position of the molten aluminum transfer component based on its moving speed, running route, and running time during molten aluminum transfer; updating the amount of molten aluminum transported by the molten aluminum transfer component after the aluminum alloy melting furnace adds molten aluminum to the molten aluminum transfer component to be the sum of the original amount of molten aluminum transported by the molten aluminum transfer component and the amount added; and updating the amount of molten aluminum transported by the molten aluminum transfer component after the molten aluminum transfer component adds molten aluminum to the molten aluminum holding furnace to be the difference between the original amount of molten aluminum transported by the molten aluminum transfer component and the amount added. Set the status parameters and update rules for the aluminum liquid holding furnace, including: The status parameters of the aluminum liquid holding furnace include: the amount of aluminum liquid in the aluminum liquid holding furnace; The update actions for the status parameters of the aluminum liquid holding furnace include: when the aluminum liquid transfer component adds liquid to the aluminum liquid holding furnace, the aluminum liquid volume of the aluminum liquid holding furnace is updated to the sum of the original aluminum liquid volume and the added liquid volume; when the quantitative casting machine takes liquid from the aluminum liquid holding furnace, the aluminum liquid volume of the aluminum liquid holding furnace is updated to the difference between the original aluminum liquid volume and the taken liquid volume. The status parameters of the quantitative casting machine are set, including: the status of the quantitative casting machine, wherein the status of the quantitative casting machine is standby or working, the quantitative casting volume, the quantitative casting interval, and the time until the next quantitative casting. The second simulation rules, based on the collaborative working process of the aluminum alloy melting furnace, the aluminum liquid transfer components, and the aluminum liquid holding furnace, include: The coordination rules for the aluminum alloy melting furnace include: when the aluminum casting manufacturing process ends, the aluminum liquid holding amount in the aluminum alloy melting furnace is the lower limit of the holding amount; when the amount of aluminum liquid melted in the aluminum alloy melting furnace meets the amount of aluminum liquid required by the production plan, the melting burner will be in standby mode and will not be updated to working mode. The coordination rules for the aluminum liquid holding furnace include: when the amount of aluminum liquid in the holding furnace is lower than or equal to the lower limit of the holding capacity, the holding furnace needs to be replenished with aluminum liquid by the aluminum liquid transfer component. The amount of aluminum liquid added is the difference between the upper limit of the holding capacity and the original amount of aluminum liquid in the holding furnace at the time of replenishment; when the amount of aluminum liquid in the holding furnace is lower than the amount of aluminum liquid that the quantitative casting machine can normally take, the quantitative casting machine is updated to standby mode until the amount of aluminum liquid required for the holding capacity is met, at which point the quantitative casting machine is updated to working mode; when the planned production of the aluminum casting process ends, the amount of aluminum liquid in the holding furnace is the lower limit of the holding capacity. The coordination rules for the molten aluminum transfer component include: the time for the molten aluminum transfer component to take molten aluminum from the aluminum alloy melting furnace is equal to the time required to add molten aluminum to the aluminum holding furnace minus the degassing time of the molten aluminum and the transportation time from the aluminum alloy melting furnace to the aluminum holding furnace; the amount of molten aluminum taken by the molten aluminum transfer component from the aluminum alloy melting furnace is the difference between the upper limit of the molten aluminum supplied to the aluminum holding furnace and the original amount of molten aluminum in the aluminum holding furnace at the time of addition; if the amount of molten aluminum taken is greater than the maximum capacity of the molten aluminum transfer component, then the maximum capacity is taken. Aluminum liquid volume; when the liquid taking time of any two or more aluminum liquid transfer components is less than the threshold for combined liquid taking and transportation, and the total aluminum liquid volume they need is less than or equal to the maximum capacity of the aluminum liquid transfer component, then one aluminum liquid transfer component can be used to transport and supply multiple aluminum liquid holding furnaces simultaneously; when the aluminum liquid transfer component takes liquid from the aluminum alloy melting furnace, if the aluminum liquid volume of the aluminum alloy melting furnace is insufficient to meet the required aluminum liquid volume, then the liquid taking volume is the difference between the aluminum liquid volume of the aluminum alloy melting furnace and the lower limit of the aluminum liquid volume of the aluminum alloy melting furnace.

2. The intelligent operation simulation method for aluminum casting manufacturing process based on digital twin as described in claim 1, characterized in that: The equipment, layout, and operating sequence for the aluminum molten metal supply process in aluminum casting manufacturing include: The layout refers to the relative positions of the equipment in each aluminum liquid supply process within the workshop; The aforementioned operational sequence refers to the process of equipment operation and mutual coordination in the aluminum liquid supply process, including: the aluminum alloy melting furnace melts the aluminum alloy to obtain aluminum liquid, which is then transported to the aluminum liquid degasser through the aluminum liquid transfer component to degas the aluminum liquid, the degassed aluminum liquid is then transported to the aluminum liquid holding furnace through the aluminum liquid transfer component and liquid is added to the aluminum liquid holding furnace, the aluminum liquid holding furnace holds the aluminum liquid at a certain temperature, and the quantitative casting machine takes liquid from the aluminum liquid holding furnace and casts it.

3. The intelligent operation simulation method for aluminum casting manufacturing process based on digital twin as described in claim 1, characterized in that: The input parameters are: melting rate of aluminum alloy melting furnace, upper and lower limits of heat preservation of aluminum alloy melting furnace, upper and lower limits of heat preservation of aluminum liquid holding furnace, amount of liquid that the quantitative casting machine can normally take, threshold for combining liquid taking and transportation, maximum capacity of aluminum liquid transportation components, number of products to be produced, quantitative casting machine's quantitative casting amount and quantitative casting interval.

4. The intelligent operation simulation method for aluminum casting manufacturing process based on digital twin as described in claim 1, characterized in that: The output parameters are: the working status change sequence of the melting burner of the aluminum alloy melting furnace, the melting speed change sequence of the aluminum alloy melting furnace, the aluminum liquid volume change sequence of the aluminum alloy melting furnace, the aluminum liquid volume change sequence of each aluminum liquid holding furnace, the number of times each aluminum liquid holding furnace is added, and the duration of production stoppage for each quantitative casting machine.

5. The intelligent operation simulation method for aluminum casting manufacturing process based on digital twin as described in claim 1, characterized in that: Abnormal events that may occur during the aluminum casting manufacturing process include: emergency orders, fluctuations in yield rates, production stoppages, execution deviations, and / or equipment performance degradation.

6. The intelligent operation simulation method for aluminum casting manufacturing process based on digital twin as described in claim 1, characterized in that: The method further includes: Select the actual production order to obtain the actual status parameter sequence of the equipment for each aluminum liquid supply process during actual production; Using the actual process parameters and production plan of the aluminum liquid supply process corresponding to the actual production order as input parameters, intelligent operation simulation of the aluminum casting manufacturing process is carried out, and the simulation status parameter sequence of the equipment of each aluminum liquid supply process is output. The actual state parameter sequence is compared with the simulated state parameter sequence to determine whether the difference between each state parameter sequence is less than the error threshold. When the difference between the state parameter sequences is greater than the error threshold, the first and second simulation rules are adjusted for iterative optimization until the difference between the state parameter sequences is less than the error threshold.

7. An electronic device comprising a memory and a processor, characterized in that, The memory is coupled to the processor; wherein the memory is used to store program data, and the processor is used to execute the program data to implement the intelligent operation simulation method for aluminum casting manufacturing process based on digital twin as described in any one of claims 1-6.

8. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the program is executed by the processor, it implements the intelligent operation simulation method for aluminum casting manufacturing process based on digital twin as described in any one of claims 1-6.

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