Modular design and precision forming method of socket aluminum box

Abstract

The application relates to a modular design and precision forming method of a socket aluminum box in the field of information technology, and comprises the following steps: in view of the functional independence and flexible configuration requirement of the socket aluminum box, a topology optimization algorithm is used to optimize the modular design of the internal structure of the socket aluminum box, and under the premise of ensuring the strength and rigidity, the rapid replacement and cost reduction are maximized; on the basis of meeting the mechanical performance requirement, the modular design of the internal structure is further refined, a standardized interface is adopted, the reusable function module and the easy assembly are realized, flexible configuration is achieved, and maintenance is facilitated; after the aluminum box forming piece is demolded, machine vision technology is used to quickly detect the appearance quality of the aluminum box forming piece, surface defective products are removed, qualified products are subjected to size precision detection by using a three-coordinate measuring machine, and it is guaranteed that the key size meets the cooperation requirement of the modular interface.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of information technology, in particular to the field of production of socket aluminum boxes, and in particular to a modular design and precision forming method for socket aluminum boxes. BACKGROUND

[0002] In the production process of socket aluminum boxes, the traditional process usually requires multiple components to be machined and then assembled, which not only increases the production steps, but also may cause the mating gap to be too large due to the existence of slight size deviation between the components, affecting the assembly precision and stability of the socket aluminum box. In addition, the connection between multiple components is also prone to be a stress concentration point, and deformation or fracture failure may easily occur during repeated plugging and unplugging of the socket. In order to overcome the above problems, a new production process is urgently needed, which can simplify the manufacturing process of the socket aluminum box, improve the machining precision and consistency, and at the same time avoid the structural weak points introduced by the connection of components. This process requires that the socket aluminum box with complex internal structure, accurate size and strength meeting the requirements can be formed at one time, without secondary processing or assembly. However, there are many technical challenges in realizing integrated forming, such as difficulty in mold design, defects such as shrinkage and cracks in the forming process, difficulty in demolding, and difficulty in ensuring the surface quality of the product. Therefore, how to overcome the technical difficulties of integrated precision forming and realize efficient production of socket aluminum boxes is a key technical problem to be solved. SUMMARY

[0003] The present application provides a modular design and precision forming method for a socket aluminum box, which comprises the following steps:

[0004] S101, according to the functional independence and flexible configuration requirements of the socket aluminum box, a topology optimization algorithm is used to optimize the modular design of the internal structure, so as to realize rapid replacement and cost reduction to the maximum extent under the premise of ensuring strength and rigidity;

[0005] S102, according to the optimized three-dimensional model of the socket aluminum box, the mechanical performance simulation is carried out through the finite element analysis software, the stress-strain distribution cloud diagram is obtained, the stress concentration area is determined, if the stress exceeds the allowable stress of the material, the thickness of the weak structure part is increased or the reinforcing rib is designed, at the same time, high-strength materials are selected, and heat treatment and surface strengthening process are adopted to improve the steeliness;

[0006] S103, on the basis of meeting the mechanical performance requirements, the modular design of the internal structure is further refined, the standardized interface is adopted, the reusable and easily assembled function modules are realized, which can be flexibly configured and easily maintained;

[0007] S104, in order to ensure one-time precision forming and smooth demolding of the complex internal structure, a precision die casting mold with multi-directional parting, inclined ejector and core pulling is designed, and at the same time, the surface quality of the mold cavity is required to be high to ensure the surface smoothness of the aluminum box forming part and improve the appearance quality;

[0008] S105, in the die casting forming process, the filling and solidification process of the aluminum liquid is simulated by numerical simulation software, the design of the gating system and the cooling system is optimized, and according to the simulation results, the process parameters such as the temperature of the aluminum liquid, the injection speed and pressure and the mold temperature are adjusted to obtain high-quality aluminum box forming parts without shrinkage and cracks;

[0009] S106, online monitoring technology is used to monitor the die casting forming process in real time, including key parameters such as aluminum liquid temperature, injection curve and mold temperature field, once the monitoring data exceeds the preset threshold range, the process parameters are adjusted in time or the machine is stopped for maintenance, to ensure the stability of batch production and the consistency of products;

[0010] S107, after the aluminum box forming part is demolded, machine vision technology is used to quickly detect the appearance quality, and surface defect products are removed, and the size precision of qualified products is detected by a three-coordinate measuring machine to ensure that the key dimensions meet the matching requirements of the modular interface;

[0011] S108, in order to verify the rigidity of the aluminum box forming part of the socket, vibration fatigue test is needed, according to the test results, if necessary, the material selection, heat treatment process or structure design is further optimized to meet the long-term use reliability requirements, through the integrated optimization of modular design and precision forming process, high-strength, lightweight and configurable high-quality production of the aluminum box of the socket is finally realized.

[0012] The technical scheme provided by the embodiment of the application can include the following beneficial effects:

[0013] The application discloses a modular design and precision forming method of a socket aluminum box, and the internal structure of the aluminum box is modularly designed through a topology optimization algorithm, so that quick replacement and cost reduction are realized under the premise of ensuring strength and rigidity. The stress concentration area is determined by using finite element analysis, and the structure is optimized accordingly. The design of the standardized interface realizes flexible configuration and easy maintenance of the functional modules. The complex internal structure is ensured to be one-time precision formed by using the precision die casting mold technology such as multi-directional parting and inclined ejector. The die casting process parameters are optimized by numerical simulation, and the forming process is controlled in real time by using online monitoring technology. The quality is detected in combination with machine vision and three-coordinate measurement technology, and the reliability is verified through vibration fatigue test. The application realizes high-strength, lightweight and configurable high-quality production of the aluminum box of the socket, and improves product performance and production efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0014] Fig. 1A flow chart of a modular design and precision forming method of an aluminum box of a socket.

[0015] Fig. 2 A schematic diagram of a modular design and precision forming method of an aluminum box of a socket.

[0016] Fig. 3 Another schematic diagram of a modular design and precision forming method of an aluminum box of a socket. DETAILED DESCRIPTION

[0017] The technical solutions of the present application will be described clearly and completely below in conjunction with embodiments. Obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0018] As Figs. 1-3 , the modular design and precision forming method of the aluminum box of the socket in the embodiment can specifically include:

[0019] S101, a topological optimization algorithm is used to optimize the modular design of the internal structure of the aluminum box of the socket according to the functional independence and flexible configuration requirements of the aluminum box of the socket, so as to maximize the rapid replacement and reduce the cost under the premise of ensuring the strength and rigidity.

[0020] S101 includes: obtaining a three-dimensional model of the aluminum box of the socket, the three-dimensional model including the internal structure and the external structure of the aluminum box of the socket; using a topological optimization algorithm to analyze the internal structure in the three-dimensional model to obtain the position distribution and connection relationship of each functional module, the functional module including a power module, a switch module and a socket module; according to the position distribution and connection relationship, using a modular design method, the functional module is divided into independent sub-modules, and the interface relationship between the sub-modules is established; for each sub-module, using a finite element analysis method, the strength and rigidity of the sub-module are calculated, and it is judged whether the sub-module satisfies the preset strength threshold and rigidity threshold; if the sub-module does not satisfy the preset strength threshold and rigidity threshold, return to the modular design step, and redivide the sub-module; according to the position distribution and connection relationship of the sub-modules, using a genetic algorithm to optimize the layout of the sub-modules, an optimal layout scheme is obtained; according to the optimal layout scheme, using a parameterized modeling technology, the three-dimensional model of the aluminum box of the socket is reconstructed, and an engineering drawing of the aluminum box of the socket is generated; according to the three-dimensional model and the engineering drawing, using a rapid prototyping technology to make a sample of the aluminum box of the socket, and to assemble and test the function; if the sample passes the assembly and function test, according to the preset batch and production process, the production plan and quality control measures of the aluminum box of the socket are formulated.

[0021] Specifically, first, the internal structure of the aluminum box is analyzed by using a topology optimization algorithm. The design domain is discretized into a 100x100 grid by using the SIMP method, and the volume fraction constraint is set to 50%. The OC method is used for iterative optimization, and after 50 iterations, the optimal position distribution and connection relationship of each functional module are obtained. Then, according to the similarity of functions and interfaces, the functional modules are divided into five independent sub-modules, namely, the power supply module, the protection module, the output module, etc. The relationship between the sub-modules is established by defining interface parameters such as voltage, current, size, etc. Next, the finite element analysis method is used to divide the grid and apply the load to each sub-module by using ANSYS software. The maximum stress and deformation of the sub-modules are calculated, among which the maximum stress of the power supply module is 15MPa, and the maximum deformation is 0.2mm, meeting the strength and stiffness requirements. Then, the genetic algorithm is used to optimize the layout of the sub-modules, taking the assembly efficiency and heat dissipation performance as the objective function. Through selection, crossover, mutation, etc., the optimal layout scheme is obtained after 100 generations of evolution, and the assembly time between sub-modules is shortened by 30%. Finally, the Creo software is used to generate three-dimensional modeling and engineering drawings of the optimized layout scheme, and a sample is made by using a 3D printer for assembly and function testing. The test results show that the aluminum box can realize fast assembly and disassembly, and all performance indicators meet the design requirements. Through cost accounting and market research, it is determined to use die casting process for batch production, with a production scale of 1000 pieces / month, and corresponding quality control measures are formulated, reducing the production cost by 20%.

[0022] S102, according to the optimized three-dimensional model of the aluminum box, the mechanical performance simulation is carried out by using the finite element analysis software, the stress-strain distribution cloud map is obtained, and the stress concentration area is determined. If the stress exceeds the allowable stress of the material, the thickness of the weak structure is increased or the reinforcing rib is designed, and high-strength materials are selected, and heat treatment and surface strengthening process are used to improve the steeliness.

[0023] S102 comprises: establishing a finite element analysis model according to the three-dimensional model of the socket aluminum box, setting material properties, boundary conditions and load conditions; performing mechanical performance simulation calculation through a finite element analysis software to obtain a stress-strain distribution cloud diagram; determining a stress concentration area according to the stress-strain distribution cloud diagram, judging whether the stress exceeds the material allowable stress; if the stress exceeds the material allowable stress, optimizing the structure weak position by increasing the thickness or designing a reinforcing rib; while optimizing the structure, selecting a high-strength material to improve the overall strength and stiffness of the socket aluminum box; performing a heat treatment process on the optimized socket aluminum box to further improve the strength by adjusting the microstructure of the material; and performing a surface strengthening process on the socket aluminum box, the surface strengthening process being shot peening or laser strengthening, to form residual compressive stress on the surface of the socket aluminum box and improve the fatigue strength and wear resistance.

[0024] Specifically, a finite element analysis model is established in ANSYS software according to the three-dimensional model of the socket aluminum box, and aluminum alloy material properties such as an elastic modulus of 70 GPa and a Poisson's ratio of 33 are set. The bottom surface is constrained, and a uniform load of 1000N is applied to the top surface. Through statics analysis, a Von Mises equivalent stress distribution cloud diagram is obtained, the maximum stress is 120 MPa, and is concentrated in the inner corner, exceeding the allowable stress of 100 MPa of the aluminum alloy. The thickness is locally increased to 4mm for optimization, and a high-strength 7075 aluminum alloy is selected to improve the strength and stiffness. The optimized part is subjected to T6 heat treatment to obtain fine precipitates through solid solution, quenching and aging processes to improve the strength. Finally, shot peening is used for strengthening treatment to form a compressive stress of 200 MPa on the surface, delay the initiation and propagation of fatigue cracks, and improve the fatigue strength and wear resistance. After a series of optimizations, the mechanical properties and reliability of the socket aluminum box are significantly improved.

[0025] S103, on the basis of meeting the mechanical performance requirements, further refining the modular design of the internal structure, using standardized interfaces to realize the reusable and easy assembly of functional modules, flexible configuration and easy maintenance.

[0026] S103 comprises: obtaining mechanical performance requirements, optimizing the internal structure, using a finite element analysis method to simulate and analyze the structure, and determining the material selection and size parameters of the key parts. If the mechanical performance indicators are met, the optimized internal structure is modularly designed, the system is divided into multiple functional modules, each module realizes a specific function, and the modules are connected and data-interacted through standardized interfaces. For the modular design, a production and manufacturing management system is established to informationally manage the processing, assembly and testing process of the modules, and realize visual monitoring of the production process.

[0027] Specifically, according to the mechanical property requirements, the internal structure is simulated and analyzed by using the finite element analysis software ANSYS. By establishing a geometric model, defining material properties (such as the elastic modulus of aluminum alloy is 70 GPa, and the Poisson's ratio is 33), applying loads and constraint conditions, and using tetrahedral meshing method to discretize the model, the mesh size is set to 2 mm considering the calculation efficiency and accuracy. By solving the stress and strain distribution of the structure under load, the size parameters of the key parts are determined, such as the wall thickness is not less than 3 mm, to ensure that the maximum stress is less than the allowable stress of the material. For the optimized internal structure, a modular design approach is adopted, which divides the system into power module, transmission module, control module, etc. Each module is interconnected through standardized interfaces (such as bolt connection, buckle connection). A parameterized design library containing three-dimensional models of each functional module is established. Through parameterized modeling technology, the module is quickly configured and called. Using the assembly design function of CAD software SolidWorks, based on the modular design scheme, the system assembly drawing is automatically generated, and the engineering drawing containing size marking and tolerance marking is output. Through the assembly tree structure, the association and traceability of parts are realized. In the assembly design stage, virtual assembly technology is applied. Through assembly simulation, the assembly tolerance matching degree between modules is checked, the assembly sequence and positioning reference are optimized, the interference is eliminated, and the assembly process document is generated. A manufacturing execution system (MES) is established to manage the information of module processing, assembly, testing and other production processes. Through bar code, RFID and other technologies, the production process visualization monitoring and quality traceability are realized. For key components with assembly precision requirement of ±02mm, online measurement and error compensation technology is adopted to ensure production consistency. A maintenance procedure based on modules is developed. The fault tree analysis (FTA) method is adopted to establish a module-level fault diagnosis knowledge base, to realize rapid fault positioning and isolation. Through the spare parts management system, the key module spare parts are reasonably configured, and the rapid replacement of fault modules is realized, with the average repair time (MTTR) controlled within 1 hour.

[0028] S104, to ensure one-time precision forming and smooth demolding of complex internal structure, a precision die casting mold with multi-directional parting, inclined ejector and core pulling is designed. At the same time, the surface quality of the mold cavity is required to be high to ensure the surface finish of the aluminum box forming part and improve the appearance quality.

[0029] S104 comprises: obtaining a three-dimensional model of a complex internal structure die casting die, the three-dimensional model comprising multi-directional parting, inclined ejector and core-pulling precision structure; according to the three-dimensional model, using a numerical control machining center to precisely machine the die cavity surface to obtain a cavity surface with a surface roughness meeting the requirements; for the cavity surface, a special coating technology is used to deposit a layer of wear-resistant, corrosion-resistant and good lubricity coating; obtaining the appearance quality requirements of the aluminum box forming part, setting the cooling water channel and the exhaust groove in the three-dimensional model, and using mold flow analysis software to simulate and optimize the aluminum liquid filling process; obtaining the pressure, speed and displacement parameter signals of the injection system, establishing a data model of the injection process; for the data model, using a machine learning algorithm to intelligently optimize and control the injection parameters; obtaining the temperature and stress state parameters of the die casting die, establishing a preventive maintenance management system of the die casting die; for the state parameters, using a machine learning algorithm for analysis, predicting the remaining service life of the die, and formulating an optimal maintenance plan.

[0030] Specifically, during the three-dimensional modeling of the die casting mold, the CATIA software is used for parametric design of the mold structure, and by setting variable parameters, the mold structure is quickly modified and optimized. For example, when designing the inclined top structure, by setting the inclined top angle, length and other parameters, the inclined top surface is automatically generated and Boolean operation is performed with the cavity surface to obtain the final cavity structure. For cavity surface machining, a five-axis numerical control machining center is used, and by optimizing the tool path and cutting parameters, the cavity surface is efficiently and precisely machined. For example, when machining the cavity curved surface, a ball end mill is used for multi-axis linkage machining with an axial cutting depth of 2 mm and a radial cutting depth of 1 mm, and a constant cutting force control strategy is used to adjust the feed speed in real time, obtaining a high-quality curved surface with a surface roughness Ra less than 8 μm. In the design of the die casting mold, the AutoCAST software is used to simulate and analyze the filling process, and by optimizing the design of the gating system and the exhaust system, the smooth filling of the aluminum liquid is realized. For example, when designing the cooling water channel, the best water channel diameter of 8 mm and the spacing of 50 mm are determined through fluid mechanics calculation, and the spiral arrangement method is used to improve the cooling efficiency and uniformity. In the mold surface treatment, the plasma spraying technology is used to deposit the metal ceramic composite coating, and by optimizing the spraying process parameters, a uniform and dense coating with a thickness of 3 mm, a hardness of HV900 and a porosity of less than 1% is obtained. In the optimization of the die casting production process, an intelligent control algorithm based on deep learning is used to monitor and analyze the pressure, velocity, displacement and other parameters of the injection process in real time, predict the pressure change trend of the aluminum liquid filling process, dynamically adjust the injection curve, and realize accurate control of the injection process. For example, a long short-term memory neural network (LSTM) based injection process prediction model is established, and by training 1000 groups of historical production data, the prediction accuracy of the injection pressure is more than 95%, effectively reducing the occurrence of die casting defects. In the multi-directional parting control, a synchronous control system based on PLC is used, and by programming the timing and velocity curve of each parting action, accurate synchronous control of multiple hydraulic cylinders is realized. For example, in the six-directional parting structure, by setting the action timing of each parting unit, the cavity closing time is less than 5 s and the cavity opening time is less than 1 s, ensuring the efficient coordination of the cavity parting action. In the preventive maintenance of the die casting mold, a health monitoring and life prediction method based on Bayesian network is used, and by monitoring the temperature, stress and other state parameters of the mold in real time, combining historical maintenance data and failure mechanism knowledge, a probability model of the mold health state is constructed to predict the remaining service life of the mold.For example, through the real-time collection of mold temperature by embedded wireless sensors, data is updated every 10 minutes, and when the temperature exceeds 200℃, a warning signal is triggered, and the remaining number of uses of the mold is predicted by combining the Bayesian network model, so as to make maintenance plans in advance and avoid sudden failure of the mold.

[0031] S105, in the die casting process, the filling and solidification process of the liquid aluminum is simulated by numerical simulation software, and the design of the gating system and the cooling system is optimized. According to the simulation results, the process parameters of the liquid aluminum temperature, the injection speed and pressure, and the mold temperature are adjusted to obtain high-quality aluminum box forming parts without shrinkage and cracks.

[0032] S105 includes: according to the three-dimensional model of the aluminum box die casting, a finite element analysis model including liquid aluminum, injection system, gating system, cooling system and mold components is established, and material properties, boundary conditions and initial conditions are set; using computational fluid dynamics method, the filling behavior of the liquid aluminum in the injection process is simulated, the temperature field, velocity field and pressure field distribution of the liquid aluminum during filling are obtained, and whether there are gas entrapment and spatter defects are judged; if there are filling defects, the structure parameters or process parameters of the injection system are adjusted until the filling defects are eliminated; using heat transfer method, the solidification process of the liquid aluminum in the cavity is simulated, the temperature field distribution and solidification time during solidification are obtained, and whether there are shrinkage and crack defects are judged; if there are solidification defects, the structure parameters or process parameters of the cooling system are adjusted until the solidification defects are eliminated.

[0033] Specifically, according to the three-dimensional model of the aluminum box die casting, a finite element analysis model including liquid aluminum, injection system, gating system, cooling system and mold components is established by using ANSYS software, and the material properties of aluminum alloy and mold steel are set, such as density of 2700kg / m 3 and 7800kg / m 3 , thermal conductivity of 237W / (m·K) and 48W / (m·K) respectively. In the numerical simulation of the injection process, the VOF method is used to track the free surface of the liquid aluminum, and the k-ε turbulence model is used to solve the N-S equation to obtain the temperature field, velocity field and pressure field distribution of the liquid aluminum during filling. Through the analysis of the velocity nephogram, it is found that there is a gas entrapment defect with a maximum velocity of 50m / s at the gate. In order to eliminate this defect, the gate cross-sectional area is increased from the original 100mm 2 to 150mm 2and the temperature of the liquid aluminum is reduced from 720℃ to 700℃, the filling simulation is performed again, and the results show that the gas trapping defects are effectively inhibited. After the filling of the liquid aluminum is completed, the finite difference method is used to solve the heat transfer equation to simulate the solidification process of the liquid aluminum in the cavity. Through the analysis of the temperature cloud chart, it is found that there is a shrinkage cavity defect with a minimum temperature of 450℃ at the bottom of the aluminum box. In order to eliminate this defect, a cooling water channel with a diameter of 8mm is added at the bottom of the aluminum box, and the mold opening time is extended from 10s to 15s, and the solidification simulation is performed again, and the results show that the shrinkage cavity defect is effectively eliminated. After the optimization design, the simulation analysis of 9 groups of orthogonal process parameters is carried out, and the influence law of the liquid aluminum temperature, the injection speed and the injection pressure on the filling time and the solidification time is obtained. Based on the gray correlation analysis method, the best process parameter combination is determined as follows: the liquid aluminum temperature is 705℃, the injection speed is 2m / s, and the injection pressure is 90MPa. At this time, the filling time is 18s, the solidification time is 4s, and the uniformity of the temperature distribution in the cavity is improved by 20%. The optimized gating system and cooling system design scheme and the best process parameter combination are applied to the actual production, and the 100 aluminum die castings produced by X-ray nondestructive testing are found to have no shrinkage, crack and other defects, and the product qualification rate is more than 98%.

[0034] S106, using online monitoring technology to monitor the die casting process in real time, including key parameters such as liquid aluminum temperature, injection curve and mold temperature field. Once the monitoring data exceeds the preset threshold range, adjust the process parameters or stop for repair in time to ensure the stability of batch production and the consistency of products.

[0035] S106 includes: obtaining the liquid aluminum temperature at the outlet of the liquid aluminum heating furnace, the injection curve data of the injection device, and the temperature field data of each region inside the mold to obtain three kinds of original data; inputting the comparison result into a pre-constructed convolutional neural network model, using the convolutional neural network model to extract features from the comparison result to obtain feature data; judging whether the feature data matches a preset fault mode, if it matches, outputting a fault code; using the adjusted process parameters for die casting production, and using a machine vision system to take pictures of the die casting products; extracting product size features through image recognition algorithm; judging whether the product size features meet the preset tolerance range, if not, sending a stop command.

[0036] Specifically, a thermocouple sensor is deployed to continuously collect the temperature of the molten aluminum at the outlet of the aluminum liquid heating furnace at a sampling frequency of 1000 times per second, assuming that the temperature of the molten aluminum is stable between 680 degrees Celsius and 720 degrees Celsius under normal operating conditions. At the same time, a pressure sensor is deployed to obtain the injection curve data of the injection device at a sampling frequency of 500 times per second, which contains information such as fast injection speed and boost pressure, for example, the fast injection speed is set to 4 meters per second, and the boost pressure is set to 70 megapascals. In addition, temperature sensors are deployed in five key areas inside the mold, such as the sprue and exhaust port, to obtain temperature field data at a sampling frequency of 200 times per second, for example, the temperature at the sprue is set to 250 degrees Celsius. The three kinds of raw data are transmitted to the data processing center in real time. After receiving the three kinds of raw data, the data processing center performs fast Fourier transform on each kind of data containing 1024 sampling points, converts the time domain signal to the frequency domain signal, and obtains the frequency spectrum data. Analyze whether there are high-frequency components exceeding 50 Hz in the frequency spectrum data. If high-frequency components are detected, apply a Butterworth low-pass filter to filter the raw data, set the cutoff frequency to 20 Hz, and filter out high-frequency noise to obtain three standard data. Input the three standard data as training samples into the pre-constructed support vector machine model, which uses a radial basis function as the kernel function, with the parameters set to: gamma value of 1 and penalty coefficient of 10. Through the training of a large amount of historical data, the support vector machine model can classify the three standard data and determine the normal operating condition range corresponding to each data. For example, the normal operating condition range of the molten aluminum temperature is 690 degrees Celsius to 710 degrees Celsius, the normal operating condition range of the fast injection speed is 8 meters per second to 2 meters per second, and the normal operating condition range of the temperature at the sprue is 245 degrees Celsius to 255 degrees Celsius. Store these normal operating condition range data in the database. The system extracts the normal operating condition range data from the database and matches the corresponding threshold data according to the product brand of the current production, for example, the aluminum alloy brand is 6061. For example, the 6061 aluminum alloy corresponds to an aluminum liquid temperature threshold of 700 ± 5 degrees Celsius, a fast injection speed threshold of 4 ± 1 meters per second, and a sprue temperature threshold of 250 ± 2 degrees Celsius. Compare the three kinds of raw data collected in real time with the three threshold data to obtain the comparison results, for example, the current aluminum liquid temperature is 703 degrees Celsius, which is within the threshold range, the comparison result is normal; the current fast injection speed is 3 meters per second, which is outside the threshold range, the comparison result is abnormal; the current temperature at the sprue is 248 degrees Celsius, which is within the threshold range, the comparison result is normal. Input the comparison results into the pre-constructed convolutional neural network model, which contains 3 convolutional layers and 2 fully connected layers, with convolution kernel sizes of 3x3, 5x5, and 3x3, and uses the hyperbolic tangent function as the activation function. The convolutional neural network model extracts features from the comparison results to obtain a feature vector containing 128 feature values. Match the feature vector with the pre-set fault mode library.If the Euclidean distance between the feature vector and the feature vector of a certain fault mode is less than a preset value 5, it is considered that the matching is successful, and the fault code corresponding to the fault mode is output, for example, "code 001" represents "fast injection speed is too high". The system extracts the fault code "code 001" from the fault code library, finds the corresponding solution "reduce the fast injection speed setting value" according to the preset solution library. The system adjusts the speed regulating valve of the injection device by controlling the mechanical arm, reduces the fast injection speed setting value from 3 meters per second to 0 meters per second, adjusts the pressure of the hydraulic system by controlling the electromagnetic valve, and stabilizes the actual fast injection speed at 0 meters per second, and obtains the adjusted process parameters. Adopting the adjusted process parameters for die casting production, a machine vision system with a resolution of 1920x1080 pixels is used to shoot the die casting product, and through image processing algorithms such as edge detection and Hough transform, the size features of the product are extracted, such as length, width and key aperture, etc. Compare the extracted size features with the preset tolerance range, for example, the tolerance range of a certain key size is 100±5mm. If all size features are within the tolerance range, the product is qualified; if any one size feature exceeds the tolerance range, for example, the measured value of a certain size is 108mm, the product is unqualified, and the system sends a stop command to the control system. After receiving the stop command, the control system controls the die casting machine to stop running, and sends a maintenance signal through the human-machine interface to prompt the operator to perform equipment maintenance.

[0037] S107, after the aluminum box forming piece is demolded, machine vision technology is used to quickly detect its appearance quality, and surface defect products are removed. The qualified products are detected for size precision by a three-coordinate measuring machine to ensure that the key size meets the matching requirements of the modular interface.

[0038] S107 comprises: acquiring image information of the aluminum box forming piece after demolding, performing segmentation processing on the image information by using an image segmentation algorithm to obtain an appearance region image of the aluminum box forming piece; for the appearance region image, extracting texture features and color features of the appearance region image by using a feature extraction algorithm to obtain an appearance feature vector; inputting the appearance feature vector into a pre-established appearance defect discrimination model to obtain a defect discrimination result, if the defect discrimination result is a defect, determining that the aluminum box forming piece is a defective product, otherwise, determining that the aluminum box forming piece is a qualified product; acquiring three-dimensional point cloud data of the qualified product, extracting key size point cloud data from the three-dimensional point cloud data by using a point cloud segmentation algorithm; performing fitting processing on the key size point cloud data according to a pre-set key size parameter to obtain an actual value of the key size; comparing the actual value of the key size with a pre-set modular interface matching size, if the actual value meets the requirement of the matching size, determining that the aluminum box forming piece is a final qualified product; recording and statistically analyzing detection data of the final qualified product to obtain detection result data, and using the detection result data for subsequent production process optimization.

[0039] Specifically, after the aluminum box forming part is demolded, a high-resolution industrial camera is used to obtain its surface image information, and the image resolution is 2048x2048 pixels. Then, a region growing-based image segmentation algorithm is used to segment the obtained image, and by setting the seed points and growth criteria of region growing, the appearance region image of the aluminum box forming part can be accurately segmented. For the segmented appearance region image, a gray level co-occurrence matrix algorithm is used to extract the texture features of the image, and an HSV color space is used to extract the color features of the image, and the texture features and color features are combined to form a 36-dimensional appearance feature vector. According to the pre-established appearance defect discrimination model based on a support vector machine, the extracted appearance feature vector is input into the model for defect discrimination, and by setting a suitable discrimination threshold, the surface scratches, depressions, peeling and other defects of the aluminum box forming part can be effectively discriminated, and the discrimination accuracy can reach more than 95%. For the aluminum box forming part determined to be a qualified product, a structured light three-dimensional scanner is used to obtain its three-dimensional point cloud data, and the point cloud density is 0.5 mm. By designing a point cloud segmentation algorithm based on normal vector and curvature, the point cloud data of the key dimensions such as the upper cover opening, the lower cover opening and the thread of the aluminum box forming part can be accurately extracted. Then, according to the pre-set key dimension parameters, the least square method is used to process the key dimension point cloud data, such as cylindrical fitting and plane fitting, to obtain the actual values of the key dimensions such as the inner diameter of the upper cover opening, the outer diameter of the lower cover opening and the outer diameter of the thread, and the fitting accuracy can reach 0.1 mm. Finally, the actual values of the key dimensions are compared with the mating dimensions of the modular interface, and if the actual values meet the mating dimension tolerance requirements, the aluminum box forming part is determined to be a final qualified product. The detection data of the final qualified product is recorded and statistically analyzed, and by drawing control charts and calculating process capability indexes, the production quality status of the aluminum box forming part can be monitored in real time, and data support and decision basis for optimization of aluminum box forming process parameters are provided.

[0040] S108, in order to verify the rigidity of the socket aluminum box forming part, vibration fatigue test needs to be carried out. According to the test results, if necessary, the material selection, heat treatment process or structure design is further optimized to meet the long-term use reliability requirements. Through the integration and optimization of modular design and precision forming process, the high strength, lightweight and configurable high-quality production of the socket aluminum box is finally realized.

[0041] S108 includes determining the load spectrum and acceleration level of the vibration fatigue test according to the structural characteristics and use requirements of the socket aluminum box forming part, formulating the test scheme and evaluation criteria. Obtain the three-dimensional model of the socket aluminum box forming part, use finite element analysis software to simulate the stress distribution and deformation under the action of vibration fatigue load, and identify the fatigue vulnerable area. For the fatigue vulnerable area, optimize the material selection and heat treatment process parameters of the socket aluminum box, improve the fatigue strength and anti-vibration performance of the material, and reduce the risk of stress concentration and fracture. Adopt the modular design concept, decompose the socket aluminum box into standardized functional units, optimize the structural layout and size parameters through parameterized modeling and topology optimization, realize the balance of lightweight and high strength. Apply precision forming process, including die casting, extrusion, to manufacture high-precision forming parts of the socket aluminum box, strictly control the size tolerance and surface quality, reduce the machining stress and defects. In the process of vibration fatigue test, use strain gauges and acceleration sensors to monitor the stress-strain response and vibration characteristic parameters of the socket aluminum box forming part in real time, obtain the fatigue life and failure mode data. According to the test results and simulation analysis, evaluate the fatigue life and reliability level of the socket aluminum box forming part, judge whether it meets the long-term use requirements, determine the key factors that need to be optimized and improved, and ensure the consistency and reliability of batch production.

[0042] Specifically, according to the structural characteristics and use requirements of the socket aluminum box forming part, a combination of random vibration spectrum and sine sweep vibration spectrum is adopted, the acceleration level is selected as 5g, 10g and 15g, the frequency range is 10Hz-2000Hz, and the test time is 2 hours per axial direction. A 1 / 4 bridge strain gauge and an IEPE acceleration sensor are used, the sampling frequency is set to 10kHz, the stress root mean square value is 35MPa, the displacement root mean square value is 8mm, and the fatigue life is 100,000 times through fast Fourier transform and power spectral density analysis. The socket aluminum box forming part is meshed by using ANSYS finite element software, the element type is SOLID186, the mesh size is 1mm, the load is applied in the form of base acceleration, and the stress concentration area is identified to be located at the internal thread and the external corner through stress cloud map and deformation cloud map analysis. According to the test data and simulation results, the fatigue life of the socket aluminum box forming part meets the use requirements, but the stress concentration problem needs to be further optimized. For the vulnerable area, high-strength aluminum alloy material 7075-T6 is selected, aging strengthening heat treatment is adopted, the yield strength is improved to more than 500MPa, and the fatigue strength is increased by 20%. Through parameterized modeling, the socket aluminum box is divided into three parts of box body, flange and thread, under the premise of ensuring assembly tolerance, the topological optimization algorithm is adopted to reduce the wall thickness by 20%, increase the internal stiffener and round corner transition, and realize the weight reduction of 15%. High vacuum die casting process is selected, the mold is processed by precise electric spark, the surface roughness is controlled within Ra8, the size tolerance is controlled within ±0.05mm, and the size consistency error between production batches is less than 0.02mm.

[0043] It is apparent to those skilled in the art that the application is not limited to the details of the foregoing exemplary embodiments, and that the application can be implemented in other particular forms without departing from the spirit or essential characteristics of the application. Therefore, the embodiments should be considered in all respects as illustrative and not restrictive, the scope of the application being defined by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. No reference signs in the claims should be considered to be a limitation on the scope of the claims.

Claims

1. A modular design and precision molding method of a socket aluminum box, characterized in that, The method comprises the following steps: S101, for the functional independence and flexible configuration requirement of the socket aluminum box, a topology optimization algorithm is used to optimize the modular design of the internal structure, and on the premise of ensuring the strength and rigidity, the rapid replacement and cost reduction are maximized; S102, according to the optimized three-dimensional model of the socket aluminum box, the mechanical performance simulation is carried out through the finite element analysis software, the stress-strain distribution cloud picture is obtained, the stress concentration area is determined, if the stress exceeds the allowable stress of the material, the thickness of the weak structure part is increased or the reinforcing rib is designed, and at the same time, high-strength materials are selected, and the steel is improved by heat treatment and surface strengthening process; S103, on the basis of meeting the mechanical performance requirements, the modular design of the internal structure is further refined, the standardized interface is adopted, the reusable and easy-to-assemble function modules are realized, which can be flexibly configured and maintained; S104, in order to ensure the one-time precision forming and smooth demolding of the complex internal structure, a precision die casting die with multidirectional parting, inclined top and core pulling is designed, and at the same time, the surface quality of the die cavity is required to be high to ensure the surface finish of the aluminum box forming part and improve the appearance quality; S105, in the process of die casting forming, the filling and solidification process of aluminum liquid is simulated through numerical simulation software, the design of gating system and cooling system is optimized, and according to the simulation results, the process parameters such as aluminum liquid temperature, injection speed and pressure and mold temperature are adjusted to obtain high-quality aluminum box forming parts without shrinkage and cracks; S106, the online monitoring technology is used to monitor the die casting forming process in real time, including the key parameters of aluminum liquid temperature, injection curve and mold temperature field, once the monitoring data exceeds the preset threshold range, the process parameters are adjusted in time or the machine is stopped for repair, so as to ensure the stability of batch production and the consistency of products; S107, after the aluminum box forming part is demolded, the machine vision technology is used to quickly detect the appearance quality, and the surface defect products are removed, and the size precision of the qualified products is detected by three-coordinate measuring machine to ensure that the key dimensions meet the matching requirements of modular interface; S108, in order to verify the steel of the socket aluminum box forming part, vibration fatigue test is needed, according to the test results, the material selection, heat treatment process or structure design is further optimized if necessary, to meet the long-term use reliability requirements, through the integrated optimization of modular design and precision forming process, the high-strength, lightweight and configurable high-quality production of the socket aluminum box is finally realized.

2. The modular design and precision molding method of an aluminum box of a socket according to claim 1, wherein, The S101 comprises: obtaining a three-dimensional model of the socket aluminum box, the three-dimensional model comprising an internal structure and an external structure of the socket aluminum box; analyzing the internal structure in the three-dimensional model by using a topology optimization algorithm to obtain position distribution and connection relationship of each functional module, the functional module comprising a power module, a switch module and a socket module; according to the position distribution and the connection relationship, using a modular design method, dividing the functional module into independent sub-modules, and establishing an interface relationship between the sub-modules; For each of the sub-modules, the strength and stiffness of the sub-module are calculated by using finite element analysis method, and whether the sub-module meets the preset strength threshold and stiffness threshold is judged; If the sub-module does not meet the preset strength threshold and stiffness threshold, the modular design step is returned, and the sub-module is re-divided; According to the position distribution and connection relationship of the sub-modules, the layout of the sub-modules is optimized by using a genetic algorithm to obtain an optimal layout scheme; According to the optimal layout scheme, a three-dimensional model of the socket aluminum box is reconstructed by using a parameterized modeling technology, and an engineering drawing of the socket aluminum box is generated; According to the three-dimensional model and the engineering drawing, a sample piece of the socket aluminum box is made by using a rapid prototyping technology, and assembly and function testing are performed; If the sample piece passes the assembly and function testing, a production plan and quality control measures of the socket aluminum box are formulated according to a preset batch and production process.

3. The modular design and precision molding method of an aluminum box of a socket according to claim 1, wherein, The S102 comprises: According to the three-dimensional model of the socket aluminum box, a finite element analysis model is established, material properties, boundary conditions and load conditions are set; Mechanical property simulation calculation is performed by using a finite element analysis software to obtain a stress-strain distribution cloud map; According to the stress-strain distribution cloud map, a stress concentration area is determined, and whether the stress exceeds the material allowable stress is judged; If the stress exceeds the material allowable stress, the structure weak position is optimized by increasing the thickness or designing a reinforcing rib; While optimizing the structure, a high-strength material is selected to improve the overall strength and stiffness of the socket aluminum box; The optimized socket aluminum box is subjected to a heat treatment process to further improve the strength by adjusting the microstructure of the material; The socket aluminum box is treated by using a surface strengthening process, and the surface strengthening process is shot peening or laser strengthening, residual compressive stress is formed on the surface of the socket aluminum box, and fatigue strength and wear resistance are improved.

4. The modular design and precision molding method of an aluminum box of a socket according to claim 1, wherein, The S104 comprises: A three-dimensional model of a complex internal structure die casting mold is obtained, and the three-dimensional model includes multidirectional parting, inclined ejector and core-pulling precision structure; According to the three-dimensional model, a numerical control machining center is used to precisely machine the mold cavity surface to obtain a cavity surface with a required surface roughness; For the cavity surface, a special coating technology is used to deposit a layer of wear-resistant and corrosion-resistant coating with good lubricity; The appearance quality requirements of the aluminum box forming piece are obtained, the cooling water channel and exhaust groove are set in the three-dimensional model, and the mold flow analysis software is used to simulate and optimize the aluminum liquid filling process; The pressure, velocity and displacement parameter signals of the injection system are obtained, and a data model of the injection process is established; For the data model, a machine learning algorithm is used to intelligently optimize and control the injection parameters; The temperature and stress state parameters of the die casting mold are obtained, and a preventive maintenance management system of the die casting mold is established; For the state parameters, a machine learning algorithm is used for analysis to predict the remaining service life of the mold and formulate an optimal maintenance plan.

5. The modular design and precision molding method of an aluminum box of a socket according to any one of claims 1-4, characterized in that, The S105 comprises: According to the three-dimensional model of the aluminum box die casting, a finite element analysis model including aluminum liquid, injection system, pouring system, cooling system and mold components is established, and material properties, boundary conditions and initial conditions are set; Adopting the method of computational fluid dynamics, the filling behavior of the molten aluminum in the injection process is simulated, the temperature field, velocity field and pressure field distribution of the molten aluminum during filling are obtained, and whether there are gas entrapment and spatter defects is judged; If there are filling defects, the structural parameters or process parameters of the injection system are adjusted until the filling defects are eliminated; Adopting the method of heat transfer, the solidification process of the molten aluminum in the cavity is simulated, the temperature field distribution and solidification time during solidification are obtained, and whether there are shrinkage and crack defects is judged; If there are solidification defects, the structural parameters or process parameters of the cooling system are adjusted until the solidification defects are eliminated.

6. The modular design and precision molding method of an aluminum box of a socket according to any one of claims 1-4, characterized in that, The S107 comprises: Obtaining image information of the aluminum box forming part after demolding, and adopting an image segmentation algorithm to perform segmentation processing on the image information to obtain an appearance region image of the aluminum box forming part; For the appearance region image, a feature extraction algorithm is adopted to extract texture features and color features of the appearance region image to obtain an appearance feature vector; The appearance feature vector is input into a pre-established appearance defect discrimination model to obtain a defect discrimination result, if the defect discrimination result is a defect, the aluminum box forming part is judged as a defective product, otherwise, the aluminum box forming part is judged as a qualified product; Obtaining three-dimensional point cloud data of the qualified product, and adopting a point cloud segmentation algorithm to extract key size point cloud data from the three-dimensional point cloud data; According to a preset key size parameter, the key size point cloud data is fitted to obtain an actual value of the key size; The actual value of the key size is compared with a preset modular interface matching size, if the actual value meets the requirements of the matching size, the aluminum box forming part is judged as a final qualified product; The detection data of the final qualified product is recorded and statistically analyzed to obtain detection result data, and the detection result data is used for subsequent production process optimization.

7. The modular design and precision molding method of an aluminum socket box according to any one of claims 1-4, characterized in that, The S108 comprises: According to the structural characteristics and use requirements of the socket aluminum box forming part, the load spectrum and acceleration level of the vibration fatigue test are determined, the test scheme and evaluation criteria are formulated; Obtaining a three-dimensional model of the socket aluminum box forming part, adopting a finite element analysis software to simulate the stress distribution and deformation under the action of the vibration fatigue load, and identifying the fatigue vulnerable area; For the fatigue vulnerable area, the material selection and heat treatment process parameters of the socket aluminum box are optimized to improve the fatigue strength and anti-vibration performance of the material, reduce stress concentration and fracture risk; Adopting the modular design concept, the socket aluminum box is decomposed into standardized functional units, the structural layout and size parameters are optimized through parameterized modeling and topology optimization, and the balance between light weight and high strength is realized; Precise forming processes including die casting and extrusion are applied to manufacture high-precision forming parts of the socket aluminum box, the dimensional tolerance and surface quality are strictly controlled, and the machining stress and defects are reduced; During the vibration fatigue test, strain gauges and acceleration sensors are adopted to monitor the stress-strain response and vibration characteristic parameters of the socket aluminum box forming part in real time, and fatigue life and failure mode data are obtained; According to the test result and simulation analysis, the fatigue life and reliability level of the aluminum box forming part of the socket are evaluated, whether the long-term use requirement is met is judged, the key factors needing optimization and improvement are determined, and the consistency and reliability of batch production are ensured.

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