Liquid metal pouring control method and device for metal casting

Abstract

The present invention discloses a method and device for controlling the pouring of molten metal for metal casting, and relates to the technical field of metal casting. The method comprises: exploring the filling capacity of the target metal liquid in casting, matching the pouring constraint characteristics in combination with the workpiece characteristics, and based on this, performing low-element pouring simulation to determine the directional pouring strategy, traversing the strategy to set the deviation correction trigger matrix, performing PLC programming on the strategy and the matrix for control and deviation correction, synchronously monitoring and returning data, and performing feedback adjustment management based on the data and deviation correction response. The method solves the technical problems in the prior art that the control of the molten metal pouring process is not accurate, efficient, flexible, and cannot be timely fed back and adjusted. By realizing accurate, efficient, flexible, and timely fed back and adjusted control of the molten metal pouring, the technical effects of improving the quality of castings, improving production efficiency, and reducing scrap rates are achieved.

Description

Technical Field

[0001] The present application relates to the technical field of metal casting, and in particular to a method and device for controlling the pouring of molten metal for metal casting. Background Art

[0002] In the field of metal casting, the quality and efficiency issues of the molten metal pouring process have become increasingly prominent, becoming a key factor restricting the improvement of product quality and production efficiency. Traditional molten metal pouring control usually lacks in-depth exploration of the target metal liquid filling capacity, and the pouring strategy relies more on experience and judgment, lacks scientific basis and accuracy, which makes the castings prone to various defects and affects their quality and performance. Moreover, the previous pouring simulation technology is complex and computationally intensive, and the results are inaccurate, making it difficult to effectively guide the pouring operations in actual production. In addition, the control method during the pouring process is relatively simple, lacking a flexible correction mechanism, and it is impossible to make timely and effective adjustments in the face of deviations, resulting in increased scrap rates and low production efficiency.

[0003] At present, relevant technologies still have technical problems such as the control of the molten metal pouring process is not accurate, efficient, flexible enough and cannot provide timely feedback and adjustments. Summary of the invention

[0004] The present application provides a molten metal pouring control method and device for metal casting, which exploits the target metal liquid filling capacity of the casting, matches the pouring constraint characteristics in combination with the workpiece characteristics, and based on this, performs low-element pouring simulation to determine the directional pouring strategy, traverses the strategy to set the deviation correction trigger matrix, and performs PLC programming on the strategy and matrix for control and deviation correction, synchronously monitors and returns data, and performs feedback adjustment management based on the data and deviation correction response, thereby achieving the technical effect of improving the quality of castings, improving production efficiency, and reducing scrap rates by realizing accurate, efficient, flexible and timely feedback and adjustment control of molten metal pouring.

[0005] The present application provides a method for controlling molten metal pouring for metal casting, comprising:

[0006] Explore the liquid filling capacity of the casting target metal, combine the workpiece characteristics, and match the casting constraint characteristics, wherein the liquid filling capacity corresponds to a multi-stage molten state; based on the casting constraint characteristics, the workpiece characteristics and equipment specifications, perform low-element casting simulation to determine the directional casting strategy for the entire casting cycle of the workpiece, wherein the low-element casting simulation is based on simulation redundancy reduction and simulation simplification as standards; traverse the directional casting strategy, set the correction trigger matrix, wherein the correction trigger point of each correction element is different, and the correction element includes a control element and a response element; perform PLC programming on the directional casting strategy and the correction trigger matrix, and perform automated casting control and correction response to deviation exceeding the limit; perform casting monitoring simultaneously, pre-process the front end and send back real-time casting data; based on the real-time casting data and the correction response, perform feedback adjustment management of casting control.

[0007] The present application also provides a molten metal pouring control device for metal casting, comprising:

[0008] A casting constraint feature matching module, the casting constraint feature matching module is used to explore the liquid filling capacity of the casting target metal, and match the casting constraint features in combination with the workpiece features, wherein the liquid filling capacity corresponds to a multi-stage molten state; a casting simulation module, the casting simulation module is used to perform low-element casting simulation based on the casting constraint features, the workpiece features and equipment specifications, and determine the directional casting strategy for the entire casting cycle of the workpiece, wherein the low-element casting simulation is based on simulation redundancy reduction and simulation simplification as standards; a correction trigger matrix setting module, the correction trigger matrix setting module is used to traverse the directional casting strategy The invention discloses a method for controlling the pouring process of a casting system, and a method for controlling the pouring process of a casting system. The method comprises the following steps: first, setting a correction trigger matrix, wherein the correction trigger point of each correction element is different, and the correction element includes a control element and a response element; a programming module, wherein the programming module is used to perform PLC programming on the directional pouring strategy and the correction trigger matrix, and perform automatic pouring control and correction response to deviation exceeding the limit; a pouring monitoring synchronization module, wherein the pouring monitoring synchronization module is used to synchronously perform pouring monitoring, pre-process at the front end and return real-time pouring data; and a feedback regulation management module, wherein the feedback regulation management module is used to perform feedback regulation management of pouring control based on the real-time pouring data and the correction response.

[0009] The molten metal pouring control method and device for metal casting proposed in this application first explore the target metal liquid filling capacity of the casting, match the pouring constraint characteristics in combination with the workpiece characteristics, and based on this, perform low-element pouring simulation to determine the directional pouring strategy, traverse the strategy to set the correction trigger matrix, program the strategy and matrix through PLC for control and correction, synchronously monitor and return data, and perform feedback adjustment management based on the data and correction response. By achieving accurate, efficient, flexible and timely feedback and adjustment control of the molten metal pouring, the technical effect of improving the quality of castings, improving production efficiency and reducing scrap rate can be achieved. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] In order to more clearly illustrate the technical solution of the embodiment of the present invention, the accompanying drawings of the embodiment of the present invention will be briefly introduced below. A flow chart is used in the present application to illustrate the operations performed by the device according to the embodiment of the present application. It should be understood that the previous or following operations are not necessarily performed precisely in order. On the contrary, various steps can be processed in reverse order or simultaneously as needed. At the same time, other operations can also be added to these processes, or one or more operations can be removed from these processes.

[0011] Figure 1 A schematic flow chart of a method for controlling the pouring of molten metal for metal casting provided in an embodiment of the present application;

[0012] Figure 2 A schematic diagram of the structure of a molten metal pouring control device for metal casting provided in an embodiment of the present application.

[0013] Explanation of the reference numerals: pouring constraint feature matching module 10 , pouring simulation module 20 , correction trigger matrix setting module 30 , programming module 40 , pouring monitoring synchronization module 50 , feedback adjustment management module 60 . DETAILED DESCRIPTION

[0014] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below.

[0015] In order to make the purpose, technical solutions and advantages of the present application clearer, the present application will be further described in detail below in conjunction with the accompanying drawings. The described embodiments should not be regarded as limiting the present application. All other embodiments obtained by ordinary technicians in the field without making creative work are within the scope of protection of this application.

[0016] In the following description, reference is made to "some embodiments", which describe a subset of all possible embodiments, but it is understood that "some embodiments" may be the same subset or different subsets of all possible embodiments, and may be combined with each other without conflict, and the terms "first\second" involved are merely to distinguish similar objects and do not represent a specific ordering of objects. The terms "including" and "having" and any variations are intended to cover non-exclusive inclusions, for example, a process, method, device, product, or server that includes a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or modules that are not clearly listed or inherent to these processes, methods, products, or devices. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those generally understood by technicians in the technical field of this application. The terms used herein are for the purpose of describing the embodiments of the present application only.

[0017] The present application provides a method and device for controlling the pouring of molten metal for metal casting, such as Figure 1 As shown, the method includes:

[0018] Step S100, explore the liquid filling capacity of the target metal for casting, combine the workpiece characteristics, and match the casting constraint characteristics, wherein the liquid filling capacity corresponds to a multi-stage molten state. Specifically, in the initial stage of metal casting, it is necessary to explore the liquid filling capacity of the target metal for casting. Since the target metal may be a single metal or an alloy, targeted analysis is required. For a single metal, it is necessary to consider the influence of factors such as its purity and crystal structure on the liquid filling capacity, and study the melting point, liquid viscosity, surface tension and other characteristics of the metal at different temperatures to determine its flow and filling capacity in a molten state. For alloys, due to the diversity of components, the evaluation of its liquid filling capacity is more complicated, and it is necessary to analyze the content of each element in the alloy, the interaction and the formed phase structure. The addition of different elements may change the melting point range of the alloy and affect its fluidity and solidification behavior in a multi-stage molten state. After understanding the liquid filling capacity of the target metal, it is also necessary to combine the specific characteristics of the workpiece to be cast, the shape complexity, size, and wall thickness difference of the workpiece. Different shapes will affect the filling process of the molten metal. For example, workpieces with complex shapes may require better molten metal fluidity to ensure that all parts can be fully filled; large workpieces need to consider the temperature maintenance and fluidity maintenance of the molten metal in a longer process, and need to match the casting constraint characteristics, including the material and structure of the mold, the design of the casting system, the performance of the casting equipment, etc. The mold cavity shape and exhaust capacity will affect the flow path of the molten metal and gas discharge; the gate position, size and shape of the casting system determine the speed and method of the molten metal entering the cavity; the heating capacity and temperature control accuracy of the casting equipment will also affect the temperature and fluidity of the molten metal. By comprehensively analyzing the liquid filling capacity of the target metal, workpiece characteristics and casting constraint characteristics, it can provide an accurate and reliable basis for the subsequent casting process formulation, thereby improving the quality and production efficiency of castings.

[0019] In a possible implementation, the liquid filling capacity of the casting target metal is explored, combined with the workpiece characteristics, and the casting constraint characteristics are matched, wherein the liquid filling capacity corresponds to a multi-stage molten state, and step S100 further includes step S110, using the target metal as an index to perform industrial big data retrieval to determine the casting record. Specifically, the target metal is clearly set as a key index identifier, and in the massive industrial big data, this target metal is used as the key clue for search. The industrial big data covers a wide range of casting-related information, including casting process parameters of different metal materials, performance in actual production, quality inspection results, etc. By using the target metal as an index for precise search, it is possible to screen out casting records directly related to it from the complex ocean of data. The records contain specific cases of casting using the target metal in the past, experimental data, and various detailed information in the production process, providing targeted original data for subsequent analysis and research.

[0020] Step S120, based on the multi-level melting state, clustering the casting records to determine multiple clusters. Specifically, since the target metal has the characteristic of multi-level melting state, it may show different melting behaviors under different temperature and composition conditions. The previously retrieved casting records are classified and processed. The clustering algorithm will group the records according to the similarity of the multi-level melting state to form multiple clusters. The records in each cluster have certain commonalities in terms of melting state. For example, some records may represent the melting of the target metal at a lower temperature, while others reflect the melting characteristics at a higher temperature or a specific composition ratio. Clustering helps to organize complex data in a meaningful pattern, so that similar casting situations can be analyzed in a centralized manner, providing a clear and organized basis for subsequent in-depth exploration of the rules.

[0021] Step S130, traverse the multiple clusters to determine the pouring characteristics of the casting mold cavity, wherein the pouring characteristics at least include fluidity and solidification characteristics. Specifically, after completing the clustering process, each cluster is inspected and analyzed in detail in turn. In this process, the key characteristics that directly affect the casting mold cavity effect are focused on. Fluidity is an important aspect, which determines the filling capacity and uniformity of the molten metal in the cavity. Good fluidity can ensure that the molten metal reaches every corner of the cavity smoothly and reduces the generation of defects. Solidification characteristics are also critical, including the time point when solidification starts, the speed of the solidification process, and the final organizational structure after solidification. The solidification characteristics not only affect the internal quality of the casting, but are also closely related to the subsequent processing technology. Through comprehensive and detailed traversal analysis, the characteristic performance of the casting situation represented by each cluster in the casting mold cavity can be accurately grasped.

[0022] Step S140, mapping the multi-level molten state and the pouring characteristics to determine the liquid filling capacity. Specifically, a one-to-one correspondence is established between the multi-level molten state of the target metal identified previously and the pouring characteristics obtained by traversing the clusters. The mapping is like building a bridge to connect the change of the molten state with the actual performance in the pouring process. By analyzing the mapping relationship, it is understood how the pouring characteristics change accordingly under different molten conditions, so that the liquid filling capacity of the target metal can be accurately and comprehensively evaluated and determined, which has extremely important guiding significance for optimizing the casting process, improving the quality of castings, and predicting casting results.

[0023] Step S200, based on the casting constraint features, the workpiece features and equipment specifications, a low-element casting simulation is performed to determine the directional casting strategy for the entire casting cycle of the workpiece, wherein the low-element casting simulation is based on simulation redundancy reduction and simulation simplification as the standard. Specifically, the casting constraint features are obtained, including the structural characteristics of the mold, such as the shape, size, complexity of the cavity, and the layout and parameters of the casting system, etc., the workpiece features are clarified, such as the geometric shape, size, precision requirements, and material properties of the workpiece, and the equipment specifications are understood, such as the maximum casting speed, temperature control range, and pressure bearing capacity of the casting equipment. Based on the various information obtained above, a low-element casting simulation is performed, based on simulation redundancy reduction and simulation simplification as the standard, discarding the elements and complex calculation processes that have little or no effect on the final result, and only retaining the key elements that have a significant impact on the casting results. For example, in the simulation model, the influence of the slight roughness of the mold surface on the flow of the molten metal is simplified, or some in specific The heat transfer method with less effect under certain conditions is simplified to reduce unnecessary calculation and data processing, thereby improving the efficiency and feasibility of simulation. When conducting low-element casting simulation, the flow, filling and solidification process of molten metal in the entire casting cycle of the workpiece is simulated to obtain key parameters such as velocity distribution, temperature change, and pressure change of the molten metal. Through the analysis and evaluation of the simulation results, various factors are comprehensively analyzed to finally determine the directional casting strategy for the entire casting cycle of the workpiece. The strategy covers a series of specific operational instructions such as the start time of casting, the change curve of casting speed, the control of casting temperature, and the pause and continuation of casting, so as to ensure that the molten metal can fill the cavity evenly and stably to avoid defects, while meeting the quality requirements and production efficiency requirements of the workpiece.

[0024] In a possible implementation, based on the casting constraint features, the workpiece features and equipment specifications, a low-element casting simulation is performed to determine the directional casting strategy for the entire casting cycle of the workpiece, wherein the low-element casting simulation is based on simulation redundancy reduction and simulation simplification as the standard, and step S200 further includes step S210, interactive casting simulation data, data redundancy screening and simulation simplification based on simulation analysis requirements, and determining pre-simulation conditions. Specifically, in actual operation, the acquisition of interactive casting simulation data is achieved through a professional database management system and a data exchange protocol. For the acquired data, according to the clearly formulated simulation analysis requirements, for example, the focus this time is on the influence of the casting speed and temperature and the metal liquid composition on the casting quality, the principal component analysis algorithm is used to accurately and efficiently screen out data that is not related to the factors, such as the appearance color of the mold, the supplier of the material and other obviously redundant data, and with the help of the simplification function of the finite element analysis model, the complex simulation model is effectively simplified, such as simplifying the fine three-dimensional mold structure into a two-dimensional model with a coarser grid with similar flow and heat transfer characteristics, and determining the pre-simulation conditions that meet the subsequent simulation requirements.

[0025] Step S220, performing pouring simulation based on the pre-simulation conditions. Specifically, after determining the pre-simulation conditions, commercial simulation software is used in combination with a high-performance computing cluster to perform pouring simulation to obtain results with practical application value.

[0026] Step S230, wherein the simulation analysis requirements include simulation elements and simulation restoration degree, and data redundancy screening and simulation simplification are performed based on the simulation analysis requirements, including. Specifically, the simulation analysis requirements can be specifically and clearly defined and described, and the simulation elements can be clearly defined as key factors such as pouring speed, molten metal temperature, molten metal composition, and mold material. The simulation restoration degree can be quantified and clarified by setting specific accuracy requirements, such as requiring the error between the simulation result and the actual measurement result to be within 5%.

[0027] Step S240, based on the simulation elements, the data parts corresponding to the invalid simulation elements in the casting simulation data are screened out. Specifically, in actual data processing, relying on professional knowledge and experience, as well as pre-set simulation element standards, invalid simulation elements that have no direct effect on the current simulation analysis are identified. For example, when studying the flow and solidification of molten metal, the element of tiny scratches on the mold surface can be quickly and thoroughly screened out using data screening scripts, thereby significantly reducing the amount of data and improving the efficiency of subsequent processing.

[0028] Step S250, based on the simulation restoration degree, the effective simulation elements are simplified and simulated. Specifically, according to the pre-set and specific simulation restoration degree requirements, such as requiring the simulation results to reflect the actual situation to an extent of 80%, the simulation elements that are identified as effective, such as the flow velocity of the molten metal, can be simplified using the standard k-ε model in the turbulence model. For the heat transfer process, the lumped parameter method can be used for simplification, ensuring that the simulation results can meet the preset restoration degree requirements, and greatly improving the simulation operation speed and efficiency.

[0029] Step S300, traverse the directional pouring strategy, set the deviation correction trigger matrix, wherein the deviation correction trigger point of each deviation correction element is different, and the deviation correction element includes a control element and a response element. Specifically, the determined directional pouring strategy is traversed, and every detail of the strategy, every possible situation, and the response methods under different conditions are checked and studied. In the process of traversal, the deviation correction trigger matrix is ​​set. The matrix is ​​the key basis for judging when the pouring process needs to be corrected. The deviation correction elements include control elements and response elements. The control elements mainly refer to those factors that can be actively adjusted and controlled, such as the adjustment range of the pouring speed, the change in the pouring temperature, the extension or shortening of the pouring time, etc. The response element is the passive feedback and response to various changes in the pouring process, such as changes in the fluidity of the molten metal, the increase or decrease in the pressure in the mold, the degree of shrinkage during the solidification of the casting, etc., due to the differences in the nature, importance and influence of each correction element on the final pouring effect. , so their respective correction trigger points are also different. Take the pouring speed in the control element as an example. If the pre-set pouring speed is a specific value, when the actual pouring speed deviates from the set value to a certain extent, the correction operation will be triggered. The degree of deviation is the correction trigger point of the pouring speed control element. For the mold pressure in the response element, if a safe pressure range is set according to the material and structural strength of the mold, when the mold pressure exceeds this range, the correction measure will be triggered. The boundary of the pressure range is the correction trigger point of the response element of the mold pressure. By accurately setting a unique and appropriate correction trigger point for each correction element, a complete, accurate and targeted correction trigger matrix is ​​constructed, which provides a solid foundation and reliable basis for timely discovery and effective correction of deviations in the pouring process.

[0030] In a possible implementation, the directional pouring strategy is traversed, and a correction trigger matrix is ​​set, wherein the correction trigger points of each correction element are different, and the correction element includes a control element and a response element. Step S300 further includes step S310, traversing the directional pouring strategy, combining the casting record, and mining the risk elements of the entire strategy cycle, wherein the risk elements are marked with strategy nodes. Specifically, the determined directional pouring strategy is checked, combined with the past casting records, and experience is obtained from the records. Through in-depth analysis, the risk elements that may exist in the entire strategy execution cycle are mined, and the corresponding strategy nodes are marked for each risk element, that is, it is clear at which specific link or step of the strategy the risk may occur.

[0031] Step S320, based on sensitivity and influence, set the deviation tolerance interval for the risk factor, wherein the deviation tolerance interval is positively correlated with sensitivity and influence. Specifically, for each risk factor mined, evaluate its sensitivity and influence. Sensitivity refers to the ease with which the risk factor is disturbed or changed by external factors, such as the impact of vibration on the accuracy of the pouring position. If the accuracy of the pouring position is easily deviated due to vibration, the sensitivity is high. The influence refers to the degree of influence of the risk factor on the overall pouring of the entire workpiece once a problem occurs. Based on the two evaluation indicators, set the deviation tolerance interval for each risk factor. The deviation tolerance interval is positively correlated with sensitivity and influence, that is, the higher the sensitivity and the greater the influence of the risk factor, the wider its deviation tolerance interval.

[0032] Step S330, integrate the deviation tolerance intervals, set the deviation correction trigger with the interval critical value, and integrate to generate the deviation correction trigger matrix. Specifically, the deviation tolerance intervals of all risk factors are comprehensively sorted and integrated, and the critical value of each deviation tolerance interval is used as the trigger point to determine whether a deviation correction operation is required. Through integration and setting, a complete deviation correction trigger matrix is ​​finally generated. The matrix can monitor the changes of risk factors in real time during the pouring process. Once the critical value is reached or exceeded, the deviation correction action is triggered in time to ensure the smooth progress of the pouring process and the stability of the workpiece quality.

[0033] Step S400, PLC programming is performed on the directional pouring strategy and the correction trigger matrix to perform automated pouring control and correction response to deviation exceeding the limit. Specifically, the directional pouring strategy and the correction trigger matrix are converted into program codes that can be recognized and executed by the PLC, and various parameters, conditions and logical relationships in the strategy and matrix are accurately digitally expressed. When programming the PLC, the input and output signals are clearly defined. The input signals include real-time monitoring data from sensors, such as pouring temperature, speed, pressure, etc. The output signals are used to control actuators, such as motors for adjusting pouring speed, heating or cooling devices for controlling pouring temperature, etc. Through programming, various regulations and requirements in the directional pouring strategy are converted into the control logic of the PLC. For example, it is set to output specific control signals at specific times or conditions to achieve predetermined pouring speed and temperature changes, and the correction trigger is set to output specific control signals at specific times or conditions to achieve predetermined pouring speed and temperature changes. The deviation judgment conditions and corresponding corrective actions in the matrix are also programmed into the PLC program. When the input monitoring data indicates that the actual pouring situation deviates from the predetermined strategy and the deviation exceeds the set threshold, the PLC can quickly identify and issue control instructions based on the preset corrective action. In the actual pouring process, the PLC system receives and processes input signals in real time, and performs automated pouring control according to the programmed logic. Once the deviation exceeds the limit, the corrective response is immediately initiated, and the pouring parameters are adjusted in time to ensure that the pouring process always complies with the predetermined strategy, thereby ensuring the final pouring quality. The entire process realizes the transformation from strategy and matrix to PLC program, and then to actual automated control and timely correction to form a pouring control system.

[0034] Step S500, synchronously perform pouring monitoring, pre-process the front end and return the real-time pouring data. Specifically, during the pouring process, pouring monitoring is carried out synchronously, and various sensors and monitoring equipment, such as temperature sensors, pressure sensors, flow rate sensors, etc., are arranged at the pouring site to collect the key parameters of the pouring process in real time. The collected data is first pre-processed at the front end, and the front-end equipment will perform preliminary processing and screening on the original data, such as removing obvious noise interference, and converting the data format for subsequent transmission and analysis. The pre-processed data will be quickly returned to the control center or data processing server through wired or wireless communication methods. In the process of data return, an efficient and stable data transmission protocol is adopted to ensure the integrity and accuracy of the data, as well as the real-time nature. After the control center receives the real-time pouring data, it can evaluate and analyze the pouring process in real time, provide timely and accurate basis for subsequent control decisions, and realize real-time monitoring and data feedback of the pouring process.

[0035] Step S600, based on the real-time pouring data and the deviation correction response, feedback adjustment management of pouring control is performed. Specifically, relevant information of real-time pouring data and deviation correction response is obtained. Real-time pouring data is collected in real time by various sensors and monitoring equipment during the pouring process, including temperature, pressure, flow rate, pouring volume and many other key parameters. The deviation correction response is a record of the corrective measures taken by the system and their effects when deviation exceeds the limit during the pouring process. The data and response are deeply analyzed and evaluated, and the changing trend of the real-time pouring data is analyzed to determine whether it meets the expected pouring control target. The effectiveness of the deviation correction response is evaluated to see whether it successfully controls the deviation within an acceptable range. According to the results of the analysis and evaluation, a corresponding feedback adjustment strategy is formulated. If the real-time pouring data shows that certain parameters deviate from the predetermined range, or the deviation correction response effect is not ideal, The pouring control parameters need to be adjusted. For example, if the temperature is too high, the pouring speed needs to be reduced or the working parameters of the cooling system need to be adjusted. If the correction response fails to effectively control the deviation, the correction trigger conditions need to be reset or the amplitude of the correction action needs to be adjusted. After the feedback adjustment strategy is formulated, the strategy is converted into specific control instructions, and adjustments are implemented through corresponding control equipment and systems. For example, the pouring speed can be changed by adjusting the motor speed, and the flow rate can be adjusted by controlling the valve. After the feedback adjustment is implemented, the pouring process continues to be monitored and data collected to form a continuous closed-loop feedback adjustment management process, and the pouring control is continuously optimized according to new data and responses to ensure that the entire pouring process is always in a good control state, and finally a high-quality cast product is obtained.

[0036] In a possible implementation, based on the real-time pouring data and the correction response, feedback adjustment management of pouring control is performed, and step S600 further includes step S610, obtaining solidification requirements, and the solidification requirements include synchronous solidification standards and sequential solidification standards. Specifically, the specific requirements for solidification are obtained from relevant process documents, design specifications or customer needs, and the synchronous solidification standards and sequential solidification standards are clearly covered. The synchronous solidification standards usually involve relevant regulations that all parts of the casting should complete solidification as much as possible at the same time under specific conditions; the sequential solidification standards focus on the specific requirements for different parts of the casting to solidify in a certain order.

[0037] Step S620, based on the synchronous solidification standard, determine the first fast flow rate threshold. Specifically, according to the acquired synchronous solidification standard, analysis and calculation are performed, and it is analyzed that synchronous solidification requires the molten metal to be quickly and evenly distributed and solidified in the mold. Through relevant theoretical models, empirical formulas and actual experimental data, a faster flow rate threshold that can meet the synchronous solidification requirements is determined, that is, the first fast flow rate threshold, which ensures that the molten metal can quickly fill the mold within the specified time and achieve the effect of synchronous solidification.

[0038] Step S630, based on the sequential solidification standard, determine the second slow flow rate threshold. Specifically, according to the sequential solidification standard, since sequential solidification requires different parts of the casting to solidify in a specific order and time, it is necessary to more accurately control the flow rate of the molten metal. Through the simulation analysis of the flow and solidification of the molten metal during the sequential solidification process, combined with the empirical parameters in actual production, a relatively slow flow rate threshold is determined, that is, the second slow flow rate threshold, which helps to achieve the solidification of the casting in a predetermined sequence, thereby achieving the expected quality and performance requirements.

[0039] Step S640, based on the first fast flow rate threshold and the second slow flow rate threshold, the pouring flow rate is controlled. Specifically, after determining the first fast flow rate threshold and the second slow flow rate threshold, the two thresholds are applied to the flow rate control during the pouring process. In the actual pouring operation, the flow rate of the molten metal is monitored in real time. If the flow rate is lower than the second slow flow rate threshold, measures are taken to increase the flow rate to meet the requirements of sequential solidification; if the flow rate is higher than the first fast flow rate threshold, the flow rate is appropriately reduced to avoid uneven solidification or other quality problems caused by excessive flow. By continuously comparing and adjusting the real-time flow rate with the two thresholds, precise control of the pouring flow rate is achieved, thereby ensuring that the solidification process meets the expected standards.

[0040] Step S650, wherein, if the flow rate amplitude modulation is greater than the preset amplitude modulation, the instantaneous flow rate regulation is converted to a multi-step continuous regulation. Specifically, during the flow rate regulation process, if the flow rate amplitude that needs to be adjusted exceeds the preset amplitude value, in order to avoid excessive impact and instability on the pouring process, the original instantaneous flow rate regulation method will be converted to a multi-step continuous regulation, which means that the flow rate is not adjusted to the target value at one time, but is gradually adjusted in multiple smaller steps. For example, if the flow rate needs to be greatly reduced from a higher value, it is not reduced instantly, but the flow rate is gradually reduced in multiple times, each time by a smaller amplitude, until the target flow rate is reached. The multi-step continuous regulation method can make the pouring process more stable and controllable, reduce the adverse effects that may be caused by sudden changes in flow rate, and further improve the stability of pouring quality and solidification effect.

[0041] In a possible implementation, the pouring flow rate is controlled based on the first fast flow rate threshold and the second slow flow rate threshold, and step S640 further includes step S641, switching of the pouring basin and directional constraints of the pouring liquid are performed based on the pouring liquid state and the solidification requirements, wherein the pouring liquid state includes the pouring liquid uniformity, pouring liquid flow rate, and the pouring liquid slag content. Specifically, during the entire pouring process, the pouring liquid state information is continuously monitored and obtained, including key parameters such as its uniformity, flow rate, and slag content, and the set solidification requirements are clarified, whether it is a synchronous solidification standard or a sequential solidification standard, and whether to switch the pouring basin and constrain the flow direction of the pouring liquid is determined according to the information and requirements.

[0042] Step S642, wherein, if the uniformity of the pouring liquid does not meet the preset uniformity / the actual flow rate of the pouring liquid is greater than the pre-controlled flow rate / the slag content of the pouring liquid is greater than the preset slag content, the ordinary pouring basin is switched to the inoculated pouring basin. Specifically, the acquired pouring liquid state parameters are evaluated in real time. If it is found that the uniformity of the pouring liquid does not meet the preset standard, it means that it may affect the solidification effect and the quality of the casting; or the actual flow rate of the pouring liquid exceeds the pre-controlled flow rate, resulting in a loss of control of the solidification process; or the slag content of the pouring liquid exceeds the preset slag content, introducing impurities that affect the quality. In any of the above situations, in order to improve the pouring conditions, the ordinary pouring basin originally used will be switched to the inoculated pouring basin.

[0043] Step S643, wherein, if it is the synchronous solidification standard, an ordinary pouring basin is applied, and if it is the sequential solidification standard, the ordinary pouring basin and the inoculation pouring basin are switched based on the state of the casting liquid. Specifically, if the solidification requirement is the synchronous solidification standard, since synchronous solidification usually requires a faster flow rate and time limit, an ordinary pouring basin can meet this requirement more directly and quickly, so an ordinary pouring basin is applied at this time, and if it is the sequential solidification standard, due to the complexity of its solidification process and more sophisticated requirements for conditions, it is necessary to decide whether to continue to use the ordinary pouring basin or switch to the inoculation pouring basin based on the actual state of the casting liquid, that is, uniformity, flow rate and slag content, etc., through a flexible switching mechanism to adapt to different solidification standards and actual casting liquid states, thereby ensuring that the final solidification effect and casting quality meet expectations.

[0044] In a possible implementation, if the uniformity of the pouring liquid does not meet the preset uniformity / the actual flow rate of the pouring liquid is greater than the pre-controlled flow rate / the slag content of the pouring liquid is greater than the preset slag content, the ordinary pouring basin is switched to the inoculation pouring basin, and step S642 further includes step S6421, the inoculation pouring basin includes a first chamber and a second chamber isolated by an inoculation plate, and the inoculation plate is provided with a plurality of through holes. Specifically, it is clarified that it is composed of two chambers, the two chambers are isolated from each other by an inoculation plate, and there are a plurality of through holes on the inoculation plate, which lays the foundation for the subsequent description of the flow process of the pouring liquid.

[0045] Step S6422, the pouring liquid in the first chamber is diverted and buffered based on the through holes opened on the inoculation plate, and then transferred to the second chamber for workpiece casting. Specifically, the pouring liquid in the first chamber will be diverted through these through holes when it contacts the inoculation plate because of the through holes opened on the inoculation plate. In the process of passing through the through holes, the flow rate and pressure of the pouring liquid will change, which plays a buffering role. The pouring liquid after diversion and buffering will flow to the second chamber, and then flow out of the second chamber for workpiece casting, so that the pouring liquid can be more evenly distributed and in a more stable flow state before entering the workpiece, thereby helping to improve the casting quality.

[0046] The embodiment of the present application adopts the method of exploring the target metal liquid filling capacity of the casting, matching the pouring constraint characteristics with the workpiece characteristics, and based on this, performing low-element pouring simulation to determine the directional pouring strategy, traversing the strategy to set the correction trigger matrix, and performing PLC programming on the strategy and matrix for control and correction, synchronously monitoring and returning data, and performing feedback adjustment management based on the data and correction response. By realizing accurate, efficient, flexible and timely feedback and adjustment control of the molten metal pouring, the technical effect of improving the quality of castings, improving production efficiency and reducing the scrap rate is achieved.

[0047] In the above, refer to Figure 1 The metal casting control method for molten metal according to an embodiment of the present invention is described in detail. Figure 2 A molten metal pouring control device for metal casting according to an embodiment of the present invention is described.

[0048] The molten metal pouring control device for metal casting according to the embodiment of the present invention is used to solve the technical problems in the prior art that the control of the molten metal pouring process is not accurate, efficient, flexible, and cannot be timely fed back and adjusted. By realizing accurate, efficient, flexible, and timely feedback and adjustment control of the molten metal pouring, the technical effects of improving the quality of castings, improving production efficiency, and reducing the scrap rate are achieved. The molten metal pouring control device for metal casting includes: a pouring constraint feature matching module 10, a pouring simulation module 20, a correction trigger matrix setting module 30, a programming module 40, a pouring monitoring synchronization module 50, and a feedback adjustment management module 60.

[0049] The casting constraint feature matching module 10 is used to explore the liquid filling capacity of the casting target metal, and match the casting constraint features in combination with the workpiece features, wherein the liquid filling capacity corresponds to a multi-level melting state;

[0050] The pouring simulation module 20 is used to perform low-element pouring simulation based on the pouring constraint characteristics, the workpiece characteristics and equipment specifications, and determine the directional pouring strategy for the full pouring cycle of the workpiece, wherein the low-element pouring simulation is based on simulation redundancy reduction and simulation simplification as standards;

[0051] The correction trigger matrix setting module 30 is used to traverse the directional pouring strategy and set the correction trigger matrix, wherein the correction trigger point of each correction element is different, and the correction element includes a control element and a response element;

[0052] The programming module 40 is used to perform PLC programming on the directional pouring strategy and the deviation correction trigger matrix, and perform automatic pouring control and deviation correction response when the deviation exceeds the limit;

[0053] The pouring monitoring synchronization module 50 is used to synchronously perform pouring monitoring, pre-process at the front end and return real-time pouring data;

[0054] The feedback adjustment management module 60 is used to perform feedback adjustment management of pouring control based on the real-time pouring data and the deviation correction response.

[0055] The specific configuration of the pouring constraint feature matching module 10 will be described in detail below. As described above, the liquid filling capacity of the casting target metal is excavated, and the pouring constraint features are matched in combination with the workpiece features, wherein the liquid filling capacity corresponds to a multi-level molten state, and the pouring constraint feature matching module 10 further includes: an industrial big data retrieval unit, the industrial big data retrieval unit is used to perform industrial big data retrieval to determine the casting record with the target metal as an index; a clustering processing unit, the clustering processing unit is used to cluster the casting record based on the multi-level molten state to determine a plurality of clustering clusters; a pouring feature determination unit, the pouring feature determination unit is used to traverse the plurality of clustering clusters to determine the pouring features of the casting mold cavity, wherein the pouring features at least include fluidity and solidification characteristics; a liquid filling capacity determination unit, the liquid filling capacity determination unit is used to map the multi-level molten state and the pouring features to determine the liquid filling capacity.

[0056] The specific configuration of the pouring simulation module 20 will be described in detail below. As described above, based on the pouring constraint features, the workpiece features and equipment specifications, a low-element pouring simulation is performed to determine the directional pouring strategy for the entire pouring cycle of the workpiece, wherein the low-element pouring simulation is based on simulation redundancy reduction and simulation simplification as the standard, and the pouring simulation module 20 further includes: a pre-simulation condition determination unit, the pre-simulation condition determination unit is used to interact with the pouring simulation data, perform data redundancy screening and simulation simplification based on the simulation analysis requirements, and determine the pre-simulation conditions; a pouring simulation unit, the pouring simulation unit is used to perform pouring simulation based on the pre-simulation conditions; a simulation analysis requirement composition unit, the simulation analysis requirement composition unit is used in which the simulation analysis requirements include simulation elements and simulation restoration degree, and perform data redundancy screening and simulation simplification based on the simulation analysis requirements, including: a data screening unit, the data screening unit is used to screen out the data portion corresponding to the invalid simulation elements in the pouring simulation data based on the simulation elements; a simplified simulation processing unit, the simplified simulation processing unit is used to perform simplified simulation processing on the effective simulation elements based on the simulation restoration degree.

[0057] The specific configuration of the correction trigger matrix setting module 30 will be described in detail below. As described above, the directional pouring strategy is traversed to set the correction trigger matrix, wherein the correction trigger points of each correction element are different, and the correction element includes a control element and a response element. The correction trigger matrix setting module 30 further includes: a risk factor mining unit, the risk factor mining unit is used to traverse the directional pouring strategy, and in combination with the casting record, to mine the risk factors of the entire strategy cycle, and the risk factors are marked with strategy nodes; a deviation tolerance interval setting unit, the deviation tolerance interval setting unit is used to set the deviation tolerance interval for the risk factor based on sensitivity and influence, wherein the deviation tolerance interval is positively correlated with sensitivity and influence; a correction trigger setting unit, the correction trigger setting unit is used to integrate the deviation tolerance interval, set the correction trigger with the interval critical value, and integrate to generate the correction trigger matrix.

[0058] The specific configuration of the feedback regulation management module 60 will be described in detail below. As described above, based on the real-time pouring data and the correction response, the feedback regulation management of the pouring control is performed, and the feedback regulation management module 60 further includes: a solidification requirement acquisition unit, the solidification requirement acquisition unit is used to acquire the solidification requirement, and the solidification requirement includes a synchronous solidification standard and a sequential solidification standard; a first fast flow rate threshold determination unit, the first fast flow rate threshold determination unit is used to determine the first fast flow rate threshold based on the synchronous solidification standard; a second slow flow rate threshold determination unit, the second slow flow rate threshold determination unit is used to determine the second slow flow rate threshold based on the sequential solidification standard; a pouring flow rate control unit, the pouring flow rate control unit is used to control the pouring flow rate based on the first fast flow rate threshold and the second slow flow rate threshold; a multi-step continuous adjustment unit, the multi-step continuous adjustment unit is used in which, if the flow rate amplitude modulation is greater than the preset amplitude modulation, the instantaneous flow rate regulation is converted into a multi-step continuous adjustment.

[0059] Wherein, the pouring flow rate control unit is used to control the pouring flow rate based on the first fast flow rate threshold and the second slow flow rate threshold, and the pouring flow rate control unit further includes: a gate basin switching subunit, the gate basin switching subunit is used to switch the gate basin and constrain the pouring liquid orientation based on the pouring liquid state and the solidification requirement, wherein the pouring liquid state includes the pouring liquid uniformity, the pouring liquid flow rate, and the pouring liquid slag content; an inoculation gate basin switching subunit, the inoculation gate basin switching subunit is used to switch the ordinary gate basin to the inoculation gate basin if the pouring liquid uniformity does not meet the preset uniformity / the actual pouring liquid flow rate is greater than the pre-controlled flow rate / the pouring liquid slag content is greater than the preset slag content; a gate basin application judgment subunit, the gate basin application judgment subunit is used to apply the ordinary gate basin if it is the synchronous solidification standard, and switch the ordinary gate basin and the inoculation gate basin based on the pouring liquid state if it is the sequential solidification standard.

[0060] Among them, the inoculation gate basin switching subunit is used, if the uniformity of the casting liquid does not meet the preset uniformity / the actual flow rate of the casting liquid is greater than the pre-controlled flow rate / the slag content of the casting liquid is greater than the preset slag content, the ordinary gate basin is switched to the inoculation gate basin, and the inoculation gate basin switching subunit further includes: an inoculation gate basin structure microunit, the inoculation gate basin structure microunit is used for the inoculation gate basin to include a chamber and a second chamber isolated based on an inoculation plate, and a plurality of through holes are opened on the inoculation plate; a diversion buffer microunit, the diversion buffer microunit is used for the casting liquid in the first chamber, based on the through holes opened in the inoculation plate, to perform diversion buffering, and then transfer to the second chamber for workpiece casting.

[0061] The molten metal pouring control device for metal casting provided in an embodiment of the present invention can execute the molten metal pouring control method for metal casting provided in any embodiment of the present invention, and has the corresponding functional modules and beneficial effects of the execution method.

[0062] Although the present application makes various references to certain modules in the device according to the embodiments of the present application, any number of different modules may be used and run on the user terminal and / or server, and the various units and modules included are only divided according to functional logic, but are not limited to the above division, as long as the corresponding functions can be achieved; in addition, the specific names of the functional units are only for the convenience of distinguishing each other, and are not used to limit the scope of protection of the present invention.

[0063] The above specific implementation manner does not constitute a limitation to the protection scope of the present application. It should be understood by those skilled in the art that various modifications, combinations and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present application should be included in the protection scope of the present application. In some cases, the actions or steps recorded in the present application can be performed in an order different from that in the embodiment and can still achieve the desired results. In addition, the process depicted in the accompanying drawings does not necessarily require the specific order or continuous order shown to achieve the desired results. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

Claims

1. A method for controlling the pouring of molten metal for metal casting, characterized in that: The method comprises: Exploring the liquid filling capacity of the casting target metal, combining the workpiece characteristics, and matching the casting constraint characteristics, wherein the liquid filling capacity corresponds to a multi-level molten state; Based on the casting constraint characteristics, the workpiece characteristics and equipment specifications, a low-element casting simulation is performed to determine a directional casting strategy for the entire casting cycle of the workpiece, wherein the low-element casting simulation is based on simulation redundancy reduction and simulation simplification as standards; Traversing the directional pouring strategy, setting a deviation correction trigger matrix, wherein the deviation correction trigger point of each deviation correction element is different, and the deviation correction element includes a control element and a response element; PLC programming is performed on the directional pouring strategy and the deviation correction trigger matrix to perform automated pouring control and deviation correction response when the deviation exceeds the limit; Simultaneously monitor pouring, pre-process at the front end and send back real-time pouring data; Based on the real-time pouring data and the deviation correction response, feedback adjustment management of pouring control is performed; The low-element pouring simulation comprises: Interactive pouring simulation data, data redundancy screening and simulation simplification based on simulation analysis requirements, and determine pre-simulation conditions; Based on the pre-simulation conditions, performing pouring simulation; The simulation analysis requirements include simulation elements and simulation restoration degree, and data redundancy screening and simulation simplification are performed based on the simulation analysis requirements, including: Based on the simulation elements, the data portion corresponding to the invalid simulation elements in the casting simulation data is screened out; Based on the degree of simulation restoration, the effective simulation elements are simplified for simulation processing; The method of exploring the liquid filling capacity of the casting target metal includes: Using the target metal as an index, industrial big data retrieval is performed to determine casting records; Based on the multi-level melting states, clustering the casting records to determine a plurality of clusters; Traversing the plurality of clusters to determine the pouring characteristics of the pouring mold cavity, wherein the pouring characteristics at least include fluidity and solidification characteristics; Mapping the multi-stage melting state and the casting characteristics to determine the liquid filling capacity; The traversing the directional pouring strategy and setting the deviation correction trigger matrix includes: Traversing the directional casting strategy, combining the casting records, mining the risk factors of the whole cycle of the strategy, wherein the risk factors are marked with strategy nodes; Based on the sensitivity and impact, a deviation tolerance interval is set for the risk factor, wherein the deviation tolerance interval is positively correlated with the sensitivity and impact; The deviation tolerance intervals are integrated, and correction trigger settings are performed based on interval thresholds, and the correction trigger matrix is ​​generated through integration.

2. The method for controlling the pouring of molten metal for metal casting according to claim 1, characterized in that: The method further comprises: Acquiring solidification requirements, wherein the solidification requirements include synchronous solidification standards and sequential solidification standards; determining a first fast flow rate threshold based on a synchronous coagulation criterion; Based on the sequential coagulation criteria, determining a second slow flow rate threshold; Based on the first fast flow rate threshold and the second slow flow rate threshold, performing pouring flow rate control; If the flow rate amplitude modulation is greater than the preset amplitude modulation, the instantaneous flow rate regulation is converted into multi-step continuous regulation.

3. The method for controlling the pouring of molten metal for metal casting according to claim 2, characterized in that: The method further comprises: Based on the pouring liquid state and the solidification requirements, switching of the pouring basin and directional constraints of the pouring liquid are performed, wherein the pouring liquid state includes pouring liquid uniformity, pouring liquid flow rate, and pouring liquid slag content; If the uniformity of the pouring liquid does not meet the preset uniformity / the actual flow rate of the pouring liquid is greater than the pre-controlled flow rate / the slag content of the pouring liquid is greater than the preset slag content, the ordinary pouring basin is switched to the inoculated pouring basin; Among them, if the synchronous solidification standard is adopted, a common pouring basin is applied; if the sequential solidification standard is adopted, the common pouring basin and the inoculation pouring basin are switched based on the state of the pouring liquid.

4. The method for controlling the pouring of molten metal for metal casting according to claim 3, characterized in that: The method further comprises: The inoculation pouring basin comprises a first chamber and a second chamber separated by an inoculation plate, and the inoculation plate is provided with a plurality of through holes; The pouring liquid in the first chamber is divided and buffered based on the through holes opened in the inoculation plate, and then flows to the second chamber for pouring the workpiece.

5. A molten metal pouring control device for metal casting, characterized in that: The device is used to implement the molten metal pouring control method for metal casting according to any one of claims 1 to 4, and the device comprises: A casting constraint feature matching module, which is used to explore the liquid filling capacity of the casting target metal and match the casting constraint features in combination with the workpiece features, wherein the liquid filling capacity corresponds to a multi-level melting state; A casting simulation module, wherein the casting simulation module is used to perform low-element casting simulation based on the casting constraint characteristics, the workpiece characteristics and equipment specifications, and determine the directional casting strategy for the entire casting cycle of the workpiece, wherein the low-element casting simulation is based on simulation redundancy reduction and simulation simplification as standards; A deviation correction trigger matrix setting module, wherein the deviation correction trigger matrix setting module is used to traverse the directional pouring strategy and set a deviation correction trigger matrix, wherein the deviation correction trigger point of each deviation correction element is different, and the deviation correction element includes a control element and a response element; A programming module, the programming module is used to perform PLC programming on the directional pouring strategy and the deviation correction trigger matrix, and perform automatic pouring control and deviation correction response when the deviation exceeds the limit; A pouring monitoring synchronization module, which is used to synchronously perform pouring monitoring, pre-process at the front end, and return real-time pouring data; A feedback regulation management module is used to perform feedback regulation management of pouring control based on the real-time pouring data and the deviation correction response.

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