Metal liquid flow control method, device, equipment, medium and system for negative pressure suction casting

Abstract

The present application relates to a method, device, equipment, medium and system for controlling the flow of molten metal for negative pressure suction casting, and the method includes: adjusting the heating power of the heating element corresponding to the crucible block based on the target suction casting time corresponding to the molten metal in the crucible, the heating element including a laser transmitter; obtaining the number of received light points based on the infrared receiver, the number of received light points is used to characterize the parameters of the situation in which the molten metal flowing out of the crucible blocks the transmission of infrared rays; if the number of received light points is lower than the target light point number range, it is determined that the melting of the crucible block is completed and the molten metal flows out of the crucible, the heating element is controlled to stop heating, and the suction casting pump is controlled to start, so that the suction casting pump performs negative pressure suction casting on the molten metal. The present application automatically controls the start of the suction casting pump, improves the accuracy of identifying the flow state of the molten metal, ensures that the entire filling process is stable and efficient, improves the flow filling efficiency of the high-temperature melt, and improves the quality of the negative pressure suction casting casting.

Description

Technical Field

[0001] The present application relates to the technical field of negative pressure suction casting, and in particular to a method, device, equipment, medium and system for controlling a metal liquid flow for negative pressure suction casting. Background Art

[0002] At present, the combination of vacuum suspension melting technology and negative pressure suction casting technology has achieved a new casting method. After the metal reaches the predetermined pouring temperature through vacuum suspension melting in the crucible, a high-temperature melt is formed. There is a block at the bottom of the crucible, and the height of the block is only 3 to 7 mm. When the block is heated and melted by the high-temperature melt and the induction coil around the block, the suction casting pump is turned on to apply pressure to the high-temperature melt. The high-temperature melt flows from the bottom of the crucible to the mold under this negative pressure environment, thus completing the entire casting process.

[0003] Generally speaking, after the melt reaches the predetermined pouring temperature, it is necessary to maintain a certain power for a period of time to make the temperature of the molten metal more stable. Due to its small thickness, the blockage is prone to melt-through during this process, resulting in the high-temperature melt being poured prematurely when the temperature is not stable.

[0004] In addition, in the casting method that combines vacuum suspension melting and negative pressure suction casting, there are certain defects in the control of the metal liquid flow, because the suction casting pump is mainly turned on by human observation. When the flow of the high-temperature melt is observed by the smelting personnel, the smelting personnel turn on the suction casting switch, and pressure can be applied to the melt at this time. The time error generated in the middle will significantly reduce the flow filling efficiency of the high-temperature melt, thereby reducing the quality of the negative pressure suction casting. Therefore, it is necessary to explore new observation schemes to improve the flow filling efficiency of the melt. Summary of the invention

[0005] In order to improve the flow filling efficiency of high temperature melt and improve the quality of negative pressure suction castings, the present application provides a metal liquid flow control method, device, equipment, medium and system for negative pressure suction casting.

[0006] In a first aspect, the present application provides a method for controlling a metal liquid flow for negative pressure suction casting, comprising:

[0007] Based on the target suction casting time corresponding to the molten metal in the crucible, adjusting the heating power of the heating element corresponding to the crucible block, the heating element comprising a laser emitter;

[0008] Based on the infrared receiver, the number of received light points is obtained, where the number of received light points is used to characterize the parameter of the situation that the molten metal flowing out of the crucible blocks the transmission of infrared rays;

[0009] If the number of received light points is lower than the target light point number range, it is determined that the crucible block has been melted and the molten metal has flowed out of the crucible, the heating element is controlled to stop heating, and the suction casting pump is controlled to start so that the suction casting pump performs negative pressure suction casting on the molten metal.

[0010] The beneficial effects of the present application are as follows: when it is identified through the number of received light points that the crucible block is completely melted and molten metal is flowing out, the suction casting pump is automatically controlled to start, thereby improving the accuracy of identifying the flow state of the molten metal, significantly reducing the difficulty of manual operation, reducing the risk of manual operation, improving the stability and safety of production, ensuring that the entire filling process is stable and efficient, improving the flow filling efficiency of the high-temperature melt, and improving the quality of negative pressure suction castings.

[0011] Further, before determining whether the number of received light points is lower than the target light point number range, the method further includes:

[0012] Acquiring thermal physical property parameter information corresponding to the metal liquid, wherein the thermal physical property parameter information includes fluid dynamic viscosity;

[0013] Based on the thermophysical property parameter information, the target light spot number range is acquired.

[0014] The beneficial effect of adopting the above further scheme is that the target light spot number range can be automatically updated according to the thermal physical property parameter information corresponding to the molten metal. By automatically updating the target light spot number range, the sensitivity of infrared detection of metal droplet size can be adjusted, thereby accurately controlling the flow of molten metals of different materials and different viscosities.

[0015] Further, after the control of the suction casting pump is started, it also includes:

[0016] Based on the current heating temperature of the molten metal in the crucible and the thermophysical property parameter information, a target solidification time corresponding to the molten metal is obtained, wherein the target solidification time is the time required for the molten metal to completely solidify after entering the mold from the crucible;

[0017] Based on the new number of received light points, it is determined whether the molten metal in the crucible has completely flowed out; if the molten metal has completely flowed out, the current solidification time is recorded, and when the current solidification time reaches the target solidification time, the suction casting pump is controlled to be closed.

[0018] The beneficial effect of adopting the above further scheme is that when the molten metal in the crucible completely flows out and the current solidification time of the molten metal reaches the target solidification time, the suction casting pump can be controlled to automatically shut down in time, which significantly reduces the difficulty of manual operation, reduces the risk of manual operation, and improves the quality of negative pressure suction castings.

[0019] Furthermore, after the number of received light points is lower than the target light point number range and before determining that the melting of the crucible block is complete and the molten metal flows out of the crucible, the method further includes:

[0020] Based on the infrared receiver, obtaining a plurality of receiving light spot positions;

[0021] Based on the positions of the plurality of received light spots, obtaining the blocking form of the object that blocks the infrared transmission;

[0022] If the blocking shape is not the flow shape corresponding to the current metal liquid, re-execute the step of obtaining the number of received light points;

[0023] If the blocking shape is the flow shape corresponding to the current molten metal, the step of determining that the melting of the crucible block is complete and the molten metal flows out of the crucible is performed.

[0024] The beneficial effect of adopting the above further scheme is that the infrared receiver can capture the signal of the metal liquid blocking the infrared rays in real time, can quickly identify the flow pattern of the metal liquid, can timely find the abnormal situation in the flow of the metal liquid, so as to take timely measures to make adjustments, and ensure that the metal liquid flows out of the crucible according to the expected flow pattern. It can adapt to the detection needs of different metal liquid types, flow speeds and flow patterns.

[0025] Further, after the control of the suction casting pump is started, it includes:

[0026] Predicting the flow trend of the molten metal based on the real-time blocking morphology;

[0027] Based on the flow trend, operating parameters of the suction casting pump are adjusted.

[0028] The beneficial effect of adopting the above further solution is that by real-time monitoring of the flow of molten metal and dynamically adjusting the operating parameters of the suction casting pump according to the predicted results, it can ensure that the molten metal can be accurately and evenly filled into various areas of the mold, thereby improving the quality and consistency of the casting. Real-time monitoring and dynamic adjustment make the production process more controllable and reduce the uncertainty and risk in the production process.

[0029] Further, the obtaining of a target solidification time corresponding to the molten metal based on the current heating temperature of the molten metal in the crucible and the thermophysical property parameter information includes:

[0030] Based on the current heating temperature and the thermophysical property parameter information, obtaining the initial solidification time corresponding to the molten metal;

[0031] Based on the plurality of blocking forms, obtaining the flow path and distribution of the molten metal entering the mold;

[0032] Based on the flow path and the distribution condition, the initial coagulation time is adjusted to obtain the target coagulation time.

[0033] The beneficial effect of adopting the above further scheme is: by adjusting the initial solidification time based on the flow path and distribution, it is possible to ensure that the solidification process of the molten metal in the mold is more uniform and stable, thereby reducing the occurrence of defects such as shrinkage cavities and shrinkage, and improving the solidification quality of the casting.

[0034] In a second aspect, the present application provides a metal liquid flow control device for negative pressure suction casting, comprising:

[0035] A power adjustment module, used to adjust the heating power of a heating element corresponding to the crucible block based on a target suction casting time corresponding to the molten metal in the crucible, wherein the heating element includes a laser emitter;

[0036] A light point number acquisition module is used to acquire the number of received light points based on an infrared receiver, wherein the number of received light points is used to characterize the parameters of the situation in which the molten metal flowing out of the crucible blocks the transmission of infrared rays;

[0037] The control module is used to determine that the melting of the crucible block is complete and the molten metal flows out of the crucible when the number of received light points is lower than the target light point number range, control the heating element to stop heating, and control the suction casting pump to start, so that the suction casting pump performs negative pressure suction casting on the molten metal.

[0038] In a third aspect, the present application provides an electronic device, including a processor and a memory, wherein the processor is coupled to the memory;

[0039] The processor is used to execute the computer program stored in the memory so that the electronic device performs the method as described in any one of the first aspects.

[0040] In a fourth aspect, the present application provides a computer-readable storage medium, comprising a computer program or instructions, which, when executed on a computer, enables the computer to execute the method as described in any one of the first aspects.

[0041] In a fifth aspect, the present application provides a metal liquid flow control system for negative pressure suction casting, comprising a crucible, a melt, a crucible block, a heating element, an infrared transmitter, an infrared receiver, a processor, a suction casting pump and a mold;

[0042] The crucible is used to hold the melt and heat the melt to obtain molten metal; the crucible includes a graphite tube arranged at the bottom, and the crucible block is arranged in the graphite tube;

[0043] The heating element is used to heat the crucible block, and the heating element includes a laser emitter; the heating element is in communication connection with the processor, and the processor is used to adjust the heating power of the heating element corresponding to the crucible block based on the target suction casting time corresponding to the molten metal in the crucible;

[0044] The infrared transmitter and the infrared receiver are arranged below the crucible block, and the infrared transmitter is used to send infrared rays to the infrared receiver;

[0045] The infrared receiver is in communication connection with the processor, and the processor is further used to obtain the number of received light points based on the infrared receiver, wherein the number of received light points is used to characterize the parameter of the situation that the molten metal flowing out of the crucible blocks the transmission of infrared rays;

[0046] The processor is also used to determine that the crucible block has been melted and the molten metal has flowed out of the crucible when the number of received light points is lower than the target light point number range, control the heating element to stop heating, and control the suction casting pump to start, so that the suction casting pump performs negative pressure suction casting on the molten metal, and the molten metal enters the mold. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 This is a structural diagram of a metal liquid flow control system for negative pressure suction casting according to an embodiment of the present application;

[0048] Figure 2 This is a schematic diagram of the process of the metal liquid flow control method for negative pressure suction casting according to an embodiment of the present application;

[0049] Figure 3 This is a structural block diagram of a metal liquid flow control device for negative pressure suction casting according to an embodiment of the present application;

[0050] Figure 4 This is a structural block diagram of an electronic device according to an embodiment of the present application.

[0051] In the accompanying drawings, the components represented by the reference numerals are listed as follows:

[0052] 1. Crucible; 2. Melt; 3. Graphite tube; 4. Secondary coil; 5. Metal rod; 6. Laser transmitter; 7. Infrared transmitter; 8. Infrared receiver; 9. Mold; 10. Signal amplifier; 11. Relay; 12. Suction casting pump. DETAILED DESCRIPTION

[0053] The present application is further described in detail below in conjunction with the accompanying drawings.

[0054] like Figure 1 As shown, an embodiment of the present application provides a metal liquid flow control system for negative pressure suction casting, including a crucible 1, a melt 2, a crucible block, a heating element, an infrared transmitter 7, an infrared receiver 8, a processor, a suction casting pump 12 and a mold 9.

[0055] The crucible 1 is used to contain a melt 2 and heat the melt 2 to obtain a molten metal; the crucible 1 includes a graphite tube 3 arranged at the bottom, and the crucible block is arranged in the graphite tube 3.

[0056] In this embodiment, the crucible block can be a columnar metal rod 5 made of the same material as the melt 2. The height of the metal rod 5 can be 3-8 cm. The columnar metal rod 5 runs through the entire graphite tube 3. By increasing the height of the metal rod 5, the melting time of the crucible block can be extended, so that the molten metal liquid in the crucible 1 has sufficient time for heating and insulation, thereby providing a higher pouring temperature and improving the quality of the casting to a certain extent.

[0057] The heating element is used to heat the crucible block, and the heating element includes a laser emitter 6; the heating element is connected to the processor for communication, and the processor is used to adjust the heating power of the heating element corresponding to the crucible block based on the target suction casting time corresponding to the molten metal in the crucible 1. The target suction casting time is the time when the metal rod 5 is heated to complete melting, that is, the time when the molten metal in the crucible 1 starts to flow into the mold 9.

[0058] In this embodiment, the heating element may further include a secondary coil 4, which is disposed around the metal rod 5. The laser emitter 6 and the secondary coil 4 are used as heat sources to heat the metal rod 5 at the bottom of the crucible 1. The heat source first heats the bottom of the columnar metal rod 5. When the bottom of the metal rod 5 melts, the upper metal rod 5 gradually falls off and is further heated by the laser heat source. The whole process continues until the molten metal liquid inside the crucible 1 flows smoothly into the mold cavity 9. Not only is the melting efficiency of the columnar metal rod 5 accelerated, but also the melting time of the metal rod 5 and the time of pouring the metal liquid into the mold 9 can be accurately controlled by controlling the power of the laser emitter 6.

[0059] The infrared transmitter 7 and the infrared receiver 8 are arranged below the crucible block, and the infrared transmitter 7 is used to send infrared rays to the infrared receiver 8. The infrared receiver 8 is communicatively connected with the processor, and the processor is further used to obtain the number of received light points based on the infrared receiver 8, and the number of received light points is used to characterize the parameters of the situation that the metal liquid flowing out of the crucible 1 blocks the transmission of infrared rays.

[0060] The processor is also used to determine that the crucible block has been melted and the molten metal has flowed out of the crucible 1 when the number of received light points is lower than the target light point number range, control the heating element to stop heating, and control the suction casting pump 12 to start, so that the suction casting pump 12 performs negative pressure suction casting on the molten metal, and the molten metal enters the mold 9.

[0061] By introducing the infrared receiver and the infrared transmitter 7, the flow of the molten metal can be monitored in real time. A signal amplifier 10 can also be arranged between the infrared receiver 8 and the processor, and the signal amplifier 10 is used to amplify the signal output by the infrared receiver 8. The infrared rays emitted by the infrared transmitter 7 can be displayed on the infrared receiver 8 in the form of light spots, and the signal amplifier 10 can display the current number of received light spots and the rated number of light spots. When the molten metal does not flow out of the crucible 1, the infrared rays emitted by the infrared transmitter 7 can be completely received by the infrared receiver 8, and the number of received light spots at this time is equal to the rated number of light spots.

[0062] The processor is electrically connected to a relay 11, and the relay 11 is electrically connected to a suction casting pump 12. The suction casting pump 12 applies pressure to the high-temperature melt 2, and the high-temperature melt 2 flows to the mold 9 through the bottom of the crucible 1 under a negative pressure environment, thereby completing the entire casting process. As the temperature of the molten metal reaches the predetermined requirement, the metal rod 5 is completely melted by the laser, and the molten metal begins to flow, blocking the transmission of infrared rays, and the number of light spots received by the infrared receiver decreases. When the number of received light spots is lower than the target light spot number range, the processor controls the relay 11 to work, thereby turning on the suction casting pump 12 and entering the negative pressure suction casting process.

[0063] The target light spot number range can be automatically updated according to the thermophysical property parameter information corresponding to the molten metal. By automatically updating the target light spot number range, the sensitivity of infrared detection of metal droplet size can be adjusted, thereby accurately controlling the flow of molten metals of different materials and viscosities.

[0064] In the process of laser melting the columnar metal rod 5, due to the small volume of the metal rod 5, the generated molten metal droplets are small, and the number of light spots blocked is also small. By setting the target light spot number range, the detection error caused by the droplets generated by the metal rod 5 can be completely eliminated. When the columnar metal rod 5 is not completely melted, the number of received light spots is not less than the target light spot number range, and the processor controls the relay 11 not to work. At this time, the suction casting pump 12 is in a closed state, saving energy consumption. Through this closed-loop control process, the system can more accurately identify the flow state of the molten metal, and change the working state of the suction casting pump 12 through real-time feedback, which significantly reduces the difficulty of manual operation, reduces the risk of manual operation, improves the stability and safety of production, ensures that the entire filling process is stable and efficient, improves the flow filling efficiency of the high-temperature melt 2, and improves the quality of negative pressure suction castings.

[0065] Based on the same technical concept, the embodiment of the present application provides a method for controlling the flow of metal liquid for negative pressure suction casting using the above-mentioned control system for the flow of metal liquid, which can be executed by a device, which can be a server or a terminal device, wherein the server can be an independent physical server, or a server cluster or distributed system composed of multiple physical servers, or a cloud server providing cloud computing services. The terminal device can be a smart phone, a tablet computer, a desktop computer, etc., but is not limited thereto.

[0066] like Figure 2 As shown, a method for controlling the flow of metal liquid for negative pressure suction casting is performed by an electronic device. The main process of the method is described as follows (steps S101 to S104):

[0067] Step S101: Based on the target suction casting time corresponding to the molten metal in the crucible, the heating power of the heating element corresponding to the crucible block is adjusted, and the heating element includes a laser emitter.

[0068] In this embodiment, the molten metal is heated by the target suction casting time so that the molten metal in the crucible can reach a desired temperature. The target suction casting time corresponding to the current molten metal can be preset in the electronic device.

[0069] The electronic device may store a first correspondence between the target suction casting time, the material of the crucible block and the heating strategy of the heating element. The heating element may also include a secondary coil, and the heating strategy is a parameter characterizing the heating power of the secondary coil and the laser transmitter. After obtaining the heating strategy corresponding to the target suction casting time, the working parameters of the secondary coil and the laser transmitter are adjusted according to the heating strategy so that the target suction casting time is reached when the crucible block can be completely melted.

[0070] Step S102: Based on the infrared receiver, the number of received light points is obtained, where the number of received light points is used to characterize the parameters of the situation in which the molten metal flowing out of the crucible blocks the transmission of infrared rays.

[0071] Step S103: determine whether the number of received light points is lower than the target light point number range; if so, proceed to step S104; if the number of received light points is not lower than the target light point number range, reacquire the number of received light points.

[0072] As an optional implementation of this embodiment, the infrared transmitter may remain turned on, that is, may always send infrared rays to the infrared receiver.

[0073] As another optional implementation of this embodiment, the infrared emitter may be controlled to be turned on within a preset time away from reaching the target suction casting time, and the infrared emitter may be controlled to be turned off when the molten metal in the crucible completely flows out.

[0074] When the crucible block melts and the molten metal begins to flow out, the droplets of molten metal will block the transmission of part of the infrared rays, causing the number of light points received by the infrared receiver to change, so that the flow of the molten metal can be identified based on the number of light points received.

[0075] Step S104: determining that the melting of the crucible block is complete and the molten metal flows out of the crucible, controlling the heating element to stop heating, and controlling the suction casting pump to start, so that the suction casting pump performs negative pressure suction casting on the molten metal.

[0076] When it is identified through the number of received light spots that the crucible block is completely melted and molten metal is flowing out, the suction casting pump is automatically controlled to start, which improves the accuracy of identifying the flow state of the molten metal, significantly reduces the difficulty of manual operation, reduces the risk of manual operation, improves the stability and safety of production, ensures that the entire filling process is stable and efficient, improves the flow filling efficiency of the high-temperature melt, and improves the quality of negative pressure suction castings.

[0077] In this embodiment, before step S103, the following processing is also included: obtaining thermophysical property parameter information corresponding to the metal liquid, the thermophysical property parameter information including fluid dynamic viscosity; based on the thermophysical property parameter information, obtaining the target light spot number range.

[0078] The electronic device stores a second correspondence between the material of the molten metal, the heating temperature of the molten metal in the crucible and the thermophysical property parameter information. By querying the second correspondence, the thermophysical property parameter information corresponding to the current molten metal can be obtained.

[0079] As an optional implementation of this embodiment, the staff can manually input the material corresponding to the current molten metal before performing the negative pressure suction casting operation. As another optional implementation of this embodiment, the electronic device can crawl the total production work order corresponding to the negative pressure suction casting operation, and the total production work order includes the materials of the molten metal corresponding to different negative pressure suction casting operations. The material of the molten metal corresponding to the current negative pressure suction casting operation can be obtained through the total production work order.

[0080] The electronic device also stores a third correspondence between different thermophysical parameter information and different target light point number ranges. The target light point number range can be automatically updated according to the thermophysical parameter information corresponding to the molten metal. By automatically updating the target light point number range, the sensitivity of infrared detection of metal droplet size can be adjusted, thereby accurately controlling the flow of molten metal of different materials and different viscosities.

[0081] In this embodiment, after step S104, the following processing is also included: based on the current heating temperature of the molten metal in the crucible and the thermophysical property parameter information, the target solidification time corresponding to the molten metal is obtained, and the target solidification time is the time required for the molten metal to completely solidify after entering the mold from the crucible; based on the new number of received light points, it is judged whether the molten metal in the crucible has completely flowed out; if the molten metal has completely flowed out, the current solidification time is recorded, and when the current solidification time reaches the target solidification time, the suction casting pump is controlled to be closed.

[0082] The electronic device also stores a fourth correspondence between different heating temperatures, thermophysical parameter information and different target solidification times. According to the fourth correspondence, the target solidification time corresponding to the current molten metal can be obtained. The infrared receiver re-collects infrared rays to obtain a new number of received light points. When the new number of received light points is within the target light point range, the molten metal in the crucible flows out completely.

[0083] When the molten metal in the crucible completely flows out and the current solidification time of the molten metal reaches the target solidification time, the suction casting pump can be controlled to automatically shut down in time, which significantly reduces the difficulty of manual operation, reduces the risk of manual operation, and improves the quality of negative pressure suction castings.

[0084] In this embodiment, after the number of received light points is lower than the target light point number range and before determining that the crucible block has been completely melted and the molten metal has flowed out of the crucible, the following processing is also included: based on the infrared receiver, a plurality of received light point positions are obtained; based on the plurality of received light point positions, a blocking form of an object that blocks infrared transmission is obtained; if the blocking form is not the flow form corresponding to the current molten metal, the step of obtaining the number of received light points is re-executed; if the blocking form is the flow form corresponding to the current molten metal, the step of determining that the crucible block has been completely melted and the molten metal has flowed out of the crucible is executed.

[0085] The infrared receiver may include a plurality of infrared receiving modules, which are arranged in a regular pattern to form an infrared receiving array, and each infrared receiving module is responsible for detecting infrared transmission conditions in a specific area.

[0086] According to the arrangement and geometric relationship of the infrared receiving array, the infrared receiving module whose light spot is blocked is identified, and the specific positions of multiple receiving light spots, that is, multiple receiving light spot positions, are obtained. After the receiving light spot positions are identified, the pattern or form formed by these light spots is further analyzed to determine the blocking form of the object blocking the infrared rays, and the blocking form may include the blocking shape and flow direction.

[0087] A series of known molten metal flow patterns are pre-stored in the electronic device as a reference. In real-time analysis, the currently identified blocking pattern is matched with the pre-stored flow pattern to determine whether the flow state of the molten metal meets expectations.

[0088] If the blocking pattern does not match the current molten metal flow pattern, the electronic device will re-execute the step of obtaining the number of received light points and can adjust the sensitivity of the infrared receiving array or recalibrate the system. If the match is successful, the electronic device will determine that the crucible block has been melted and the molten metal is flowing out of the crucible according to the expected flow pattern. At this time, the electronic device controls the heating element to stop heating and starts the suction casting pump for negative pressure suction casting.

[0089] The infrared receiving array can capture the signal of the metal liquid blocking the infrared rays in real time, quickly identify the flow pattern of the metal liquid, and promptly find abnormal conditions in the flow of the metal liquid, so as to take timely measures to make adjustments and ensure that the metal liquid flows out of the crucible in the expected flow pattern. It can adapt to the detection needs of different metal liquid types, flow speeds and flow patterns.

[0090] In this embodiment, before obtaining the positions of multiple receiving light spots, the infrared receiving array may be calibrated, and the calibration process may include adjusting the sensitivity of the infrared receiving module according to the current heating temperature of the molten metal in the crucible. By automatically adjusting the sensitivity of the infrared receiving module, the infrared receiving module is ensured to work stably to adapt to working environments at different temperatures.

[0091] In this embodiment, after step S104, the following processing is also included: predicting the flow trend of the molten metal based on the real-time blocking form; and adjusting the operating parameters of the suction casting pump based on the flow trend.

[0092] A mathematical model or simulation model of molten metal flow can be established in electronic equipment, which can comprehensively consider factors such as the thermophysical parameters of molten metal (such as density, viscosity, surface tension, etc.), flow velocity, temperature gradient, and mold shape. The real-time acquired blocking morphology is input into the model to predict the flow trend of molten metal. The predicted flow trend can include the flow direction, velocity, and flow rate of the molten metal.

[0093] According to the predicted flow trend, the operating parameters of the suction casting pump are dynamically adjusted. The operating parameters of the suction casting pump may include parameters such as the pumping rate and the pumping time. For example, if it is predicted that the molten metal will flow to a specific area of ​​the mold, the pumping rate of the specific area can be increased to accelerate the filling of the molten metal; if it is concluded from the flow trend that the solidification time of the molten metal in a specific area is longer than that of the molten metal in other areas, the pumping time of the specific area can be increased to reduce the solidification time of the specific area.

[0094] By monitoring the flow of molten metal in real time and dynamically adjusting the operating parameters of the suction casting pump based on the predicted results, it is possible to ensure that the molten metal can be accurately and evenly filled into all areas of the mold, thereby improving the quality and consistency of the castings. Real-time monitoring and dynamic adjustment make the production process more controllable and reduce uncertainty and risk in the production process.

[0095] In this embodiment, the electronic device also stores a predictive solidification model that is established based on the thermophysical parameters of the molten metal (such as melting point, thermal conductivity, density, etc.) and the material and shape of the mold, and is able to predict the solidification process of the molten metal in the mold. Real-time data such as the current heating temperature of the molten metal, the flow velocity, and the temperature distribution of the mold are input into the predictive solidification model. The predictive solidification model can be used to simulate the solidification process of the molten metal in the mold, and the solidification time and solidification sequence of the molten metal in each area of ​​the mold can be obtained. According to the simulated solidification time and solidification sequence, the solidification conditions of each area in the mold are analyzed, and areas that may have local solidification risks are identified. It is easy to understand that an area with local solidification risks means that the molten metal in the area is about to solidify.

[0096] When adjusting the operating parameters of the suction casting pump, it is necessary to consider the solidification of the molten metal to reduce the possibility of local solidification in areas where there is a risk of local solidification.

[0097] Specifically, adjusting the operating parameters of the suction casting pump based on the flow trend specifically includes:

[0098] According to the flow trend of the molten metal and the solidification conditions of each area in the mold, a specific parameter adjustment strategy for the suction casting pump is formulated, and the parameter adjustment strategy includes the adjustment range, adjustment timing, etc.; according to the formulated adjustment strategy, the operating parameters of the suction casting pump are adjusted in real time; during the parameter adjustment process, the flow and solidification data of the molten metal in the mold are continuously collected, and compared and analyzed with the expected results corresponding to the adjustment strategy. If it is found that the actual solidification situation is inconsistent with the expected results, the parameter adjustment strategy should be adjusted in time to improve the accuracy and reliability of negative pressure suction casting.

[0099] Adjustment timing refers to choosing the best time to adjust the parameters of the suction casting pump during the casting process according to the flow state of the molten metal and changes in the solidification process.

[0100] Combined with the historical parameter adjustment data of the suction casting pump corresponding to the negative pressure suction casting operation, the optimal adjustment range and adjustment timing corresponding to the current flow trend and solidification situation are obtained. The historical parameter adjustment data includes the corresponding relationship between different flow trends, solidification conditions, parameter adjustment strategies and actual solidification conditions after adjustment. The optimal adjustment range is comprehensively considered based on the flow velocity, solidification time and actual solidification conditions of the molten metal to ensure that the adjusted parameters can both promote the flow of the molten metal and prevent local solidification; the optimal adjustment timing can ensure that the molten metal is evenly filled in the mold and will not solidify prematurely. At the same time, factors such as production efficiency, product quality and production cost need to be considered. By reasonably determining the adjustment range and adjustment timing, the casting process of the molten metal can be optimized and product quality and production efficiency can be improved.

[0101] In this embodiment, the target solidification time corresponding to the molten metal is obtained based on the current heating temperature of the molten metal in the crucible and the thermophysical property parameter information, which specifically includes the following processing: based on the current heating temperature and the thermophysical property parameter information, the initial solidification time corresponding to the molten metal is obtained; based on the multiple blocking forms, the flow path and distribution of the molten metal entering the mold are obtained; based on the flow path and the distribution, the initial solidification time is adjusted to obtain the target solidification time.

[0102] During the flow of molten metal, infrared receivers are used to continuously capture signals of molten metal blocking infrared rays, and based on these signals, the flow path and distribution of the molten metal in the mold are reconstructed. The flow path can include the various channels and areas that the molten metal passes through after flowing out of the crucible, and the distribution describes the filling degree and density of the molten metal in each area.

[0103] Based on the current heating temperature and thermophysical property parameter information of the molten metal in the crucible, the initial solidification time of the molten metal can be calculated using an empirical formula or a simulation model. The initial solidification time refers to the initial time required for the molten metal to flow out of the crucible and begin to solidify.

[0104] The initial solidification time can be adjusted based on the flow path and distribution obtained. For example, if the molten metal fills unevenly or there are voids in a certain area of ​​the mold, the solidification time of that area can be extended to ensure that the molten metal is completely solidified.

[0105] By adjusting the initial solidification time based on the flow path and distribution, the solidification process of the molten metal in the mold can be ensured to be more uniform and stable, thereby reducing the occurrence of defects such as shrinkage cavities and shrinkage, and improving the solidification quality of the casting.

[0106] Based on the same technical concept, the present application also provides a metal liquid flow control device for negative pressure suction casting, such as Figure 3 As shown, the metal liquid flow control device 200 for negative pressure suction casting mainly includes:

[0107] A power adjustment module 201 is used to adjust the heating power of a heating element corresponding to the crucible block based on a target suction casting time corresponding to the molten metal in the crucible, wherein the heating element includes a laser emitter;

[0108] A light point number acquisition module 202 is used to acquire the number of received light points based on an infrared receiver, wherein the number of received light points is used to characterize the parameter of the situation in which the molten metal flowing out of the crucible blocks the transmission of infrared rays;

[0109] The control module 203 is used to determine that the melting of the crucible block is complete and the molten metal flows out of the crucible when the number of received light points is lower than the target light point number range, control the heating element to stop heating, and control the suction casting pump to start so that the suction casting pump performs negative pressure suction casting on the molten metal.

[0110] Optionally, before the control module 203, the method further includes:

[0111] A property information acquisition module is used to acquire the thermophysical property parameter information corresponding to the metal liquid, wherein the thermophysical property parameter information includes the fluid dynamic viscosity;

[0112] The range acquisition module is used to acquire the target light spot number range based on the thermophysical property parameter information.

[0113] Optionally, after the control module 203, the following is further included:

[0114] A time acquisition module is used to acquire a target solidification time corresponding to the molten metal based on the current heating temperature of the molten metal in the crucible and the thermophysical property parameter information, wherein the target solidification time is the time required for the molten metal to completely solidify after entering the mold from the crucible;

[0115] The control closing module is used to determine whether the molten metal in the crucible has completely flowed out based on the new number of received light points; if the molten metal has completely flowed out, the current solidification time is recorded, and when the current solidification time reaches the target solidification time, the suction casting pump is controlled to be closed.

[0116] Optionally, after the number of received light points is lower than the target light point number range and before determining that the melting of the crucible block is complete and the molten metal flows out of the crucible, the method further includes:

[0117] A position acquisition module, used for acquiring positions of a plurality of received light spots based on the infrared receiver;

[0118] A morphology acquisition module is used to acquire the blocking morphology of the object that blocks the transmission of infrared rays based on the positions of the multiple received light spots; if the blocking morphology is not the flow morphology corresponding to the current molten metal, the step of acquiring the number of received light spots is re-executed; if the blocking morphology is the flow morphology corresponding to the current molten metal, the step of determining that the melting of the crucible block is complete and the molten metal has flowed out of the crucible is executed.

[0119] Optionally, after the control module 203, it includes:

[0120] A prediction trend module, used to predict the flow trend of the molten metal based on the real-time blocking morphology;

[0121] The parameter adjustment module is used to adjust the operating parameters of the suction casting pump based on the flow trend.

[0122] Optionally, the duration acquisition module includes:

[0123] An initial duration acquisition submodule is used to acquire the initial solidification duration corresponding to the molten metal based on the current heating temperature and the thermophysical property parameter information;

[0124] A path distribution acquisition submodule is used to acquire the flow path and distribution of the molten metal into the mold based on the plurality of blocking forms;

[0125] The duration adjustment submodule is used to adjust the initial coagulation duration based on the flow path and the distribution condition to obtain the target coagulation duration.

[0126] In one example, the module in any of the above devices can be one or more integrated circuits configured to implement the above methods, such as: one or more application specific integrated circuits (ASICs), or, one or more digital signal processors (DSPs), or, one or more field programmable gate arrays (FPGAs), or a combination of at least two of these integrated circuit forms.

[0127] For another example, when the modules in the device can be implemented in the form of a processing element scheduling program, the processing element can be a general-purpose processor, such as a central processing unit (CPU) or other processor that can call a program. For another example, these modules can be integrated together and implemented in the form of a system-on-a-chip (SOC).

[0128] Various objects such as various messages / information / equipment / network elements / systems / devices / actions / operations / processes / concepts that may appear in this application are named. It can be understood that these specific names do not constitute a limitation on the relevant objects. The names assigned may change with factors such as scenarios, contexts or usage habits. The understanding of the technical meaning of the technical terms in this application should be mainly determined from the functions and technical effects embodied / executed in the technical scheme.

[0129] Those skilled in the art can clearly understand that, for the convenience and brevity of description, the specific working processes of the systems, devices and modules described above can refer to the corresponding processes in the aforementioned method embodiments and will not be repeated here.

[0130] Those of ordinary skill in the art will appreciate that the modules and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professional and technical personnel can use different methods to implement the described functions for each specific application, but such implementation should not be considered to be beyond the scope of this application.

[0131] Based on the same technical concept, the present application also provides an electronic device, such as Figure 4 As shown, the electronic device 300 includes a processor 301 and a memory 302 , and may further include an information input / information output (I / O) interface 303 , one or more of a communication component 304 , and a communication bus 305 .

[0132] The processor 301 is used to control the overall operation of the electronic device 300 to complete all or part of the steps in the above-mentioned method for controlling the flow of metal liquid for negative pressure suction casting; the memory 302 is used to store various types of data to support the operation of the electronic device 300, and these data may include, for example, instructions for any application or method used to operate on the electronic device 300, and data related to the application. The memory 302 can be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as static random access memory (SRAM), electrically erasable programmable read-only memory (EEPROM), erasable programmable read-only memory (EPROM), programmable read-only memory (PROM), read-only memory (ROM), magnetic memory, flash memory, disk or optical disk. One or more.

[0133] The I / O interface 303 provides an interface between the processor 301 and other interface modules, and the above-mentioned other interface modules can be keyboards, mice, buttons, etc. These buttons can be virtual buttons or physical buttons. The communication component 304 is used to test the wired or wireless communication between the electronic device 300 and other devices. Wireless communication, such as Wi-Fi, Bluetooth, Near Field Communication (NFC), 2G, 3G or 4G, or a combination of one or more of them, so the corresponding communication component 304 can include: Wi-Fi components, Bluetooth components, NFC components.

[0134] The communication bus 305 may include a path to transmit information between the above components. The communication bus 305 may be a PCI (Peripheral Component Interconnect) bus or an EISA (Extended Industry Standard Architecture) bus, etc. The communication bus 305 may be divided into an address bus, a data bus, a control bus, etc.

[0135] The electronic device 300 can be implemented by one or more application specific integrated circuits (ASIC), digital signal processors (DSP), digital signal processing devices (DSPD), programmable logic devices (PLD), field programmable gate arrays (FPGA), controllers, microcontrollers, microprocessors or other electronic components to execute the metal liquid flow control method for negative pressure suction casting given in the above embodiment.

[0136] The electronic device 300 may include, but is not limited to, a mobile terminal such as a digital broadcast receiver, a PDA (Personal Digital Assistant), a PMP (Portable Multimedia Player), etc., and a fixed terminal such as a digital TV, a desktop computer, etc., and may also be a server, etc.

[0137] Based on the same technical concept, the present application also provides a computer-readable storage medium, on which a computer program is stored. When the computer program is executed by a processor, the steps of the above-mentioned metal liquid flow control method for negative pressure suction casting are implemented.

[0138] The computer-readable storage medium may include: a USB flash drive, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM), a magnetic disk or an optical disk, and other media that can store program codes.

[0139] The terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not expressly listed, or also includes elements inherent to such process, method, article, or apparatus.

[0140] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In the description of this application, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0141] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, without contradiction.

[0142] Although the embodiments of the present application have been shown and described above, it can be understood that the above embodiments are exemplary and cannot be understood as limitations on the present application. Ordinary technicians in this field can change, modify, replace and modify the above embodiments within the scope of the present application.

Claims

1. A method for controlling the flow of molten metal for negative pressure suction casting, characterized in that: include: Based on the target suction casting time corresponding to the molten metal in the crucible, adjusting the heating power of the heating element corresponding to the crucible block, the heating element comprising a laser emitter and a secondary coil; Based on the infrared receiver, the number of received light points is obtained, where the number of received light points is used to characterize the parameter of the situation that the molten metal flowing out of the crucible blocks the transmission of infrared rays; If the number of received light points is lower than the target light point number range, it is determined that the crucible block has been melted and the molten metal has flowed out of the crucible, the heating element is controlled to stop heating, and the suction casting pump is controlled to start, so that the suction casting pump performs negative pressure suction casting on the molten metal; After the number of received light points is lower than the target light point number range, before determining that the melting of the crucible block is complete and the molten metal flows out of the crucible, the method further includes: obtaining a plurality of received light point positions based on the infrared receiver; obtaining a blocking form of an object that blocks infrared transmission based on the plurality of received light point positions; if the blocking form is not a flow form corresponding to the current molten metal, re-executing the step of obtaining the number of received light points; if the blocking form is a flow form corresponding to the current molten metal, executing the step of determining that the melting of the crucible block is complete and the molten metal flows out of the crucible; After the control of the suction casting pump is started, the method includes: predicting the flow trend of the molten metal based on the real-time blocking form; and adjusting the operating parameters of the suction casting pump based on the flow trend; The adjusting the operating parameters of the suction casting pump based on the flow trend includes: formulating a parameter adjustment strategy for the suction casting pump based on the flow trend of the molten metal and the solidification conditions of each area in the mold, the parameter adjustment strategy including an adjustment range and an adjustment timing; adjusting the operating parameters of the suction casting pump in real time according to the formulated parameter adjustment strategy; during the parameter adjustment process, collecting the flow and solidification data of the molten metal in the mold in real time, comparing and analyzing the data with the expected results corresponding to the parameter adjustment strategy, and adjusting the parameter adjustment strategy if the actual solidification conditions do not match the expected results.

2. A method for controlling the flow of molten metal for negative pressure suction casting according to claim 1, characterized in that: Before determining whether the number of received light points is lower than the target light point number range, the method further includes: Acquiring thermal physical property parameter information corresponding to the metal liquid, wherein the thermal physical property parameter information includes fluid dynamic viscosity; Based on the thermophysical property parameter information, the target light spot number range is acquired.

3. A method for controlling the flow of molten metal for negative pressure suction casting according to claim 2, characterized in that: After the control of the suction casting pump is started, the method further comprises: Based on the current heating temperature of the molten metal in the crucible and the thermophysical property parameter information, a target solidification time corresponding to the molten metal is obtained, wherein the target solidification time is the time required for the molten metal to completely solidify after entering the mold from the crucible; Based on the new number of received light points, it is determined whether the molten metal in the crucible has completely flowed out; if the molten metal has completely flowed out, the current solidification time is recorded, and when the current solidification time reaches the target solidification time, the suction casting pump is controlled to be closed.

4. A method for controlling the flow of molten metal for negative pressure suction casting according to claim 3, characterized in that: The step of obtaining a target solidification time corresponding to the molten metal based on the current heating temperature of the molten metal in the crucible and the thermophysical property parameter information includes: Based on the current heating temperature and the thermophysical property parameter information, obtaining the initial solidification time corresponding to the molten metal; Based on the plurality of blocking forms, obtaining the flow path and distribution of the molten metal entering the mold; Based on the flow path and the distribution condition, the initial coagulation time is adjusted to obtain the target coagulation time.

5. A metal liquid flow control device for negative pressure suction casting, characterized in that: include: A power adjustment module is used to adjust the heating power of a heating element corresponding to the crucible block based on a target suction casting time corresponding to the molten metal in the crucible, wherein the heating element includes a laser emitter and a secondary coil; A light point number acquisition module is used to acquire the number of received light points based on an infrared receiver, wherein the number of received light points is used to characterize the parameters of the situation in which the molten metal flowing out of the crucible blocks the transmission of infrared rays; a control module, for determining, when the number of received light points is lower than a target light point number range, that the crucible block has been melted and the molten metal has flowed out of the crucible, controlling the heating element to stop heating, and controlling the suction casting pump to start, so that the suction casting pump performs negative pressure suction casting on the molten metal; After the number of received light points is lower than the target light point number range, and before determining that the melting of the crucible block is complete and the molten metal flows out of the crucible, the method further includes: A position acquisition module, used for acquiring positions of a plurality of received light spots based on the infrared receiver; A shape acquisition module is used to acquire the blocking shape of the object that blocks the infrared transmission based on the multiple positions of the received light spots; if the blocking shape is not the flow shape corresponding to the current molten metal, the step of acquiring the number of received light spots is re-executed; if the blocking shape is the flow shape corresponding to the current molten metal, the step of determining that the melting of the crucible block is completed and the molten metal flows out of the crucible is executed; After the control module, it includes: A prediction trend module, used to predict the flow trend of the molten metal based on the real-time blocking morphology; A parameter adjustment module is used to adjust the operating parameters of the suction casting pump based on the flow trend; the adjustment of the operating parameters of the suction casting pump based on the flow trend includes: formulating a parameter adjustment strategy for the suction casting pump based on the flow trend of the molten metal and the solidification conditions of each area in the mold, the parameter adjustment strategy including an adjustment range and an adjustment timing; adjusting the operating parameters of the suction casting pump in real time according to the formulated parameter adjustment strategy; in the process of parameter adjustment, collecting the flow and solidification data of the molten metal in the mold in real time, and comparing and analyzing them with the expected results corresponding to the parameter adjustment strategy, and adjusting the parameter adjustment strategy if the actual solidification condition does not match the expected result.

6. An electronic device, characterized in that: comprising a processor and a memory, wherein the processor is coupled to the memory; The processor is configured to execute a computer program stored in the memory, so that the electronic device executes the method according to any one of claims 1 to 4.

7. A computer-readable storage medium, characterized in that: The method comprises a computer program or an instruction, which, when executed on a computer, causes the computer to execute the method according to any one of claims 1 to 4.

8. A metal liquid flow control system for negative pressure suction casting used in the method according to any one of claims 1 to 4, characterized in that: It includes a crucible, a melt, a crucible block, a heating element, an infrared transmitter, an infrared receiver, a processor, a suction casting pump and a mold; The crucible is used to hold the melt and heat the melt to obtain molten metal; the crucible includes a graphite tube arranged at the bottom, and the crucible block is arranged in the graphite tube; The heating element is used to heat the crucible block, and the heating element includes a laser emitter; the heating element is in communication connection with the processor, and the processor is used to adjust the heating power of the heating element corresponding to the crucible block based on the target suction casting time corresponding to the molten metal in the crucible; The infrared transmitter and the infrared receiver are arranged below the crucible block, and the infrared transmitter is used to send infrared rays to the infrared receiver; The infrared receiver is in communication connection with the processor, and the processor is further used to obtain the number of received light points based on the infrared receiver, wherein the number of received light points is used to characterize the parameter of the situation that the molten metal flowing out of the crucible blocks the transmission of infrared rays; The processor is also used to determine that the crucible block has been melted and the molten metal has flowed out of the crucible when the number of received light points is lower than the target light point number range, control the heating element to stop heating, and control the suction casting pump to start, so that the suction casting pump performs negative pressure suction casting on the molten metal, and the molten metal enters the mold.

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