Green casting process and equipment full cycle energy consumption control system

Abstract

The present invention provides a full-cycle energy consumption management and control system for green casting processes and equipment, divides the frozen sand mold green casting forming technology process into three processes: low-temperature freezing of frozen sand molds, CNC machining of frozen sand molds, and low-temperature casting of frozen sand molds, calculates the energy consumption of three typical manufacturing processes respectively, proposes energy consumption management and control models for each stage, constructs a prediction model for the energy consumption of frozen sand mold freezing and casting material melting through big data, and uses machine vision online monitoring of equipment power to adjust process parameters in real time to reduce the energy consumption of the processing process, thereby achieving precise energy consumption management and control of the entire process of green casting of frozen sand molds, further optimizing the energy consumption management and energy distribution of the green casting process of frozen sand molds, and enabling the green and sustainable development of future factories.

Description

Technical Field

[0001] The present invention belongs to the technical field of energy consumption control of sand casting, and specifically relates to a green casting process and equipment energy consumption control system for frozen sand casting. Background Art

[0002] The frozen sand green casting forming technology is a digital and green sand mold modeling technology that is innovatively developed by combining CNC machining technology with frozen casting technology. It achieves precise forming of complex cavities in frozen sand molds through digital cutting, improves the manufacturing accuracy of complex sand molds, and reduces the sand mold manufacturing cycle. At the same time, water is used as an adhesive to manufacture sand blanks. No toxic gases are produced during the pouring process, and the molding sand collapses naturally, which improves the working environment of workers. It is an important development direction for the transformation and upgrading of the foundry industry.

[0003] Frozen sand green casting technology uses water as a binder during the sand molding process to freeze the sand mold at low temperatures. Therefore, the freezing process consumes a lot of energy. At the same time, the differences in material properties, process parameters, and melting parameters during sand cutting and casting also cause differences in energy consumption. Currently, research on energy consumption control is concentrated at the equipment level, and there is a lack of a full-cycle frozen sand green casting energy consumption control system. Precise energy consumption control helps optimize energy distribution, reduce energy consumption, and further enhance the green manufacturing level of frozen sand green casting technology. Conducting research on energy consumption control for the entire frozen sand green casting process is of great significance and can enable the sustainable development of the equipment manufacturing industry. Summary of the Invention

[0004] To solve the above problems, the present invention discloses a full-cycle energy consumption control system for green casting processes and equipment. The system can realize precise control of energy consumption of frozen sand mold green casting processes and equipment, solve the problem of energy waste caused by uneven energy consumption distribution, and serve the major strategic deployment of carbon neutrality and carbon peak.

[0005] In order to solve the above technical problems, the technical solution adopted by the present invention is: a green casting process and equipment full-cycle energy consumption control system, characterized in that the system includes the following steps:

[0006] S1. Divide the production process of frozen casting into three steps: frozen sand mold freezing forming, frozen sand mold CNC machining and frozen sand mold low-temperature casting. Each step corresponds to a different energy consumption control model;

[0007] S2. Establish a mathematical model for energy consumption throughout the frozen sand mold process: A frozen sand mold freezing forming energy consumption control model is established based on the types of multi-material frozen sand molds, refrigeration source power, and freezing time information; a frozen sand mold CNC machining energy consumption control model is established based on CNC cutting equipment process parameters, cutting path planning, and cutting time information; and a frozen sand mold low-temperature casting energy consumption model is established based on casting material, melting furnace power, and melting time information, forming three typical process energy consumption control models.

[0008] S3. Calculation of energy consumption model for frozen sand molds: Collect data on the temperature variation of the surface / core of multi-material frozen sand molds at different volumes as a function of freezing time, establish a freezing time process dataset for multi-material and multi-volume frozen sand molds, and use a machine learning system to obtain a prediction model for the freezing energy consumption of large-scale frozen sand molds.

[0009] S4. Calculation of energy consumption model for frozen sand mold CNC machining process: Online monitoring of cutting equipment power changes during multi-material frozen sand mold machining under different freezing temperatures, different water contents, and different cutting paths, and optimization of the energy consumption model for frozen sand mold cutting process using CNC machining technology as a control indicator;

[0010] S5. Energy consumption calculation for frozen sand low-temperature casting: Establish a dataset of casting materials, melting equipment power, and melting time, and use a machine learning system to develop a prediction model for casting material melting energy consumption;

[0011] S6. Precise control of energy consumption throughout the entire frozen sand mold process: Precise control of energy consumption is achieved through energy consumption prediction during frozen sand mold freezing and low-temperature casting. Precise control of energy consumption during the frozen sand mold forming process is achieved through online adjustment of process parameters and cutting path planning during the frozen sand mold cutting process.

[0012] Furthermore, the energy consumption control model for frozen sand mold freezing forming in S3 is as follows:

[0013]

[0014] Where E1 represents the energy consumption during the freezing forming process of the frozen sand mold, α represents the influence coefficient of different molding sand materials, β represents the influence coefficient of frozen sand molds of different volumes, P1 represents the refrigeration power of the refrigerator during the freezing process of the frozen sand mold, and t1 represents the time required for the freezing forming of the frozen sand mold.

[0015] Furthermore, the energy consumption model of the frozen sand cutting process in S4 is:

[0016] E2=F(a e ,a p ,n,v,t2) (2)

[0017] Where E2 represents the energy consumption during the frozen sand cutting process, ae represents the cutting width, ap represents the cutting width, n represents the spindle speed, v represents the feed speed, and t2 represents the time required for cutting.

[0018] Furthermore, the energy consumption model of the frozen sand casting process in S5 is:

[0019]

[0020] Where E3 represents the energy consumption during the frozen sand mold low-temperature casting process, γ represents the influence coefficient of different casting materials, P2 represents the power of the melting furnace during the casting melting process, and t3 represents the time required for the casting material to be completely melted.

[0021] Furthermore, the energy consumption prediction of the frozen sand mold freeze forming and frozen sand mold low-temperature casting process is obtained by collecting big data and using machine learning multiple linear regression to obtain a prediction model.

[0022] Furthermore, the energy consumption control during the frozen sand mold cutting process achieves low-power, fast cutting and reduces energy consumption by optimizing the cutting path and adjusting cutting process parameters in real time. 1. Optimizing the CNC tool cutting path enables continuous and uninterrupted sand mold cutting, avoiding tool idle travel during cutting of different layers and unnecessary energy consumption. 2. Using machine tool power monitoring equipment to monitor power changes during the cutting process in real time, the machine tool power is reduced by adjusting process parameters, achieving minimum power cutting while meeting cutting quality requirements and reducing equipment energy consumption.

[0023] Compared with the prior art, the present invention has the following advantages:

[0024] 1. The present invention realizes accurate calculation of energy consumption of the whole process of frozen sand green casting by establishing an energy consumption model step by step.

[0025] 2. The present invention uses machine learning to establish an energy consumption prediction model for the frozen sand mold freezing molding and casting pouring process to achieve precise control of energy consumption.

[0026] 3. The present invention optimizes cutting process parameters online by monitoring power changes during the cutting process, thereby achieving energy consumption control during the cutting process. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a process flow chart of the present invention. DETAILED DESCRIPTION

[0028] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are intended only to illustrate the present invention and are not intended to limit the scope of the present invention. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, and the terms "inward" and "outward" refer to directions toward or away from the geometric center of a particular component, respectively.

[0029] like Figure 1 The figure shows a green casting process and equipment energy consumption control system for frozen sand molds. The specific steps are as follows:

[0030] Step 1: Divide the freeze casting production process;

[0031] The green casting process of frozen sand molds is divided into three steps, namely frozen sand mold freezing forming, frozen sand mold CNC machining and frozen sand mold low-temperature casting. Different processing technologies correspond to different energy consumption control models, which are used to accurately calculate the energy consumption of the process.

[0032] Step 2: Establish a mathematical model of energy consumption for the entire frozen sand mold process;

[0033] Different energy consumption models are established for different process characteristics. An energy consumption control model for frozen sand mold freezing forming is established based on the type of multi-material frozen sand mold, cooling source power and freezing time information. An energy consumption control model for frozen sand mold CNC machining is established based on the process parameters of CNC cutting equipment, cutting path planning and cutting time information. An energy consumption control model for frozen sand mold low-temperature casting is established based on the casting material, melting furnace power and melting time information. Three typical process energy consumption control models are formed, and energy consumption at each stage is optimized according to the processing flow.

[0034] Step 3: Calculation of energy consumption model for frozen sand mold forming

[0035] Temperature sensors are installed on the surface and core of the sand mold to collect freezing time data of frozen sand molds of different volumes, such as silica sand, chromite sand, and zircon sand. A freezing time process data set of multi-material and multi-volume frozen sand molds is established. A machine learning system is used to obtain a prediction model for the freezing energy consumption of large-scale frozen sand molds, which can achieve accurate prediction of the freezing energy consumption of sand molds, reduce the excess energy consumption caused by manual estimation of freezing time, and save freezing time.

[0036] Step 4: Calculation of energy consumption model for frozen sand CNC machining;

[0037] The power meter is used to monitor online the power changes of the cutting equipment during the multi-material frozen sand mold processing process under different freezing temperatures, different water contents, and different cutting paths. When the power is stable, the cutting speed is used as the control index and adjusted at a rate of 1.1 until the power stops fluctuating, thereby optimizing the minimum energy consumption under the frozen sand mold cutting parameters.

[0038] Step 5: Calculation of energy consumption model for frozen sand mold low-temperature casting;

[0039] Establish a data set of casting materials, smelting equipment power and melting time, and use a machine learning system to develop a prediction model for casting material smelting energy consumption;

[0040] Step 6: Accurately control energy consumption throughout the entire freezing sand mold process;

[0041] Accurate control of energy consumption is achieved through energy consumption prediction of frozen sand mold freezing forming and frozen sand mold low-temperature casting, and accurate control of energy consumption of frozen sand mold forming process is achieved through online adjustment of process parameters and cutting path planning during frozen sand mold cutting process.

[0042] The technical means disclosed in the solution of the present invention are not limited to the technical means disclosed in the above-mentioned embodiment, but also include technical solutions composed of any combination of the above technical features.

Claims

1. The green casting process and equipment full cycle energy consumption control system is characterized by: The system includes the following steps: S1. Divide the production process of frozen casting into three steps: frozen sand mold freezing forming, frozen sand mold CNC machining and frozen sand mold low-temperature casting. Each step corresponds to a different energy consumption control model; S2. Establish a mathematical model for energy consumption throughout the frozen sand mold process: A multi-material, multi-structure, and multi-scale frozen sand mold freezing forming energy consumption control model is established based on the types of multi-material frozen sand molds, refrigeration source power, and freezing time information. A frozen sand mold CNC machining energy consumption control model is established based on CNC cutting equipment process parameters, cutting path planning, and cutting time information. A frozen sand mold low-temperature casting energy consumption model is established based on casting material, melting furnace power, and melting time information. These three typical process energy consumption control models are formed. S3. Calculation of energy consumption model for frozen sand mold freezing: Collect data on the temperature variation of the surface / core of multi-material frozen sand molds with different volumes as a function of freezing time, establish a multi-material and multi-volume frozen sand mold freezing time process data set, and use a machine learning system to obtain a prediction model for the freezing energy consumption of large-scale frozen sand molds; the energy consumption control model for frozen sand mold freezing in S3: Where, E1 represents the energy consumption during the freezing forming process of the frozen sand mold, α represents the influence coefficient of different molding sand materials, β represents the influence coefficient of different volumes of frozen sand molds, P1 represents the refrigeration power of the refrigerator during the freezing process of the frozen sand mold, and t1 represents the time required for the freezing forming of the frozen sand mold; S4. Calculation of energy consumption model for frozen sand mold CNC machining: Online monitoring of cutting equipment power changes during multi-material frozen sand mold machining under different freezing temperatures, different water contents, and different cutting paths, and optimization of the energy consumption model for the frozen sand mold cutting process using CNC machining technology as a control indicator; the energy consumption model for the frozen sand mold cutting process in S4: E2=F(a e ,a p ,n,v,t2) (2) Where, E2 represents the energy consumption during the frozen sand cutting process, a e Indicates the cutting width, a p represents the cutting width, n represents the spindle speed, v represents the feed rate, and t2 represents the time required for cutting; S5. Calculation of energy consumption model for frozen sand mold low-temperature casting: Establish a data set of casting materials, smelting equipment power and melting time, and use a machine learning system to obtain a prediction model for the energy consumption of casting material smelting; the energy consumption model of the frozen sand mold casting process in S5 is: Where E3 represents the energy consumption during the frozen sand casting process, γ represents the influence coefficient of different casting materials, P2 represents the power of the melting furnace during the casting melting process, and t3 represents the time required for the casting material to be completely melted. S6. Precise control of energy consumption throughout the entire frozen sand mold process: Precise control of energy consumption is achieved through energy consumption prediction during frozen sand mold freezing and low-temperature casting. Precise control of energy consumption during the frozen sand mold forming process is achieved through online adjustment of process parameters and cutting path planning during the frozen sand mold cutting process.

2. A frozen sand mold green casting process and equipment energy consumption control system according to claim 1, characterized in that: The energy consumption prediction of the frozen sand mold freeze forming and frozen sand mold low-temperature casting process is achieved by collecting big data and obtaining a prediction model through machine learning multivariate linear regression.

3. A frozen sand mold green casting process and equipment energy consumption control system according to claim 1, characterized in that: The energy consumption control of the frozen sand mold cutting process achieves low-power rapid cutting and reduces energy consumption by optimizing the cutting path and adjusting the cutting process parameters in real time.

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