A sand mold floating sand cleaning system

Abstract

The present invention relates to the field of casting technology, and provides a sand mold floating sand cleaning system, including an intelligent monitoring module, a dynamic control module, an ultrasonic cleaning module and a cleaning liquid management module. The intelligent monitoring module is responsible for collecting sand mold state data, including obtaining surface images through a high-speed camera, measuring temperature with a thermal imager, monitoring stress distribution with a stress sensor, and detecting concentration changes with a gas concentration sensor; the dynamic control module analyzes the sand mold state of each area based on the data of the intelligent monitoring module, plans the cleaning path using an algorithm, and adjusts the operating parameters of the cleaning equipment; the ultrasonic cleaning module cleans the floating sand of the target area through an array of ultrasonic cleaning heads; the cleaning liquid management module is used to manage the circulation flow rate, temperature control, and suspended particle filtration of the cleaning liquid to ensure continuous and efficient cleaning process.

Description

Technical Field

[0001] The present invention relates to the field of casting technology, and more particularly to a sand mold floating sand cleaning system. Background Art

[0002] Sand mold is a widely used mold form in the foundry industry. Through the combination of sand, adhesives and other auxiliary materials, it exhibits good air permeability, thermal stability and molding flexibility, becoming one of the preferred processes for the production of iron-based and non-iron-based castings. Sand casting has an irreplaceable position in the traditional manufacturing field and is an important means to achieve complex geometric shapes and balanced material properties in modern machinery manufacturing.

[0003] However, under the scouring and action of high-temperature molten metal, local sand particles on the surface of the sand mold may fall off, forming the so-called sand floating phenomenon. This phenomenon is not only a manifestation of the uneven performance of the sand mold material, but also affected by multiple factors such as mold design, pouring speed and molten metal characteristics. Reference 1 (Mrs. Deshmukh VS, et al., TheCritical Casting Defect in Cast Iron: Sand Inclusion – A Review. International Journal of Mechanical Engineering and Technology, 2015) pointed out that sand floating is one of the most common defects in the casting process, accounting for 30% to 40% of the total defects of castings. Its causes include cracking of the sand mold surface, high-speed molten metal scouring, mold stress concentration and insufficient permeability; in addition, the document also emphasizes the significant impact of the floating sand phenomenon on the mechanical strength, surface quality and service life of the casting, suggesting that targeted optimization work should be carried out from the perspective of casting process design.

[0004] In order to reduce the floating sand defects in sand molds, reference 2 (Jun Zheng, et al., Low carbon, high efficiency and sustainable production of traditional manufacturing methods through process design strategy: improvement process for sand casting defects. Journal of Cleaner Production, 2019) proposed three casting process optimization strategies, namely structural parameter optimization, pouring system parameter optimization and processing parameter optimization. These strategies significantly improved the casting quality and reduced resource waste and production energy consumption by adjusting the wall thickness of the casting, optimizing the runner design and controlling the pouring temperature and speed. These studies provide valuable theoretical basis and practical guidance for the improvement of traditional sand casting technology.

[0005] However, although there have been studies on reducing the probability of floating sand formation from the perspective of casting parameters and mold structure design, and there are also means such as shot blasting and mechanical grinding to deal with the floating sand that has already been produced, these methods tend to be empirical or post-remedial, and lack accurate data support and dynamic control capabilities for the state of the sand mold. As a result, on the one hand, some areas still have residual floating sand due to insufficient surface cleaning due to the density of floating sand distribution and material stress concentration; on the other hand, areas with high temperature differences or fragile surface structures are prone to excessive impact or uneven cleaning under the same processing conditions, resulting in local excessive damage, fine cracks or increased residual stress. Therefore, although the existing technology is effective in reducing floating sand and optimizing the quality of castings, it still has obvious deficiencies in real-time identification, quantitative evaluation and targeted cleaning of areas where floating sand has already appeared. Summary of the invention

[0006] In order to overcome the above-mentioned defects of the prior art, the present invention provides a sand mold floating sand cleaning system, which realizes accurate monitoring, path optimization and dynamic adjustment of the sand mold state through the synergistic effect of the intelligent monitoring module, dynamic control module, ultrasonic module and cleaning liquid management module. The intelligent monitoring module collects multi-dimensional data such as sand mold surface, temperature and stress in real time to provide decision-making basis for the dynamic control module; the dynamic control module generates an optimized path and dynamically adjusts relevant parameters, and combines ultrasonic technology and cleaning liquid management module to effectively improve the consistency of sand mold state and casting quality, meeting the high requirements of complex casting process for sand mold optimization.

[0007] To achieve the above object, the present invention provides the following technical solutions:

[0008] A sand mold floating sand cleaning system, comprising an ultrasonic cleaning module, a cleaning liquid management module, an intelligent monitoring module and a dynamic control module, wherein the intelligent monitoring module is respectively connected to the dynamic control module, the cleaning liquid management module and the ultrasonic cleaning module, and the dynamic control module is respectively connected to the ultrasonic cleaning module and the cleaning liquid management module;

[0009] The intelligent monitoring module is used to collect, process and transmit the state data of the resin sand mold, and provide basic information for subsequent cleaning path planning and dynamic adjustment, including a resin sand mold state collection unit, a resin sand mold state analysis unit and a resin sand mold state data transmission unit, the resin sand mold state collection unit includes a high-speed camera, a thermal imager, a stress sensor and a gas concentration sensor; the resin sand mold state analysis unit is used to perform region-by-region analysis and feature extraction on the data collected by the resin sand mold state collection unit, including floating sand distribution density calculation, temperature change intensity analysis, stress concentration factor calculation and gas concentration change intensity analysis; the resin sand mold state data transmission unit is used to transmit the above-generated data to the dynamic control module;

[0010] The dynamic control module is used to receive the data generated by the intelligent monitoring module, and dynamically optimize the cleaning path and adjust the cleaning parameters based on the data; the dynamic control module includes a path planning unit and an adjustment unit; the path planning unit is used to perform risk assessment and weight allocation on the area according to the floating sand distribution density, temperature change intensity, stress concentration factor and gas concentration change intensity, and generate a cleaning path through a dynamic programming algorithm; the adjustment unit adjusts the frequency, power, emission angle and array position of the ultrasonic cleaning head in real time through a proportional-integral-differential control algorithm; wherein the cost function of the dynamic programming algorithm is:

[0011] ;

[0012] In the formula, is the total value, For the The weight value of the region, For the Region and The path length between regions, For the The density of floating sand distribution in the region, For the The intensity of temperature change in the region, is the contribution coefficient of floating sand particles to the cleaning time, is the contribution coefficient of temperature change to cleaning time.

[0013] As a further solution of the present invention, the resin sand mold state analysis unit performs block processing on the sand mold surface image collected by the high-speed camera according to a preset partition standard, calculates the floating sand distribution density of each area and generates a floating sand particle distribution map. The floating sand distribution density calculation formula is:

[0014] ;

[0015] In the formula, For the The density of floating sand distribution in the region, For the The number of floating sand particles in the area, For the The area of ​​the region, For the The surface strength factor of the area is obtained through the hardness test of the resin sand mold.

[0016] As a further solution of the present invention, the resin sand mold state analysis unit is used to receive temperature data of each area of ​​the resin sand mold collected by the thermal imager, and by comparing the temperature values ​​of adjacent areas, calculate the temperature difference between each area in the horizontal and vertical directions, and determine the temperature change intensity of each area of ​​the resin sand mold in combination with the distance between adjacent areas; according to the calculated temperature change intensity, the resin sand mold state analysis unit generates a temperature change distribution map of the resin sand mold, and identifies the area where the temperature change intensity exceeds a preset threshold in the distribution map; the resin sand mold state analysis unit is used to receive stress data of each area of ​​the resin sand mold collected by the stress sensor, and record the stress value of each area as a whole; the resin sand mold state analysis unit analyzes the stress data of each area, compares the maximum stress value and the average stress value in the area, and calculates the stress concentration factor of the area; and compares the stress concentration factor with a preset threshold, and when the stress concentration factor exceeds the threshold, marks the area; generates a stress distribution map of the resin sand mold.

[0017] As a further solution of the present invention, the resin sand mold state analysis unit is used to receive the gas concentration data of each area of ​​the resin sand mold collected by the gas concentration sensor, and determine the gas concentration change intensity of each area of ​​the resin sand mold by calculating the lateral gas concentration difference and the longitudinal gas concentration difference between adjacent areas, and generate a gas concentration distribution map, wherein the calculation formula of the gas concentration change intensity is:

[0018] ;

[0019] In the formula, For the The intensity of gas concentration changes in the region, For the The gas concentration difference between a region and its lateral adjacent regions, For the The gas concentration difference between a region and its longitudinally adjacent regions, For the The lateral distance between the region and the adjacent regions, For the The vertical distance between a region and its adjacent regions.

[0020] As a further solution of the present invention, the resin sand mold state acquisition unit includes a high-speed camera, a thermal imager, a stress sensor and a gas concentration sensor. The high-speed camera is used to collect real-time images of the sand mold surface; the thermal imager is used to measure the temperature of the sand mold surface; the stress sensor is used to monitor the stress data of the resin sand mold; and the gas concentration sensor is used to detect the gas concentration generated by resin decomposition during the high-temperature pouring process of the sand mold.

[0021] As a further solution of the present invention, the path planning unit is used to generate an optimal cleaning path according to the following steps based on the floating sand particle distribution map, temperature change distribution map, stress distribution map and gas concentration distribution map provided by the intelligent monitoring module:

[0022] Step S1, analyzing the floating sand particle distribution map, identifying areas where the floating sand distribution density is greater than a preset threshold, marking them as priority cleaning areas, and assigning weight values;

[0023] Step S2, analyzing the temperature change distribution map, identifying areas where the temperature change intensity exceeds a set threshold, marking them as priority cleaning areas, and assigning weight values;

[0024] Step S3, analyzing the stress distribution map, screening areas where the stress concentration factor is greater than a preset threshold, marking them as priority cleaning areas, and assigning weight values;

[0025] Step S4, analyzing the gas concentration distribution map, identifying areas where the intensity of gas concentration change exceeds a set threshold, marking them as potential risk areas, and assigning weight values;

[0026] Step S5, based on the above weight distribution results, construct a three-dimensional space model of the sand mold, sort all marked areas in descending order of weight, and determine the cleaning priority;

[0027] Step S6, based on the sorting results, a dynamic programming algorithm is used to generate a cleaning path covering all areas.

[0028] As a further solution of the present invention, the generation of the cleaning path using a dynamic programming algorithm includes the following steps:

[0029] Step S61, inputting the center coordinates, weight values ​​and distance matrix of adjacent areas of the marked priority cleaning area into the path planning algorithm;

[0030] Step S62, using the nearest neighbor search method to generate an initial path, ensuring that the areas with the largest weights are connected in sequence from the starting point;

[0031] Step S63, using a dynamic programming algorithm and a cost function to calculate the total cost of different paths;

[0032] Step S64, optimizing the discrete path points into a continuous executable path by a curve fitting method;

[0033] Step S65, generating the shortest cleaning path covering all marked areas, and outputting it to the adjustment unit for parameter adjustment.

[0034] As a further solution of the present invention, the regulating unit adjusts the frequency, power, emission angle and array position of the ultrasonic cleaning head in real time through a proportional-integral-differential control algorithm, which specifically includes the following steps:

[0035] Step A1, receiving the target cleaning area data in the floating sand particle distribution map, temperature change distribution map, stress distribution map and gas concentration distribution map generated by the intelligent monitoring module, parsing and integrating the floating sand distribution density, temperature change intensity, stress concentration factor and gas concentration change intensity value of the target cleaning area as the input basis for adjusting the cleaning parameters;

[0036] Step A2, setting the working frequency of the ultrasonic cleaning head according to the floating sand distribution density value of the target cleaning area;

[0037] Step A3, setting the power of the ultrasonic cleaning head according to the temperature change intensity and stress concentration factor data of the target cleaning area;

[0038] Step A4, adjusting the emission angle of the ultrasonic cleaning head according to the three-dimensional coordinates and geometric characteristics of the center point of the target cleaning area provided by the path planning unit;

[0039] Step A5, using the PID control algorithm to calculate the position movement path of the ultrasonic cleaning head array, dynamically adjusting the array position to cover the target cleaning area, analyzing the center point coordinates and spatial dimensions of the target cleaning area, and adjusting the horizontal position and vertical height of the ultrasonic cleaning head array in real time;

[0040] Step A6, setting the flow rate and temperature parameters of the cleaning liquid according to the concentration change intensity and the distribution of floating sand particles in the gas concentration distribution diagram;

[0041] Step A7, integrating the adjustment results of frequency, power, emission angle, array position and cleaning liquid parameters to generate a cleaning execution instruction.

[0042] As a further solution of the present invention, the ultrasonic cleaning module is used to clean floating sand particles on the surface of the resin sand mold by ultrasonic technology, and includes an ultrasonic cleaning head, and the ultrasonic cleaning head is distributed on a supporting structure formed by an array arrangement.

[0043] As a further solution of the present invention, the cleaning liquid management module includes a liquid temperature control unit, a flow rate regulation unit and a filtration unit. The liquid temperature control unit is used to control the temperature of the cleaning liquid within a set range; the flow rate regulation unit is used to dynamically adjust the circulation speed of the cleaning liquid; the filtration unit is used to remove suspended particles in the cleaning liquid and maintain the purity of the cleaning liquid.

[0044] Compared with the prior art, the sand mold floating sand cleaning system of the present invention has the following beneficial effects:

[0045] The present invention collects multi-dimensional data of sand mold surface, temperature, stress and gas concentration through the intelligent monitoring module, and generates an optimization path in real time in combination with the dynamic control module, providing support for comprehensive analysis of the sand mold state. In contrast, the existing technology mostly adopts single parameter monitoring or static preset solutions, which are difficult to fully reflect the complex changes in the sand mold state, resulting in limited stability and quality control of the casting process.

[0046] Through the path planning and parameter adjustment capabilities of the dynamic control module, the present invention can dynamically optimize the sand mold characteristic adaptation strategy according to the changes in the sand mold state in different areas, thereby better supporting the production process of complex castings. Combined with the ultrasonic module and the cleaning liquid management module, the system can further optimize the surface state of the sand mold and improve the consistency and surface accuracy of the casting quality; in contrast, the existing technology mostly uses fixed parameters or manual adjustment methods, which is difficult to meet the diverse needs of complex casting processes, and may increase process instability due to improper adjustment. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 The present invention is a structural schematic diagram of a sand mold floating sand cleaning system.

[0048] Figure 2 The present invention is a schematic diagram of the flow of an adjustment unit of a sand mold floating sand cleaning system. DETAILED DESCRIPTION

[0049] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0050] Example 1

[0051] like Figure 1 As shown, a sand mold floating sand cleaning system includes an ultrasonic cleaning module, a cleaning liquid management module, an intelligent monitoring module and a dynamic control module.

[0052] The intelligent monitoring module in the embodiment of the present invention is respectively connected to the dynamic control module, the cleaning liquid management module and the ultrasonic cleaning module, and the dynamic control module is respectively connected to the ultrasonic cleaning module and the cleaning liquid management module.

[0053] The intelligent monitoring module is used to collect, process and transmit the state data of the resin sand mold, and provide basic information for subsequent cleaning path planning and dynamic adjustment, including a resin sand mold state collection unit, a resin sand mold state analysis unit and a resin sand mold state data transmission unit, the resin sand mold state collection unit includes a high-speed camera, a thermal imager, a stress sensor and a gas concentration sensor; the resin sand mold state analysis unit is used to perform region-by-region analysis and feature extraction on the data of each region collected by the resin sand mold state collection unit, including floating sand distribution density calculation, temperature change intensity analysis, stress concentration factor calculation and gas concentration change intensity analysis; the resin sand mold state data transmission unit is used to transmit the above-generated data to the dynamic control module, the data includes a floating sand particle distribution map, a temperature gradient map, a stress distribution map and a gas concentration distribution map.

[0054] The resin sand mold state acquisition unit in the embodiment of the present invention includes a high-speed camera, a thermal imager, a stress sensor and a gas concentration sensor. The high-speed camera is used to collect real-time images of the sand mold surface; the thermal imager is used to measure the temperature of the sand mold surface; the stress sensor is used to monitor the stress data of the resin sand mold, and the gas concentration sensor is used to detect the gas concentration generated by resin decomposition during the high-temperature pouring process of the sand mold.

[0055] The resin sand mold state analysis unit in the embodiment of the present invention divides the sand mold surface image collected by the high-speed camera into blocks according to a preset partition standard, calculates the floating sand distribution density of each area and generates a floating sand particle distribution map. The floating sand distribution density calculation formula is:

[0056] ;

[0057] In the formula, For the The density of floating sand distribution in the region, For the The number of floating sand particles in the area, For the The area of ​​the region, For the The surface strength factor of the area is obtained through the hardness test of the resin sand mold.

[0058] The resin sand mold state analysis unit in the embodiment of the present invention is used to receive the temperature data of each area of ​​the resin sand mold collected by the thermal imager, and by comparing the temperature values ​​of adjacent areas, calculate the temperature difference between each area in the horizontal and vertical directions, and determine the temperature change intensity of each area of ​​the resin sand mold in combination with the distance between adjacent areas; according to the calculated temperature change intensity, the resin sand mold state analysis unit generates a temperature change distribution map of the resin sand mold, and identifies the area where the temperature change intensity exceeds a preset threshold in the distribution map, so as to identify the high-risk area that may cause cracks to be generated due to thermal expansion, and provide a basis for the cleaning path planning and parameter adjustment of the dynamic control module; the resin The sand mold state analysis unit is used to receive stress data of each area of ​​the resin sand mold collected by the stress sensor, and record the stress value of each area as a whole; the resin sand mold state analysis unit analyzes the stress data of each area, compares the maximum stress value and the average stress value in the area, and calculates the stress concentration factor of the area; and compares the stress concentration factor with a preset threshold value. When the stress concentration factor exceeds the threshold value, the area is marked as a high stress concentration area; the resin sand mold state analysis unit generates a stress distribution map of the resin sand mold, and marks the high stress concentration area in the distribution map for the dynamic control module to optimize the cleaning path planning and adjust the cleaning parameters.

[0059] The resin sand mold state analysis unit in the embodiment of the present invention is used to receive the gas concentration data of each area of ​​the resin sand mold collected by the gas concentration sensor, and determine the gas concentration change intensity of each area of ​​the resin sand mold by calculating the lateral gas concentration difference and the longitudinal gas concentration difference between adjacent areas, and generate a gas concentration distribution map, wherein the calculation formula of the gas concentration change intensity is:

[0060] ;

[0061] In the formula, For the The intensity of gas concentration changes in the region, For the The gas concentration difference between a region and its lateral adjacent regions, For the The gas concentration difference between a region and its longitudinally adjacent regions, For the The lateral distance between the region and the adjacent regions, For the The vertical distance between a region and its adjacent regions.

[0062] The dynamic control module is used to receive data generated by the intelligent monitoring module, and dynamically optimize the cleaning path and adjust the cleaning parameters based on the data; the dynamic control module includes a path planning unit and an adjustment unit; the path planning unit is used to perform risk assessment and weight allocation on the area according to the floating sand distribution density, temperature change intensity, stress concentration factor and gas concentration change intensity, and generate a cleaning path through a dynamic planning algorithm; the adjustment unit adjusts the frequency, power, emission angle and array position of the ultrasonic cleaning head in real time through a proportional-integral-differential control algorithm, and dynamically adjusts the flow rate and temperature of the cleaning liquid according to the characteristics of different areas.

[0063] The path planning unit in the embodiment of the present invention is used to generate an optimal cleaning path according to the following steps based on the floating sand particle distribution map, temperature change distribution map, stress distribution map and gas concentration distribution map provided by the intelligent monitoring module:

[0064] Step S1, analyzing the floating sand particle distribution map, identifying areas where the floating sand distribution density is greater than a preset threshold, marking them as priority cleaning areas, and assigning weight values ​​to prioritize cleaning of areas that may affect the surface quality of the casting;

[0065] Step S2, analyzing the temperature change distribution map, identifying areas where the temperature change intensity exceeds a set threshold, marking them as priority cleaning areas, and assigning weight values ​​to prioritize high-risk areas that may cause cracks due to thermal expansion;

[0066] Step S3, analyzing the stress distribution map, screening areas where the stress concentration factor is greater than a preset threshold, marking them as priority cleaning areas, and assigning weight values ​​to prioritize areas where the sand mold may be damaged due to local stress concentration;

[0067] Step S4, analyzing the gas concentration distribution map, identifying areas where the intensity of gas concentration change exceeds a set threshold, marking them as potential risk areas, and assigning weight values ​​to handle areas where floating sand particles may fall off due to gas release;

[0068] Step S5, based on the above weight distribution results, construct a three-dimensional space model of the sand mold, sort all marked areas in descending order of weight, and determine the cleaning priority;

[0069] Step S6, based on the sorting results, a dynamic programming algorithm is used to generate a cleaning path covering all areas.

[0070] The use of a dynamic programming algorithm to generate a cleaning path in an embodiment of the present invention includes the following steps:

[0071] Step S61, inputting the center coordinates, weight values ​​and distance matrix of adjacent areas of the marked priority cleaning area into the path planning algorithm;

[0072] Step S62, using the nearest neighbor search method to generate an initial path, ensuring that the areas with the largest weights are connected in sequence from the starting point;

[0073] Step S63, using a dynamic programming algorithm and a cost function to calculate the total cost of different paths, wherein the cost function of the dynamic programming algorithm is:

[0074] ;

[0075] In the formula, is the total value, For the The weight value of the region, For the Region and The path length between regions, For the The density of floating sand distribution in the region, For the The intensity of temperature change in the region, is the contribution coefficient of floating sand particles to the cleaning time, is the contribution coefficient of temperature change to cleaning time;

[0076] Step S64, optimizing the discrete path points into a continuous executable path by a curve fitting method;

[0077] Step S65, generating the shortest cleaning path covering all marked areas, and outputting it to the adjustment unit for parameter adjustment.

[0078] The adjustment unit in the embodiment of the present invention adjusts the frequency, power, emission angle and array position of the ultrasonic cleaning head in real time through a proportional-integral-differential control algorithm, which specifically includes the following steps:

[0079] Step A1, receiving the target cleaning area data in the floating sand particle distribution map, temperature change distribution map, stress distribution map and gas concentration distribution map generated by the intelligent monitoring module, parsing and integrating the floating sand distribution density, temperature change intensity, stress concentration factor and gas concentration change intensity value of the target cleaning area as the input basis for adjusting the cleaning parameters;

[0080] Step A2, setting the working frequency of the ultrasonic cleaning head according to the floating sand distribution density value of the target cleaning area;

[0081] Step A3, setting the power of the ultrasonic cleaning head according to the temperature change intensity and stress concentration factor data of the target cleaning area;

[0082] Step A4, adjusting the emission angle of the ultrasonic cleaning head according to the three-dimensional coordinates and geometric characteristics of the center point of the target cleaning area provided by the path planning unit;

[0083] Step A5, using the PID control algorithm to calculate the position movement path of the ultrasonic cleaning head array, dynamically adjusting the array position to cover the target cleaning area, analyzing the center point coordinates and spatial dimensions of the target cleaning area, and adjusting the horizontal position and vertical height of the ultrasonic cleaning head array in real time;

[0084] Step A6, setting the flow rate and temperature parameters of the cleaning liquid according to the concentration change intensity and the distribution of floating sand particles in the gas concentration distribution diagram;

[0085] Step A7, integrating the adjustment results of frequency, power, emission angle, array position and cleaning liquid parameters to generate a cleaning execution instruction.

[0086] The ultrasonic cleaning module in the embodiment of the present invention is used to clean the floating sand particles on the surface of the resin sand mold by ultrasonic technology, and includes an ultrasonic cleaning head, and the ultrasonic cleaning head is distributed on a supporting structure formed by an array arrangement.

[0087] The installation method of the ultrasonic cleaning head in the embodiment of the present invention includes but is not limited to fixed or movable. By adjusting the height, inclination angle or axial direction of the installation fulcrum, the cleaning adaptation to different sand mold surfaces is achieved. Different areas clean the floating sand particles attached to the surface in turn according to a preset trajectory. The arrangement of the ultrasonic cleaning head array is achieved through a support frame, and the frame includes at least two or more transverse support beams and at least three or more longitudinal support beams. The support beams are connected by multi-point hinges to form a matrix grid structure. Each grid point in the grid structure is fixedly or movably connected to an ultrasonic cleaning head. The ultrasonic cleaning head adjusts its vertical distance and emission angle from the sand mold surface through a multi-point adjustment device. The multi-point adjustment device includes a displacement sensor and an electric slide rail, which is used to accurately locate the position of the ultrasonic cleaning head to cover the complex geometric surface of the sand mold.

[0088] The cleaning liquid management module in the embodiment of the present invention includes a liquid temperature control unit, a flow rate adjustment unit and a filter unit. The liquid temperature control unit is used to control the temperature of the cleaning liquid within a set range to ensure that the physical properties of the cleaning liquid meet the cleaning requirements; the flow rate adjustment unit is used to dynamically adjust the circulation speed of the cleaning liquid, and the circulation speed is adjusted according to the distribution state of floating sand particles on the surface of the sand mold; the filter unit is used to remove suspended particles in the cleaning liquid and maintain the purity of the cleaning liquid.

[0089] The filter unit of the cleaning liquid management module in the embodiment of the present invention includes at least three filter chambers connected in series, and the pore size of the filter element arranged in each chamber decreases successively from the inlet to the outlet. The filter unit also includes a real-time concentration sensor for detecting the concentration change of suspended particles in the cleaning liquid. When the concentration exceeds the set threshold, the filter unit automatically stops the liquid intake and starts the cleaning program inside the chamber to remove the accumulated impurities.

[0090] Example 2

[0091] like Figure 2 As shown, a schematic flow diagram of an adjustment unit of a sand mold floating sand cleaning system of the present invention is shown. In the figure, the adjustment unit adjusts the frequency, power, emission angle and array position of the ultrasonic cleaning head in real time through a proportional-integral-differential control algorithm, which specifically includes the following steps:

[0092] Step A1, receiving the target cleaning area data in the floating sand particle distribution map, temperature change distribution map, stress distribution map and gas concentration distribution map generated by the intelligent monitoring module, parsing and integrating the floating sand distribution density, temperature change intensity, stress concentration factor and gas concentration change intensity value of the target cleaning area as the input basis for adjusting the cleaning parameters;

[0093] Step A2, according to the floating sand distribution density value of the target cleaning area, set the working frequency of the ultrasonic cleaning head, analyze the floating sand distribution density data and compare it with a preset threshold value (20 particles / square centimeter), when the floating sand distribution density is less than the threshold, set the frequency to 30kHz to 50kHz to quickly clean the loose floating sand, when the floating sand distribution density is greater than the threshold, set the frequency to 10kHz to 20kHz to enhance the ultrasonic penetration to clean the stubborn floating sand;

[0094] Step A3, according to the temperature change intensity and stress concentration factor data of the target cleaning area, the power of the ultrasonic cleaning head is set, the temperature change intensity is analyzed and compared with the threshold value of 50°C / cm2, when the temperature change intensity exceeds the threshold value, the power is set to 100W to 300W to avoid damage to the sand mold surface due to high temperature; the stress concentration factor is analyzed and compared with the threshold value of the set range (1.5 to 3), when the stress concentration factor is within the range, the power is set to 300W to 500W to ensure the cleaning effect of stubborn floating sand;

[0095] Step A4, according to the three-dimensional coordinates and geometric characteristics of the center point of the target cleaning area provided by the path planning unit, adjust the emission angle of the ultrasonic cleaning head, analyze the surface type of the target cleaning area, when the target cleaning area is a plane, set the emission angle to 0° to 10° to act perpendicularly on the surface, when the target cleaning area is a curved surface or an inclined surface, set the emission angle to an angle of 10° to 45° with the surface normal to ensure effective coverage of the ultrasonic wave;

[0096] Step A5, using the PID control algorithm to calculate the position movement path of the ultrasonic cleaning head array, dynamically adjusting the array position to cover the target cleaning area, analyzing the center point coordinates and spatial dimensions of the target cleaning area, and adjusting the horizontal position and vertical height of the ultrasonic cleaning head array in real time. The moving range is set to a step length of 1 mm to 50 mm to ensure that the cleaning array covers the target cleaning area and avoids excessive movement;

[0097] Step A6, according to the concentration change intensity and the distribution of floating sand particles in the gas concentration distribution diagram, the flow rate and temperature parameters of the cleaning liquid are set, and the gas concentration change intensity data is analyzed. When the concentration change intensity exceeds 10ppm / cm, the flow rate of the cleaning liquid is adjusted to 0.1m / s to 0.3m / s; the floating sand distribution density is analyzed. When the density exceeds 20 particles / cm2, the cleaning liquid temperature is adjusted to 35°C to 45°C to improve the cleaning efficiency and avoid sand damage;

[0098] Step A7, integrating the adjustment results of frequency, power, emission angle, array position and cleaning liquid parameters to generate a cleaning execution instruction.

[0099] The following is a Python code example that uses the PID algorithm to adjust the frequency, power, emission angle, and array position of the ultrasonic cleaning head in real time. Please note that this example is only a starting point and may need to be adjusted according to actual conditions and device interfaces in actual applications.

[0100] class PIDController:

[0101] def __init__(self, kp=1.0, ki=0.0, kd=0.0):

[0102] self.kp = kp

[0103] self.ki = ki

[0104] self.kd = kd

[0105] self.prev_error = 0.0

[0106] self.integral = 0.0

[0107] def update(self, error):

[0108] self.integral += error

[0109] derivative = error - self.prev_error

[0110] output = self.kp * error + self.ki * self.integral + self.kd *derivative

[0111] self.prev_error = error

[0112] return output

[0113] def clean_system_adjustment(

[0114] float_sand_density=25,

[0115] temperature_strength=60,

[0116] stress_factor=2.0,

[0117] gas_concentration=15,

[0118] target_surface_type="plane",

[0119] target_center=(100.0, 200.0, 50.0),

[0120] target_area_size=(10.0, 10.0, 5.0) ):

[0122] input_params = {

[0123] "float_sand_density": float_sand_density,

[0124] "temperature_strength": temperature_strength,

[0125] "stress_factor": stress_factor,

[0126] "gas_concentration": gas_concentration

[0127] }

[0128] # Frequency setting

[0129] # The threshold is set to 20 particles / cm2

[0130] if input_params["float_sand_density"]<20:

[0131] frequency = (30e3, 50e3) # Hz

[0132] else:

[0133] frequency = (10e3, 20e3) # Hz

[0134] # Power setting

[0135] # Temperature change threshold: 50°C / cm2

[0136] # Stress Concentration Factor Range: 1.5 to 3

[0137] if input_params["temperature_strength"]>50:

[0138] power = (100, 300) # W

[0139] else:

[0140] power = (200, 300) # Default intermediate value range

[0141] if 1.5<= input_params["stress_factor"]<= 3:

[0142] # Within the stress concentration factor range, the power limit is increased

[0143] power = (max(power[0], 300), max(power[1], 500))

[0144] # Setting the emission angle

[0145] # If it is a flat surface: 0° to 10°

[0146] # If it is a curved or inclined surface: 10° to 45°

[0147] if target_surface_type == "plane":

[0148] angle = (0, 10) # degrees

[0149] else:

[0150] angle = (10, 45) # degrees

[0151] # Use PID control to adjust the array position

[0152] #Use the target center point as the reference coordinate, assuming the current array position is (0,0,0)

[0153] current_position = [0.0, 0.0, 0.0]

[0154] pid_x = PIDController(kp=0.1)

[0155] pid_y = PIDController(kp=0.1)

[0156] pid_z = PIDController(kp=0.1)

[0157] # Simulate a location update

[0158] error_x = target_center[0] - current_position[0]

[0159] error_y = target_center[1] - current_position[1]

[0160] error_z = target_center[2] - current_position[2]

[0161] move_x = pid_x.update(error_x)

[0162] move_y = pid_y.update(error_y)

[0163] move_z = pid_z.update(error_z)

[0164] # Move step length between 1mm and 50mm

[0165] def clamp_move(m):

[0166] if m>50:

[0167] return 50

[0168] elif m<1:

[0169] return 1

[0170] return m

[0171] move_x = clamp_move(move_x)

[0172] move_y = clamp_move(move_y)

[0173] move_z = clamp_move(move_z)

[0174] array_position = (

[0175] current_position[0] + move_x,

[0176] current_position[1] + move_y,

[0177] current_position[2] + move_z )

[0179] # Cleaning fluid parameter setting

[0180] # Gas concentration threshold: 10ppm / cm

[0181] # Floating sand density threshold: 20 particles / cm2

[0182] if input_params["gas_concentration"]>10:

[0183] fluid_speed = (0.1, 0.3) # m / s

[0184] else:

[0185] fluid_speed = (0.05, 0.1)

[0186] if input_params["float_sand_density"]>20:

[0187] fluid_temp = (35, 45) # °C

[0188] else:

[0189] fluid_temp = (25, 35)

[0190] # Generate cleaning execution instructions

[0191] cleaning_command = {

[0192] "frequency": frequency,

[0193] "power": power,

[0194] "angle": angle,

[0195] "array_position": array_position,

[0196] "fluid_speed": fluid_speed,

[0197] "fluid_temperature": fluid_temp

[0198] }

[0199] return cleaning_command

[0200] # Calling example

[0201] if __name__ == "__main__":

[0202] result = clean_system_adjustment()

[0203] print("Cleaning Command:", result)

[0204] This code is only used as an example. In actual applications, appropriate modifications and adjustments need to be made according to specific circumstances.

[0205] Finally: The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A sand mold floating sand cleaning system, comprising an ultrasonic cleaning module and a cleaning liquid management module, characterized in that: It also includes an intelligent monitoring module and a dynamic control module, wherein the intelligent monitoring module is connected to the dynamic control module, the cleaning liquid management module and the ultrasonic cleaning module respectively, and the dynamic control module is connected to the ultrasonic cleaning module and the cleaning liquid management module respectively; The intelligent monitoring module is used to collect, process and transmit the state data of the resin sand mold, and provide basic information for subsequent cleaning path planning and dynamic adjustment, including a resin sand mold state collection unit, a resin sand mold state analysis unit and a resin sand mold state data transmission unit, the resin sand mold state collection unit includes a high-speed camera, a thermal imager, a stress sensor and a gas concentration sensor; the resin sand mold state analysis unit is used to perform region-by-region analysis and feature extraction on the data collected by the resin sand mold state collection unit, including floating sand distribution density calculation, temperature change intensity analysis, stress concentration factor calculation and gas concentration change intensity analysis; the resin sand mold state data transmission unit is used to transmit the above-generated data to the dynamic control module; The dynamic control module is used to receive the data generated by the intelligent monitoring module, and dynamically optimize the cleaning path and adjust the cleaning parameters based on the data; the dynamic control module includes a path planning unit and an adjustment unit; the path planning unit is used to perform risk assessment and weight allocation on the area according to the floating sand distribution density, temperature change intensity, stress concentration factor and gas concentration change intensity, and generate a cleaning path through a dynamic programming algorithm; the adjustment unit adjusts the frequency, power, emission angle and array position of the ultrasonic cleaning head in real time through a proportional-integral-differential control algorithm; wherein the cost function of the dynamic programming algorithm is: ； In the formula, is the total value, For the The weight value of the region, For the Region and The path length between regions, For the The density of floating sand distribution in the region, For the The intensity of temperature change in the region, is the contribution coefficient of floating sand particles to the cleaning time, is the contribution coefficient of temperature change to cleaning time.

2. A sand mold floating sand cleaning system according to claim 1, characterized in that: The resin sand mold state analysis unit divides the sand mold surface image collected by the high-speed camera into blocks according to a preset partition standard, calculates the floating sand distribution density of each area and generates a floating sand particle distribution map. The floating sand distribution density calculation formula is: ； In the formula, For the The density of floating sand distribution in the region, For the The number of floating sand particles in the area, For the The area of ​​the region, For the The surface strength factor of the area is obtained through the hardness test of the resin sand mold.

3. A sand mold floating sand cleaning system according to claim 1, characterized in that: The resin sand mold state analysis unit is used to receive the temperature data of each area of ​​the resin sand mold collected by the thermal imager, and by comparing the temperature values ​​of adjacent areas, calculate the temperature difference between each area in the horizontal and vertical directions, and determine the temperature change intensity of each area of ​​the resin sand mold in combination with the distance between adjacent areas; according to the calculated temperature change intensity, the resin sand mold state analysis unit generates a temperature change distribution map of the resin sand mold, and identifies the area whose temperature change intensity exceeds a preset threshold in the distribution map; The resin sand mold state analysis unit is used to receive stress data of each area of ​​the resin sand mold collected by the stress sensor, and record the stress value of each area as a whole; The resin sand mold state analysis unit analyzes the stress data of each area, compares the maximum stress value and the average stress value in the area, and calculates the stress concentration factor of the area; The stress concentration factor is compared with a preset threshold value, and when the stress concentration factor exceeds the threshold value, the area is marked; and a stress distribution diagram of the resin sand mold is generated.

4. A sand mold floating sand cleaning system according to claim 1, characterized in that: The resin sand mold state analysis unit is used to receive the gas concentration data of each area of ​​the resin sand mold collected by the gas concentration sensor, and determine the gas concentration change intensity of each area of ​​the resin sand mold by calculating the lateral gas concentration difference and the longitudinal gas concentration difference between adjacent areas, and generate a gas concentration distribution map, wherein the calculation formula of the gas concentration change intensity is: ； In the formula, For the The intensity of gas concentration changes in the region, For the The gas concentration difference between a region and its lateral adjacent regions, For the The gas concentration difference between a region and its longitudinally adjacent regions, For the The lateral distance between the region and the adjacent regions, For the The vertical distance between a region and its adjacent regions.

5. A sand mold floating sand cleaning system according to claim 1, characterized in that: The resin sand mold state acquisition unit includes a high-speed camera, a thermal imager, a stress sensor and a gas concentration sensor. The high-speed camera is used to acquire real-time images of the sand mold surface; the thermal imager is used to measure the temperature of the sand mold surface; the stress sensor is used to monitor the stress data of the resin sand mold; and the gas concentration sensor is used to detect the gas concentration generated by resin decomposition during high-temperature pouring of the sand mold.

6. A sand mold floating sand cleaning system according to claim 1, characterized in that: The path planning unit is used to generate an optimal cleaning path according to the following steps based on the floating sand particle distribution map, temperature change distribution map, stress distribution map and gas concentration distribution map provided by the intelligent monitoring module: Step S1, analyzing the floating sand particle distribution map, identifying areas where the floating sand distribution density is greater than a preset threshold, marking them as priority cleaning areas, and assigning weight values; Step S2, analyzing the temperature change distribution map, identifying areas where the temperature change intensity exceeds a set threshold, marking them as priority cleaning areas, and assigning weight values; Step S3, analyzing the stress distribution map, screening areas where the stress concentration factor is greater than a preset threshold, marking them as priority cleaning areas, and assigning weight values; Step S4, analyzing the gas concentration distribution map, identifying areas where the intensity of gas concentration change exceeds a set threshold, marking them as potential risk areas, and assigning weight values; Step S5, based on the above weight distribution results, construct a three-dimensional space model of the sand mold, sort all marked areas in descending order of weight, and determine the cleaning priority; Step S6, based on the sorting results, a dynamic programming algorithm is used to generate a cleaning path covering all areas.

7. A sand mold floating sand cleaning system according to claim 6, characterized in that: Generating a cleaning path using a dynamic programming algorithm includes the following steps: Step S61, inputting the center coordinates, weight values ​​and distance matrix of adjacent areas of the marked priority cleaning area into the path planning algorithm; Step S62, using the nearest neighbor search method to generate an initial path, ensuring that the areas with the largest weights are connected in sequence from the starting point; Step S63, using a dynamic programming algorithm and a cost function to calculate the total cost of different paths; Step S64, optimizing the discrete path points into a continuous executable path by a curve fitting method; Step S65, generating the shortest cleaning path covering all marked areas, and outputting it to the adjustment unit for parameter adjustment.

8. A sand mold floating sand cleaning system according to claim 1, characterized in that: The regulating unit adjusts the frequency, power, emission angle and array position of the ultrasonic cleaning head in real time through a proportional-integral-differential control algorithm, which specifically includes the following steps: Step A1, receiving the target cleaning area data in the floating sand particle distribution map, temperature change distribution map, stress distribution map and gas concentration distribution map generated by the intelligent monitoring module, parsing and integrating the floating sand distribution density, temperature change intensity, stress concentration factor and gas concentration change intensity value of the target cleaning area as the input basis for adjusting the cleaning parameters; Step A2, setting the working frequency of the ultrasonic cleaning head according to the floating sand distribution density value of the target cleaning area; Step A3, setting the power of the ultrasonic cleaning head according to the temperature change intensity and stress concentration factor data of the target cleaning area; Step A4, adjusting the emission angle of the ultrasonic cleaning head according to the three-dimensional coordinates and geometric characteristics of the center point of the target cleaning area provided by the path planning unit; Step A5, using the PID control algorithm to calculate the position movement path of the ultrasonic cleaning head array, dynamically adjusting the array position to cover the target cleaning area, analyzing the center point coordinates and spatial dimensions of the target cleaning area, and adjusting the horizontal position and vertical height of the ultrasonic cleaning head array in real time; Step A6, setting the flow rate and temperature parameters of the cleaning liquid according to the concentration change intensity and the distribution of floating sand particles in the gas concentration distribution diagram; Step A7, integrating the adjustment results of frequency, power, emission angle, array position and cleaning liquid parameters to generate a cleaning execution instruction.

9. A sand mold floating sand cleaning system according to claim 1, characterized in that: The ultrasonic cleaning module is used to clean floating sand particles on the surface of the resin sand mold by ultrasonic technology, and includes an ultrasonic cleaning head, and the ultrasonic cleaning head is distributed on a supporting structure formed by an array arrangement.

10. A sand mold floating sand cleaning system according to claim 1, characterized in that: The cleaning liquid management module includes a liquid temperature control unit, a flow rate adjustment unit and a filter unit. The liquid temperature control unit is used to control the temperature of the cleaning liquid within a set range; the flow rate adjustment unit is used to dynamically adjust the circulation speed of the cleaning liquid; and the filter unit is used to remove suspended particles in the cleaning liquid and maintain the purity of the cleaning liquid.

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