Core package cooling monitoring system

Abstract

The invention belongs to the technical field of casting, and particularly relates to a mold core cooling monitoring system. The mold core package cooling monitoring system comprises a detection module, a transmission module, an analysis module, a processing module and an upper computer, and the detection module is arranged in a mold core package and used for detecting temperature data of the mold core package after pouring; the transmission module is arranged in the mold core bag and is used for receiving the temperature data from the detection module; the analysis module is arranged in the upper computer and is used for processing the obtained temperature data and processing the temperature data into a data format which can be directly used by the processing module; and the processing module is arranged in the upper computer and is used for processing the analyzed temperature data into an applicable chart according to a preset rule. The core package cooling monitoring system solves the problems that in the prior art, due to the fact that the pouring temperature is too high, electronic elements are damaged, data transmission is inconvenient, and collection hardware is difficult to supply power.

Description

Technical Field

[0001] The invention belongs to the technical field of casting, and more specifically, relates to a core cooling monitoring system. Background Art

[0002] Since the uneven cooling temperature of casting products when unpacking directly affects the quality of castings, the conventional means currently adopted by the foundry industry for uniform cooling of castings when unpacking is to set a cooling device around the sand box to make the castings cool down evenly and quickly. For example, Chinese patent No. CN202410586184.8 achieves the effect of rapid cooling of castings by adopting an integrated cooling structure. Chinese patent No. CN202011173053.5, the temperature control system and the casting sand box control the temperature of the cooling parts and heating parts arranged on the casting sand box through the PLC and PID feedback control modules, so as to delay the solidification of the casting and locally cool the shell.

[0003] At present, the traditional foundry industry only improves and controls the cooling structure of the casting box during the casting production process, but does not provide effective measures for temperature monitoring in a high-temperature casting environment. It is impossible to finely control the temperature of the sand box when it is opened, which causes the problem of uneven temperature when the sand box is opened and cooled, which affects the quality of the castings. Therefore, there is an urgent need for a casting system that can manage the process of cooling the castings in the sand box and cooperate with the application of the MES system to meet the requirements. Summary of the invention

[0004] The present invention provides a core package cooling monitoring system, which solves the problems in the prior art of excessively high pouring temperature causing damage to electronic components, the unfixed position of the pouring sand box in the molding pit or the molding station causing inconvenience in data transmission and difficulty in power supply for acquisition hardware.

[0005] The objective of the present invention is achieved in this way. A core package cooling monitoring system comprises a detection module, a transmission module, an analysis module, a processing module and a host computer. The detection module is arranged in the core package to detect the temperature data of the core package after pouring; the transmission module is arranged in the core package to receive the temperature data from the detection module; the analysis module is arranged in the host computer to process the obtained temperature data and process the temperature data into a data format that can be directly used by the processing module; the processing module is arranged in the host computer to process the analyzed temperature data into an applicable chart according to preset rules.

[0006] In one embodiment, the transmission module is arranged at a distance no greater than 50m from the detection module.

[0007] In one embodiment, the detection module includes a temperature measuring mechanism disposed in the core package.

[0008] In one embodiment, the transmission module includes a receiver, and the receiver and the temperature measuring mechanism directly transmit data through wireless communication.

[0009] In one embodiment, the temperature measuring mechanism is an armored K-type thermocouple.

[0010] In one embodiment, 8 to 10 armored K-type thermocouples form a group, and the collected information is collected in the receiver.

[0011] In one embodiment, the sensor of the temperature measuring mechanism is wrapped by industrial thermal insulation cotton.

[0012] In one embodiment, the detection module and the transmission module hardware are combined in the form of a domestic multi-communication interface PLC+HMI+industrial LoRa wireless K-type thermocouple+wireless sensor digital display receiving host.

[0013] In one embodiment, a data monitoring host is also included, and the data monitoring host is wireless communication.

[0014] In one embodiment, the processing module includes a host software system, and the host software system realizes functions such as real-time data acquisition, recording, query, and reminder of temperature measurement data.

[0015] The system of the present invention can collect and control the temperature data of the castings in the sand box, solve the requirements for refined management and control of the unpacking temperature in the production and operation process of the enterprise, and avoid the quality management bottleneck caused by the impact of temperature on the quality of castings. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] none. DETAILED DESCRIPTION

[0017] In order to facilitate understanding of the present invention, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more thoroughly understood.

[0018] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used herein in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more related listed items.

[0019] In the production process of casting sand box, it is necessary to measure and record the temperature value in the sand box in real time from the completion of pouring to the opening of the box. After pouring, the temperature starts to drop from about 1300 degrees. There are flames from the air vents and the edges of the sand box at the beginning. The working environment is relatively harsh, exceeding the working temperature range of most electronic components. In addition, the position of the casting sand box in the molding pit is not fixed. The casting number is issued according to the production plan, and the number is not easy to maintain in advance. The temperature measurement cycle of the sand box is about 3 consecutive days. It is inconvenient to pull the net and electricity in the molding pit, and the ground will absorb wireless signals. In response to the above difficult requirements, the present invention provides a core package cooling monitoring system, which solves the problems in the prior art of excessive pouring temperature causing damage to electronic components, the unfixed position of the casting sand box in the molding pit or the molding station causing inconvenience in data transmission, and difficulty in powering the acquisition hardware.

[0020] The object of the present invention is achieved in this way. The core package cooling monitoring system includes a detection module, a transmission module, a parsing module, a processing module, and a host computer. The detection module is arranged in the core package to detect the temperature data of the core package after pouring; the transmission module is arranged in the core package to receive the temperature data from the detection module; the parsing module is arranged in the host computer to process the obtained temperature data and process the temperature data into a data format that can be directly used by the processing module; the processing module is arranged in the host computer to process the parsed temperature data into an applicable chart according to preset rules. The transmission module is arranged at a distance of no more than 50m from the detection module.

[0021] The detection module and the transmission module hardware are combined in the form of domestic multi-communication interface PLC+HMI+industrial LoRa wireless K-type thermocouple+wireless sensor digital display receiving host, which transforms the traditional wired temperature measurement method into wireless. The long-distance transmission and anti-interference capabilities of LoRa wireless communication technology are used to solve the problems of difficult on-site wiring and signal interference. Through PLC+HMI digital acquisition interaction and information conversion transmission, the invisible becomes visible. Through convenient human-computer interaction and real-time monitoring of process temperature, the real-time collection, recording, query and reminder functions of temperature data in the sand box after pouring are realized, which greatly improves production efficiency and safety, and at the same time solves the problem of real-time monitoring of the temperature in the sand box under harsh environments with high temperature and fire.

[0022] The detection module also includes a data receiving host. Preferably, the number of channels of the data receiving host is ≥ 8 wireless sensors, the specifications of the K-type thermocouple are lithium-ion battery 4000MAH (default) / 8500MAH, standby current <3uA, battery life >3 years (under the condition of 5 minutes acquisition cycle, the specific application needs to refer to the parameter configuration), wireless communication LoRa433MHz, transmission distance >=200 meters (external suction cup antenna can reach more than 500 meters), temperature measurement range -200~1300℃, resolution 0.1℃, measurement accuracy ±2℃ / -50~220℃, other ranges 1% (after calibration), the detection module can completely replace manual inspection box by box, and the current temperature and static cooling time can be obtained immediately.

[0023] The detection module also includes a temperature measuring mechanism arranged in the core package. A handheld electric drill is used to drill holes on the outer wall of the core package at appropriate positions of the core package. Due to the differences in the sizes of the core packages, different core packages will select different numbers of thermocouples and place them in different positions. The specific principle is to measure as close to the center as possible and evenly. The thermocouple of the temperature measuring mechanism is inserted into the hole. The sensor of the temperature measuring mechanism is wrapped with industrial insulation cotton to ensure that the temperature measuring mechanism can operate in a high temperature environment and can extend the service life in a high temperature environment.

[0024] In this embodiment, the temperature measuring mechanism is an armored K-type thermocouple. Considering the timeliness requirements of the comprehensive data, such as polling the data once every 5 seconds, the armored K-type thermocouples are grouped into 8 to 10 groups, and the information is collected in the wireless receiver. The temperature measuring mechanism adopts a rechargeable lithium battery, and wireless communication is adopted between the matching receiver and the thermocouple. After measuring the on-site temperature, the temperature measuring mechanism transmits the temperature measurement value to the receiver by wireless connection. The distance between the temperature measuring mechanism and the receiver is not more than 50 meters. The detection module realizes the function of real-time collection of the current status of on-site parameters.

[0025] Due to the correspondence between the casting number and the sand box position in the actual working environment, manual maintenance is required in the system if necessary; the armored K-type thermocouple ID needs to be interactively bound in the HMI or mobile phone APP between insertion and unpacking; 8 to 10 armored K-type thermocouples can be hung in a group, and the armored K-type thermocouple ID is configured accordingly in the wireless receiving host. There is no limit on mixing within the group, but mixing between groups is not allowed, otherwise it will cause data confusion, or poor data stability due to long distance. You can also use the method of installing a metal hollow barcode or Dotcode code, and then use the matching APP or add a scanning device to the PLC control box to achieve fast binding.

[0026] The transmission module includes a receiver, and the receiver and the temperature measuring mechanism directly transmit data through wireless communication.

[0027] The transmission module also includes a data monitoring host, which is a wireless communication host and can receive up to 240 wireless sensor accesses. It has an RS485 communication interface and supports the standard Modbus_RTU protocol. Parameters can be set, and specifically alarm parameters, communication address, baud rate, ID code, etc. can be set. Data can be read in real time by the management software on the host computer to realize centralized data collection. In this embodiment, the wireless receiver is parameterized, and specifically alarm parameters, communication address, baud rate, ID code and other parameters can be set. After the parameters are set, the PLC is docked for data analysis, and the PLC, HMI, serial port gateway module, etc. are comprehensively networked to realize the transmission and flow of digital data, and finally the switch is connected to the workshop wired LAN nearby and sent to the data storage server. The transmission module realizes the function of transmitting and saving records of data collected by the Internet of Things.

[0028] The processing module includes a host software system, which realizes functions such as real-time data acquisition, recording, query, and reminder of temperature measurement data.

[0029] The upper software system can realize the functions of real-time data acquisition, recording, query, and reminder of temperature measurement data, and can also trace the quality problem records of the on-site unpacking process to meet the requirements of refined management of the production process. The armored K-type thermocouple, Lora wireless communication, PLC data acquisition and HMI interaction and other technologies are used comprehensively. The thermocouple is inserted into the hole in the sand box after pouring, and industrial insulation materials are used to protect the fragile parts of the sensor. Under the premise of instant acquisition, the long-term instant acquisition, recording, query and reminder of the internal temperature data of the sand box are realized, which solves the wiring difficulties and signal attenuation problems in the molding pit in a cost-effective way, and significantly improves the stability and service life of the sensor in harsh environments.

[0030] In this embodiment, the processing module draws a cooling temperature curve of the core package based on the production plan, unpacking plan, unpacking time, unpacking temperature, unpacking quantity and the actual temperature data after analysis, and compares the drawn cooling temperature curve with the standard cooling temperature curve to remind or warn the operator of the unpacking time, thereby effectively ensuring the shortest cooling time and that the solidification and forming of the molten metal is not affected by boxing, thereby improving the boxing efficiency, and can effectively record the actual cooling temperature and boxing time of each cast casting, providing data support for comprehensive quality monitoring of castings.

[0031] It is required to obtain the relative ambient temperature of the casting in the sand box immediately after pouring to determine whether it can be boxed. The difficulty lies mainly in the harsh working environment of the sensing, the ambient temperature exceeds the normal working range of industrial components, and there are flames; in addition, it is inconvenient to pull wires and nets in the modeling pit, the position of the sand box is uncertain, the static cooling time is long, and there is the influence of ground absorption, which leads to serious signal attenuation. It is necessary to achieve a compromise under many restrictive conditions such as wireless communication distance, signal power, endurance and data stability. In addition, it is also necessary to support the upper software system to realize complex data interaction, binding and real-time monitoring functions to ensure the continuity and accuracy of the data within a temperature measurement period of up to 3 days, while providing a user-friendly interactive interface and reminder mechanism.

[0032] The system of the present invention can collect and control the temperature data of the castings in the sand box, solve the requirements for refined management and control of the unpacking temperature in the production and operation process of the enterprise, and avoid the quality management bottleneck caused by the impact of temperature on the quality of castings.

[0033] The analysis module of the core package cooling monitoring system can realize the functions of data comparison, screening, logical operation and other aspects;

[0034] Through the implementation of this system, the application of IoT data acquisition hardware collection, flexible on-site layout, and real-time and accurate monitoring of sand box temperature changes are realized; on-site temperature detection results are regularly collected and transmitted through the wireless network, and automatically recorded through the system; the monitoring system sets basic control standards, and the system automatically records the results according to the standards and pre-set data rules, and conducts big data analysis and judgment. When it is judged that it meets and reaches the standards, the system records and prompts relevant personnel to handle tasks in a timely manner, effectively ensuring on-site sand core status compliance monitoring and timely task processing.

[0035] The technical features of the above-described embodiments may be arbitrarily combined. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0036] The above-mentioned embodiments only express several implementation methods of the present invention, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the invention patent. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be subject to the attached claims.

Claims

1. A core package cooling monitoring system, characterized in that: The core package cooling monitoring system includes a detection module, a transmission module, an analysis module, a processing module, and a host computer. The detection module is arranged in the core package to detect the temperature data of the core package after pouring; the transmission module is arranged in the core package to receive the temperature data from the detection module; the analysis module is arranged in the host computer to process the obtained temperature data and process the temperature data into a data format that can be directly used by the processing module; the processing module is arranged in the host computer to process the analyzed temperature data into an applicable chart according to preset rules.

2. The core package cooling monitoring system according to claim 1, characterized in that: The transmission module is arranged at a distance no greater than 50m from the detection module.

3. The core package cooling monitoring system according to claim 1, characterized in that: The detection module includes a temperature measuring mechanism arranged in the core package.

4. The core package cooling monitoring system according to claim 3, characterized in that: The transmission module includes a receiver, and the receiver and the temperature measuring mechanism directly transmit data through wireless communication.

5. The core package cooling monitoring system according to claim 4, characterized in that: The temperature measuring mechanism is an armored K-type thermocouple.

6. The core package cooling monitoring system according to claim 5, characterized in that: The armored K-type thermocouples are grouped into 8 to 10 pieces, and the collected information is gathered in the receiver.

7. The core package cooling monitoring system according to claim 3, characterized in that: The sensor of the temperature measuring mechanism is wrapped by industrial heat-insulating cotton.

8. The core package cooling monitoring system according to claim 1 is characterized in that the detection module and the transmission module hardware are combined in the form of a domestic multi-communication interface PLC+HMI+industrial LoRa wireless K-type thermocouple+wireless sensor digital display receiving host.

9. The core package cooling monitoring system according to claim 1 is characterized in that it also includes a data monitoring host, and the data monitoring host is wireless communication.

10. The core package cooling monitoring system according to claim 1 is characterized in that the processing module includes an upper software system, and the upper software system realizes functions such as real-time data acquisition, recording, query, and reminder of temperature measurement data.