Support casting mold with high yield and machining method thereof

Abstract

The invention relates to a high-yield support casting mold and a machining method thereof, and belongs to the technical field of casting molds, the high-yield support casting mold comprises a mold body, a monitoring module and a control module, the control module is electrically connected with the monitoring module, and the mold body is used for casting a support; the monitoring module comprises a plurality of temperature sensors, and the temperature sensors are arranged on the surface of a mold in the arc direction of a support corresponding to the mold and used for detecting the surrounding temperature of the temperature sensors and uploading the temperature data to the control module. The control module judges whether the variance of the plurality of temperature data exceeds a threshold value or not, and gives an alarm when the judgment result is yes; the device has the characteristics of high detection accuracy and capability of ensuring the yield of the brake pad bracket.

Description

Technical Field

[0001] The invention belongs to the technical field of casting molds, and in particular relates to a bracket casting mold with high yield rate and a processing method thereof. Background Art

[0002] Automobile brake pads are an important part of the automobile braking system. When the car is running, the automobile brake pads are fixed in the car wheels by brake pad brackets. When in use, they clamp the wheel components to complete the braking.

[0003] A general brake pad structure, such as a brake pad bracket disclosed in Chinese patent CN202597554U, comprises a bracket panel and a connecting frame, wherein the connecting frame is fixed on the bracket panel, and is characterized in that the bracket panel is provided with a limiting hole, the connecting frame is provided with a boss, and the boss cooperates with the limiting hole on the bracket panel; the bracket panel is also provided with a friction plate riveting hole, and the connection stability between the connecting frame and the bracket panel is good; its shape is an elongated arc, and the force direction is along its own arc edge, therefore, it is necessary to ensure the structural strength consistency of the brake pad bracket along the arc edge, and further it is necessary to ensure that the brake pad is cast. When the temperature is consistent at various places, the output rate of the brake pad bracket is finally guaranteed. The existing temperature-controlled casting mold, such as a casting mold and a method for detecting the temperature distribution of molten metal in a casting mold disclosed in Chinese patent CN107921527B, includes a copper plate and a plurality of optical fibers arranged to measure the temperature of the copper plate. Each optical fiber has a plurality of temperature measurement points arranged to measure the temperature of the copper plate while casting. By dividing the optical fibers into groups and arranging these groups to have a distance between each other, the total number of temperature measurement points can reach 500 to 1500, thereby achieving high resolution. In order to achieve higher temperature and position measurement resolution, a total number of at least 3000 temperature measurement points can be arranged; however, in the above structure, it does not make targeted improvements to the structural characteristics of the brake pad bracket, and the averagely set several sampling points cannot meet the requirements of ensuring consistency along the arc when the brake pad bracket is cast, and the detection accuracy is insufficient. Therefore, a bracket casting mold and a processing method thereof with high detection accuracy and ensuring the output rate of the brake pad bracket are required. Summary of the invention

[0004] In order to solve the above problems existing in the prior art, the present invention provides a bracket casting mold with high yield rate and a processing method thereof, which has the characteristics of high detection accuracy and ensuring the yield rate of the brake pad bracket.

[0005] The purpose of the present invention can be achieved through the following technical solutions:

[0006] A bracket casting mold with high production rate, comprising a mold body

[0007] A monitoring module and a control module, wherein the control module is electrically connected to the monitoring module, and the mold body is used for casting the bracket;

[0008] The monitoring module includes a plurality of temperature sensors, and the plurality of temperature sensors are arranged on the mold surface along the arc direction of the mold corresponding bracket. The plurality of temperature sensors are used to detect the temperature around themselves and upload a plurality of temperature data to the control module. The control module determines whether the variance of the plurality of temperature data exceeds a threshold value, and issues an alarm if the judgment result is yes.

[0009] As a preferred technical solution of the present invention, several of the temperature sensors are used to detect the temperature around themselves and upload several temperature data tn to the control module. The control module calculates the variance F of several temperature data t1, t2,..., tn, and determines whether the variance exceeds the variance threshold F0. When the judgment result is yes, an alarm is issued.

[0010] As a preferred technical solution of the present invention, the control module increases the variance threshold F0 when the yield rate exceeds the threshold, and the control module decreases the variance threshold F0 when the yield rate is lower than the threshold.

[0011] As a preferred technical solution of the present invention, the control module is pre-input with a yield coefficient G, the control module is pre-input with a process coefficient threshold G0, the control module calculates a correction coefficient A1, the control module calculates a variance F of a number of temperature data t1, t2, .., tn, the control module determines whether the variance exceeds F0×A1, and issues an alarm when the judgment result is yes; wherein, A1=G / G0×c, c is a pre-input constant.

[0012] As a preferred technical solution of the present invention, the control module divides a number of temperature sensors into a core group and a reference group. The control module determines whether the variance of the temperature data uploaded by the core group is greater than F1, and determines whether the variance of the temperature data uploaded by the reference group is greater than F2. The control module issues an alarm when one of the judgment results is negative; wherein F1 <F2。

[0013] As a preferred technical solution of the present invention, the control module defines the temperature sensors of the core group as edge group, center group and edge group in sequence along the arc direction of the mold corresponding bracket. The temperature sensors of the center group and edge group upload temperature data to the control module respectively, and the control module corrects the temperature data uploaded by the center group downward.

[0014] The present invention also provides a method for processing a bracket casting mold with a high yield rate, which is applicable to the above-mentioned bracket casting mold with a high yield rate.

[0015] Step 1: Casting the bracket with the mold body;

[0016] Step 2: A plurality of temperature sensors respectively monitor the mold temperature along the arc direction of the bracket, and upload a plurality of temperature data to the control module;

[0017] Step 3: The control module determines whether the variance of a number of temperature data exceeds a variance threshold.

[0018] The beneficial effects of the present invention are:

[0019] (1) By arranging a number of temperature sensors along the mold surface and along the arc direction of the bracket, the temperature sensors can collect data from various parts that need to maintain consistent temperature. At the same time, by judging the variance of the temperature data uploaded by the temperature sensors, the consistency of the molding temperature along the arc direction of the bracket is judged, thereby improving the structural strength consistency of the brake pad bracket along the arc edge.

[0020] (2) By making the control module adjust the variance threshold of the current batch according to the yield rate of the previous batch, when the yield rate is high, the judgment standard of the variance is lowered to prevent the alarm from being issued too frequently when it is not necessary, thereby affecting the production efficiency. When the yield rate is low and it is necessary to further improve the detection of the consistency of the structural strength of various parts of the bracket, the judgment standard of the variance is increased. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to facilitate understanding by those skilled in the art, the present invention is further described below with reference to the accompanying drawings.

[0022] Figure 1 It is a schematic diagram of the structure of the cavity part of the mold of the present invention and a schematic diagram of the arc edge direction;

[0023] Figure 2 This is a schematic diagram of the overall structure of the finished brake pad bracket;

[0024] Figure 3 is a control loop block diagram of the present invention;

[0025] Description of main component symbols:

[0026] In the figure: 1. mold; 11. cavity; 2. control module; 3. brake pad bracket. DETAILED DESCRIPTION

[0027] In order to further explain the technical means and effects adopted by the present invention to achieve the predetermined invention purpose, the specific implementation methods, structures, features and effects of the present invention are described in detail below in conjunction with the accompanying drawings and preferred embodiments.

[0028] See also Figure 1-3 , a bracket casting mold with high production rate, comprising a mold body;

[0029] Specifically, in this embodiment, the mold 1 body includes at least one set of templates and a cavity 11 surrounded by the templates, one side of the template is a flat metal surface, and when in use, molten metal raw materials are injected into the cavity 11 to complete the casting of the brake pad bracket 3;

[0030] In the present embodiment, specifically, the brake pad bracket 3 includes at least two arcuate strip metal sheets and a connecting sheet connecting the two arcuate strip metal sheets. The length ratio of the arcuate side and the narrow side of each arcuate strip metal sheet is greater than 4:1. At this time, the shape of the brake pad bracket 3 is an overall slender arc. When in use, the brake pad exerts a reaction force on the brake pad bracket 3, and the force direction is along its own arcuate side. Therefore, it is necessary to ensure the consistency of the structural strength of the brake pad bracket 3 along the arcuate side, and then it is necessary to ensure the consistency of the temperature at various locations when the brake pad is cast, and finally ensure the output rate of the brake pad bracket 3. For this purpose, it also includes a monitoring module and a control module 2, and the control module 2 is electrically connected to the monitoring module. The mold 1 body is used to cast the bracket;

[0031] Specifically, the monitoring module includes a plurality of temperature sensors, and the plurality of temperature sensors are arranged on a flat metal surface of the template;

[0032] At the same time, the surface of the mold 1 is arranged along the arc direction of the corresponding bracket of the mold 1. Specifically, the operator collects several measurement points in the cavity 11 along the arc edge of the brake pad bracket 3 in advance, and defines the direction perpendicular to the flat metal surface as the reference direction, and then projects several measurement points along the reference direction to the flat metal surface, and defines several projection points as temperature measurement points. Several temperature sensors are set at several temperature measurement points. At this time, when the temperature of the measurement point changes, the temperature at the measurement point is transmitted to the temperature measurement point along the metal constituting the mold 1. The temperature sensor measures the temperature at the temperature measurement point, and then measures the temperature at several measurement points, so that the control module 2 can know the temperature of several parts in the cavity 11;

[0033] Specifically, several temperature sensors are used to detect the temperature around them and upload several temperature data tn to the control module 2. The control module 2 calculates the variance F of several temperature data t1, t2, .., tn, and determines whether the variance exceeds the variance threshold F0. When the judgment result is yes, an alarm is issued.

[0034] When in use, several temperature sensors are used to detect the temperature around themselves and upload several temperature data to the control module 2. When the variance of several temperature data t1, t2, .., tn is large, it means that the temperature consistency along the arc direction is poor, the temperature consistency at various locations during casting is low, and the structural strength consistency at various locations after casting is low, which affects the yield. At this time, the control module 2 determines that the variance of several temperature data exceeds the threshold and issues an alarm. When the operator receives the alarm, he adjusts the process according to the temperature data, thereby improving the temperature consistency at various locations in the mold 1 and improving the yield.

[0035] In the actual production process, when the yield rate of the brake pad bracket 3 of the previous batch is high, it means that the current production process does not need too much adjustment. At this time, there is no need to frequently adjust the process according to the alarm to ensure production efficiency. When the yield rate of the previous batch is low, it means that the output rate is low, the consistency of the cast brake pad bracket 3 is poor, the temperature consistency of each part during casting is poor, and the detection module fails to detect the temperature inconsistency. At this time, it is necessary to improve the judgment standard of temperature consistency, make a stricter judgment on temperature consistency, and further reduce the impact of temperature inconsistency on the yield rate. For this reason, the control module 2 increases the variance threshold F0 when the yield rate exceeds the threshold, and the control module 2 reduces the variance threshold F0 when the yield rate is lower than the threshold;

[0036] Specifically, the control module 2 is pre-input with the yield coefficient G, the control module 2 is pre-input with the process coefficient threshold G0, the control module 2 calculates the correction coefficient A1, the control module 2 calculates the variance F of a number of temperature data t1, t2, .., tn, the control module 2 determines whether the variance exceeds F0×A1, and issues an alarm when the judgment result is yes; wherein A1=G / G0×c, c is a pre-input constant, and the yield coefficient is a coefficient that is positively correlated with the yield of the previous batch;

[0037] When the yield coefficient G of the previous batch is low, it means that the yield of the previous batch is low. At this time, it is necessary to improve the judgment standard of temperature consistency, make a stricter judgment on temperature consistency, and further reduce the impact of temperature inconsistency on the yield. At this time, the value of A1=G / G0×c is small. When the variance is smaller, the control module 2 will judge that the variance is too large, and an early warning will be issued when the variance is low, so as to improve the judgment standard of temperature consistency, make a stricter judgment on temperature consistency, and further reduce the impact of temperature inconsistency on the yield.

[0038] By making the control module 2 adjust the variance threshold of the current batch according to the yield rate of the previous batch, the judgment standard for the variance is lowered when the yield rate is high, so as to prevent the alarm from being issued too frequently when it is not necessary, thereby affecting the production efficiency. When the yield rate is low and it is necessary to further improve the detection of the consistency of the structural strength of various parts of the bracket, the judgment standard for the variance is increased.

[0039] In the actual casting process, there is a probability that the finished products produced in some production batches will have a low yield due to inconsistent structural strength, which is concentrated in a certain part of the casting. At this time, it is necessary to improve the judgment standard of the consistency of the temperature of this part of the casting, make a stricter judgment on the temperature consistency, and further reduce the impact of inconsistent temperature on the yield. To this end, the control module 2 divides a number of temperature sensors into a core group and a reference group. The control module 2 determines whether the variance of the temperature data uploaded by the core group is greater than F1, and determines whether the variance of the temperature data uploaded by the reference group is greater than F2. The control module 2 issues an alarm when one of the judgment results is no; among them, F1 <F2;

[0040] Specifically, the division of the core group and the reference group is determined by the operator based on the actual situation of the previous batch, so that the core group covers the area where the structural strength consistency problem occurs, and the remaining temperature sensors are classified as the reference group;

[0041] During casting, the control module 2 uses a smaller threshold F1 to determine whether the variance of the temperature data uploaded by the core group is too large, thereby improving the judgment standard for the consistency of the core group temperature;

[0042] By setting the core group and the reference group in advance and lowering the threshold for the core group variance judgment, a stricter judgment can be made on the temperature consistency of this part of the casting, further reducing the impact of temperature inconsistency on the yield.

[0043] In the actual casting process, the temperature of the center part will be affected by the surrounding temperature and become higher. At this time, the temperature of the center part cannot accurately reflect the actual casting temperature of the corresponding part, which affects the accuracy of the judgment of temperature consistency. For this reason, the control module 2 defines the temperature sensors of the core group as the edge group, the center group and the edge group in sequence along the arc direction of the corresponding bracket of the mold 1. The temperature sensors of the center group and the edge group upload the temperature data to the control module 2 respectively, and the control module 2 corrects the temperature data uploaded by the center group downward;

[0044] Specifically, the operator defines several sensors of the core group as the central group and the rest as the edge group through the control module 2. Each time the control module 2 receives several temperature data, for the data uploaded by the core group, the control module 2 multiplies it by a downward correction coefficient to complete the downward correction of the temperature data;

[0045] Through control module 2, the temperature sensors of the core group are defined as edge group, center group and edge group in sequence along the arc direction of the corresponding bracket of mold 1, and the temperature data uploaded by the center group is corrected downward, which reduces the influence of the surrounding temperature on the temperature of the center part and improves the accuracy of consistency judgment.

[0046] The present invention also provides a method for processing a bracket casting mold 1 with a high yield rate, which is applicable to the above-mentioned bracket casting mold 1 with a high yield rate.

[0047] Step 1: The mold 1 body is used to cast the bracket;

[0048] Step 2: a plurality of temperature sensors respectively monitor the temperature of the mold 1 along the arc direction of the bracket, and upload a plurality of temperature data to the control module 2;

[0049] Step 3: The control module 2 determines whether the variance of a number of temperature data exceeds a variance threshold.

[0050] The working principle and use process of the present invention:

[0051] When in use, molten metal raw material is injected into the mold cavity 11 to complete the casting of the brake pad bracket 3;

[0052] Several temperature sensors are used to detect the temperature around themselves and upload several temperature data to the control module 2. The control module 2 determines whether the variance of several temperature data exceeds the threshold value and issues an alarm when the judgment result is yes. The above is only a preferred embodiment of the present invention and does not limit the present invention in any form. Although the present invention has been disclosed as a preferred embodiment as above, it is not used to limit the present invention. Any technical personnel in this field can make some changes or modify the technical content disclosed above to an equivalent embodiment of equivalent changes without departing from the scope of the technical solution of the present invention. However, any brief modification, equivalent change and modification made to the above embodiment according to the technical essence of the present invention without departing from the content of the technical solution of the present invention still belongs to the scope of the technical solution of the present invention.

Claims

1. A bracket casting mold with high yield, characterized in that: It includes a mold body, a monitoring module and a control module, wherein the control module is electrically connected to the monitoring module, and the mold body is used for casting a bracket; The monitoring module includes a plurality of temperature sensors, and the plurality of temperature sensors are arranged on the mold surface along the arc direction of the mold corresponding bracket. The plurality of temperature sensors are used to detect the temperature around themselves and upload a plurality of temperature data to the control module. The control module determines whether the variance of the plurality of temperature data exceeds a threshold value, and issues an alarm if the judgment result is yes.

2. A bracket casting mold with high yield according to claim 1, characterized in that: The temperature sensors are used to detect the temperature around them and upload temperature data tn to the control module. The control module calculates the variance F of the temperature data t1, t2, .., tn, and determines whether the variance exceeds the variance threshold F0. When the determination result is yes, an alarm is issued.

3. A bracket casting mold with high yield rate according to claim 2, characterized in that: The control module increases the variance threshold F0 when the yield rate exceeds the threshold, and decreases the variance threshold F0 when the yield rate is lower than the threshold.

4. A bracket casting mold with high yield rate according to claim 3, characterized in that: The control module is pre-input with the yield coefficient G, the control module is pre-input with the process coefficient threshold G0, the control module calculates the correction coefficient A1, the control module calculates the variance F of several temperature data t1, t2, .., tn, the control module determines whether the variance exceeds F0×A1, and issues an alarm when the judgment result is yes; wherein, A1=G / G0×c, c is a pre-input constant.

5. The bracket casting mold with high yield rate according to claim 1, characterized in that: The control module divides a number of temperature sensors into a core group and a reference group. The control module determines whether the variance of the temperature data uploaded by the core group is greater than F1, and determines whether the variance of the temperature data uploaded by the reference group is greater than F2. The control module issues an alarm when one of the judgment results is negative; wherein F1 <F2。 6. A bracket casting mold with high yield rate according to claim 5, characterized in that: The control module defines the temperature sensors of the core group as edge group, center group and edge group in sequence along the arc direction of the corresponding bracket of the mold. The temperature sensors of the center group and edge group upload temperature data to the control module respectively, and the control module corrects the temperature data uploaded by the center group downward.

7. A method for processing a stent casting mold with a high yield rate, applicable to the stent casting mold with a high yield rate according to any one of claims 1 to 6, comprising the following steps: Step 1: Casting the bracket with the mold body; Step 2: A plurality of temperature sensors respectively monitor the mold temperature along the arc direction of the bracket, and upload a plurality of temperature data to the control module; Step 3: The control module determines whether the variance of a number of temperature data exceeds a variance threshold.

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