Intelligent new energy automobile tray casting forming equipment and intelligent system

Abstract

The invention discloses intelligent new energy automobile tray casting forming equipment and an intelligent system, and relates to the technical field of structural part aluminum alloy die-casting, and the intelligent new energy automobile tray casting forming equipment comprises a smelting system used for heating aluminum alloy to a molten state, a low-pressure pouring chamber installed at an outlet of the smelting system and a mold communicating with the low-pressure pouring chamber; a gas pressure supply unit is arranged outside the low-pressure pouring chamber, and the pressure supply unit adopts high-purity gas to maintain the low-pressure state of the low-pressure pouring chamber; the air ports are formed in the mold and communicated with the mold forming cavity and the exterior of the mold, and the air ports are evenly formed along the edge of the forming cavity at intervals; and the monitoring matrix is mounted in the mold to monitor the temperature change of the forming cavity in the flowing process of the molten metal in the forming cavity. The turbulence and bubble phenomena in metal flowing can be reduced by monitoring the air flowing state in the mold in real time and dynamically adjusting the pressure, and it is ensured that molten metal is diffused in the mold in a stable and uniform mode.

Description

Technical Field

[0001] The present invention relates to the technical field of aluminum alloy die-casting for structural parts, and specifically to a tray casting and forming device and an intelligent system for intelligent new energy vehicles. Background Art

[0002] In new energy vehicles, the battery tray is not just a simple carrier, but an important support for aspects such as the safety of the entire battery system and vehicle structure, thermal management, lightweight design, and intelligent manufacturing.

[0003] New energy vehicles are in a period of rapid transformation. As a core load-bearing and safety protection component, the future development of the battery tray not only depends on the progress of materials and processes, but is also closely linked to intelligent manufacturing, system integration, and sustainable development. For the manufacturing of battery trays, it is necessary to ensure better production accuracy and a more stable casting structure for the battery trays.

[0004] Publication No. CN118437905A discloses a low-pressure casting device for a new energy battery tray, including a workbench. A bracket is fixedly installed at the lower end of the workbench, a crucible is fixedly installed at the lower end of the workbench, a demolding mechanism is installed through the center of the workbench, a fixing seat is fixedly installed around the upper surface of the workbench, a mold closing mechanism is installed through the outside of each fixing seat, columns are fixedly installed at the four corners of the upper surface of the workbench, an upper cross beam is fixedly installed at the upper ends of the columns, and mounting plates are fixedly installed on both sides of the bracket; after the mold closing mechanism is formed by low-pressure casting, the material is separated from the workbench by the demolding mechanism pressing against it. By using a demolding mechanism that fits the upper surface of the workbench, when the mold closing mechanism is formed by low-pressure casting, the bottom long rod is pushed to demold the tray, improving production efficiency. An exhaust mechanism and a fan are used to create a sealed low-pressure environment in the crucible, avoiding the bubble problems easily generated by traditional high-pressure casting.

[0005] The molten aluminum alloy metal liquid is injected into the mold from the low-pressure pouring chamber. When the molten metal enters the mold, it will interact with the air inside the mold. When the molten metal enters the mold, it will push out the original air inside the mold. If the exhaust system of the mold is not perfect or the design is unreasonable, the retained air may form a local high-pressure area; the dynamic flow state of the air inside the mold will form a complex fluid interaction with the flow of the molten metal. For example, too high local air pressure or unstable air flow may cause turbulence in the metal flow, reducing the stability and uniformity of the flow layer; the presence of air will affect the local temperature field, and local temperature fluctuations will in turn affect the metal viscosity and solidification speed, thereby indirectly interfering with the expansion and directional solidification process of the molten metal in the cavity.

[0006] When the molten metal is injected from one side of the mold, an obvious filling front is formed. The air behind the front must be discharged smoothly. Otherwise, a local high-pressure area will be formed, interfering with the smooth flow of the metal and even leaving cavities or pores during solidification. Therefore, it is extremely important to adjust the exhaust state according to the changes in the filling front. Summary of the Invention

[0007] One of the objectives of the present invention is to provide a tray casting and forming device and an intelligent system for intelligent new energy vehicles. After the aluminum alloy is melted, it enters the mold for casting. During the casting process, the air flow change inside the mold is dynamically adjusted by monitoring the changes in the filling front.

[0008] To achieve the above objectives, the present invention is realized through the following technical solutions: A tray casting and forming device for intelligent new energy vehicles includes a melting system for heating the aluminum alloy to a molten state, a low-pressure pouring chamber installed at the outlet of the melting system, and a mold connected to the low-pressure pouring chamber;

[0009] A gas pressure supply unit is configured outside the low-pressure pouring chamber. The pressure supply unit uses high-purity gas to maintain the low-pressure state of the low-pressure pouring chamber and adjusts the injection pressure of the low-pressure pouring chamber according to the changes in the filling front of the molten metal inside the mold;

[0010] Air vents and their control units. The air vents are arranged in the mold and connect the mold cavity with the outside of the mold. The air vents are evenly spaced along the edge of the cavity;

[0011] A monitoring matrix is installed inside the mold to monitor the temperature change of the cavity during the flow of the molten metal inside the cavity. The control unit determines the opening and closing states of each air vent based on the filling front of the molten metal flow.

[0012] In one or more embodiments of the present invention, the mold is composed of an upper mold and a lower mold. The cavity is located inside the upper mold and the lower mold. The air vents are composed of upper air vents opened on the upper mold side and lower air vents opened on the lower mold side. Both the upper air vents and the lower air vents are connected to the cavity;

[0013] Connectors are configured on the sides of the upper air vents and the lower air vents facing away from the cavity. The connectors are respectively installed outside the upper mold and the lower mold. The connectors connect the upper air vents and the lower air vents. The connectors include air pressure sensors for detecting gas pressure, and the air pressure sensors obtain the air pressure changes of the upper air vents or the lower air vents corresponding to the connectors.

[0014] In one or more embodiments of the present invention, the monitoring matrix includes:

[0015] A mounting seat is installed on the inner sides of the upper mold and the lower mold. Multiple covers are configured inside the mounting seat, and the covers are connected to the mounting seat by bolts;

[0016] A slot is opened on the inner side of the mounting base, and the cover plate is correspondingly arranged with the slot;

[0017] A temperature sensor is installed inside the slot, and the temperature sensor detects the temperatures of the upper die and the lower die.

[0018] In one or more embodiments of the present invention, the monitoring matrix further includes:

[0019] A support spring is sleeved outside the bolt, and the support spring is used to support the cover plate;

[0020] A clamping plate is installed outside the temperature sensor, the clamping plate is sleeved outside the bolt and contacts the support spring, and the support spring supports the clamping plate;

[0021] A guide sleeve is installed on the outer walls of the upper die and the lower die, the temperature sensor extends into the guide sleeve, the guide sleeve is provided with a through hole in the middle, and one end of the guide sleeve contacting the upper die and the lower die is funnel-shaped.

[0022] In one or more embodiments of the present invention, the control unit includes:

[0023] An electromagnetic valve is installed outside the connector, and the electromagnetic valve controls the opening and closing of the connector;

[0024] An air pipe is installed at one end of the electric valve, a switching end is arranged at the end of the air pipe away from the electric valve, an exhaust hole and an air tank are arranged on one side of the switching end, and the switching end switches the connection between the air pipe and the exhaust hole or the air tank.

[0025] In one or more embodiments of the present invention, the switching end includes:

[0026] A mounting frame is arranged at one end of the air pipe and is connected to the air pipe through a nut. A guide block is arranged inside the mounting frame, a through hole is arranged in the middle of the guide block, and a magnetic block is arranged on one side of the guide block;

[0027] An electromagnet is fixed inside the mounting frame, and the electromagnet and the magnetic block are configured to control the position of the guide block;

[0028] A knob is installed outside the guide block and extends outside the mounting frame. The rotation of the knob drives the guide block to rotate and changes the aperture of the through hole communicating with the air pipe;

[0029] A top plate is arranged inside the mounting frame. The top plate is connected to the air tank, the air pipe and the exhaust hole through a hose. A compression spring is arranged on one side of the top plate to support the top plate to fit the guide block.

[0030] In one or more embodiments of the present invention, a cooling component is arranged outside the mold, and the cooling component is used to cool the mold. The cooling component includes a cooling water channel extending into the mold, and the cooling component cools the mold through the cooling water channel after the molten metal is injected into the molding cavity.

[0031] In one or more embodiments of the present invention, the exhaust port is connected to the gas pressure supply unit, which monitors the total amount of gas discharged from the exhaust port and determines the filling front range in combination with the total amount of discharged gas and the temperature changes of the upper mold and the lower mold.

[0032] The present application also provides an intelligent pallet casting control system for the above-mentioned intelligent new energy vehicle pallet casting and forming equipment. The control system includes:

[0033] A sensor unit that acquires the temperature data collected by the monitoring matrix and the supply pressure of the gas pressure supply unit;

[0034] A programmable logic controller: controls the entire casting process according to preset logic, including the melt injection speed, the exhaust sequence, and the cooling process;

[0035] Closed-loop feedback control: combines the temperature and pressure data of the sensor unit to dynamically adjust the pressure, temperature, and other key parameters through real-time feedback to ensure the consistency of the casting process;

[0036] A process logic program: stores control strategies and determines the pressure curves and pouring speeds required for different products and materials;

[0037] A touch screen operating system: operators can directly set and adjust production parameters and observe real-time data through a terminal;

[0038] A remote monitoring module: accesses the device status and production situation in real time through mobile devices and remote computers.

[0039] In one or more embodiments of the present invention, the control system further includes a data processing unit, which includes:

[0040] A historical data storage module that records key data during the casting process, including temperature curves and pressure distributions;

[0041] A data analysis module: combines the production data analysis system to predict the process fluctuation trend and equipment failures; a digital twin module: docks the real-time data with a virtual model for process simulation and optimization. In one or more embodiments of the present invention, the above-mentioned.

[0042] Through the above technical solutions, the present invention has the following beneficial effects:

[0043] 1. By monitoring the air flow state inside the mold in real time and dynamically adjusting the pressure, the turbulence and bubble phenomena in metal flow can be reduced, ensuring that the molten metal diffuses in the mold in a smooth and uniform manner. Through the optimized flow path, not only the risks of defects such as porosity, cold shut, and shrinkage cavity are reduced, but also a denser microstructure can be formed, thereby improving the mechanical properties of the casting. The dynamic adjustment of pressure can also make the metal filling more complete, filling every corner, especially showing advantages in complex geometry molds, ensuring the dimensional accuracy and surface finish of the final product.

[0044] 2. The dynamic adjustment of pressure can increase the thrust when the molten metal diffuses slowly or encounters resistance and slow down the speed when the flow is stable according to the diffusion state of the molten metal, thereby improving the filling efficiency. The precisely matched pressure control can effectively shorten the filling time and avoid the turbulence or impact phenomena caused by too fast injection. The more efficient filling process directly reduces the waiting time in casting production and helps to improve the overall output capacity of the production line, especially showing outstanding performance in the scenario of mass production.

[0045] 3. The dynamic regulation of pressure coordinates the air in the mold with the flow of molten metal by adjusting the gas discharge and metal flow pressure, avoiding defects caused by gas retention or improper pressure. Adjusting the exhaust speed can prevent the unstable flow problem caused by local vacuum while discharging the air, reducing the defective rate and significantly reducing the material waste and post - repair costs.

[0046] 4. By combining sensors and control systems, multiple data such as mold temperature, gas displacement, and metal flow rate can be collected in real time. The dynamic adjustment of pressure makes the casting process more intelligent and flexible. For molds of different shapes, pressure curves are configured to match the complex geometry, and the automatic adjustment strategy is used to respond to environmental changes during the production process. The intelligent operation not only reduces the necessity of manual intervention.

[0047] Other features and advantages of the present invention will be described in the following specification, and part of them will be obvious from the specification or understood by implementing the present invention. The objectives and other advantages of the present invention can be achieved and obtained through the structures specifically pointed out in the written specification and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Figure 1 is a perspective view of the present invention;

[0049] Figure 2 is a partial schematic view of the present invention Figure 1 ;

[0050] Figure 3 is a partial schematic view of the present invention Figure 2 ;

[0051] Figure 4Partial schematic of the present invention Figure 3 ;

[0052] Figure 5 Schematic of the lower mold of the present invention;

[0053] Figure 6 Schematic of the connection between the lower mold and the control unit of the present invention;

[0054] Figure 7 Schematic of the monitoring matrix of the present invention;

[0055] Figure 8 Schematic of the connection between the guide sleeve and the temperature sensor of the present invention;

[0056] Figure 9 Exploded view of the guide sleeve and the temperature sensor of the present invention;

[0057] Figure 10 Schematic of the clamping plate structure of the present invention;

[0058] Figure 11 Schematic of the gas tank structure of the present invention;

[0059] Figure 12 Schematic of the connector structure of the present invention;

[0060] Figure 13 Schematic of the switching end structure of the present invention;

[0061] Figure 14 Schematic of the internal structure of the switching end of the present invention;

[0062] Figure 15 Exploded view of the internal structure of the switching end of the present invention.

[0063] In the figure: 1 melting system, 2 low-pressure casting chamber, 3 mold, 4 gas pressure supply unit, 5 gas port, 6 control unit, 7 monitoring matrix;

[0064] 31 upper mold, 32 lower mold, 33 upper gas port, 34 lower gas port, 35 connector, 36 air pressure sensor;

[0065] 61 electric control valve, 62 gas tank, 63 switching end, 64 exhaust hole, 65 air pipe;

[0066] 631 mounting bracket, 632 guide block, 633 through hole, 634 magnetic block, 635 electromagnet, 636 knob, 637 top plate, 638 compression spring;

[0067] 71 mounting seat, 72 cover plate, 73 groove, 74 temperature sensor, 75 support spring, 76 clamping plate, 77 guide sleeve. Detailed implementation method

[0068] The following will disclose multiple embodiments of the present invention with the accompanying drawings. For the sake of clarity, many practical details will be described together in the following narrative. However, it should be understood that these practical details are not used to limit the present invention. That is to say, in some embodiments of the present invention, these practical details are not necessary. And if possible in implementation, the features of different embodiments can be applied interactively.

[0069] Unless otherwise defined, all terms (including technical and scientific terms) used herein have their ordinary meanings, which can be understood by those skilled in this field. Further, the definitions of the above terms in commonly used dictionaries should be interpreted as consistent with the relevant fields of the present invention in the content of this specification. Unless specifically defined otherwise, these terms will not be construed as idealized or overly formal meanings.

[0070] The following explains the relationships and terms used in this application:

[0071] Parallel: The parallel defined in this application is not limited to absolute parallelism. This definition of parallel can be understood as substantially parallel, allowing for situations where it is not absolutely parallel due to factors such as assembly tolerances, design tolerances, and the influence of structural flatness. Small-angle range errors are allowed. For example, within an assembly error range of less than 10 degrees, it can be understood as a parallel relationship.

[0072] Perpendicular: The perpendicular defined in this application is not limited to an absolute perpendicular intersection (angle of 90 degrees) relationship. It allows for a relationship where it is not an absolute perpendicular intersection due to factors such as assembly tolerances, design tolerances, and the influence of structural flatness. Small-angle range errors are allowed. For example, within an assembly error range of 80 degrees to 100 degrees, it can be understood as a perpendicular relationship.

[0073] Ground: The ground defined in this application is not limited to the ground of a certain material or area. It only represents a platform for carrying this application, and stacking, tilting, and flatness changes are allowed. For example, a cement floor, a ceramic tile floor, a working platform, etc. can all be interpreted as the ground.

[0074] The above explanations do not fully cover the relationship definitions given in this application, but only represent a part of this application.

[0075] Refer to Figures 1-4 As shown, the present invention provides a tray casting and molding device for intelligent new energy vehicles, which is used for casting and molding battery trays. When the molten metal enters the inside of the mold 3 from the pouring chamber, it can dynamically adjust the exhaust state according to the filling front.

[0076] The casting equipment includes a melting system 1 for heating aluminum alloy to a molten state, a low-pressure pouring chamber 2 installed at the outlet of the melting system 1, and a mold 3 communicating with the low-pressure pouring chamber 2;

[0077] A gas pressure supply unit 4 is configured outside the low-pressure pouring chamber 2. The pressure supply unit uses high-purity gas to maintain the low-pressure state of the low-pressure pouring chamber 2 and adjusts the injection pressure of the low-pressure pouring chamber 2 according to the change of the filling front of the molten metal inside the mold 3;

[0078] An air port 5 and its control unit 6. The air port 5 is arranged in the mold 3 and communicates the molding cavity of the mold 3 with the outside of the mold 3. The air ports 5 are evenly spaced along the edge of the molding cavity;

[0079] A monitoring matrix 7 is installed inside the mold 3 to monitor the temperature change of the molding cavity during the flow of the molten metal inside the molding cavity. The control unit 6 determines the opening and closing states of each air port 5 through the filling front of the molten metal flow.

[0080] In an implementable manner, a low air pressure is used to push the melt into the mold 3, and the filling process is carried out in a slow and continuous manner. Under the action of low pressure, problems such as flow turbulence and gas mixing are reduced during metal filling, and internal stress and defects can be effectively reduced. By maintaining continuous pressure, there is always enough metal in the low-pressure pouring chamber 2 to supplement solidification shrinkage during the solidification process.

[0081] Among them, after the molten metal enters the molding cavity and flows, an obvious filling front is formed. Combining with the good control of the air port 5 by the control unit 6, when the filling front expands, the injection speed can be increased to improve the injection efficiency. That is, when the filling front is small, local gas is more concentrated, forming local high-pressure or negative-pressure areas, which affects the smooth filling of the metal. When the filling front expands and the filling front spreads stably and evenly, the overall internal pressure tends to be balanced, the flow resistance is reduced, and increasing the injection speed can improve the injection efficiency on the basis of ensuring the injection effect.

[0082] Refer to Figures 2-6 As shown, in an embodiment, the mold 3 is composed of an upper mold 31 and a lower mold 32. The molding cavity is located inside the upper mold 31 and the lower mold 32. The air port 5 is composed of an upper air port 33 opened on the side of the upper mold 31 and a lower air port 34 opened on the side of the lower mold 32. Both the upper air port 33 and the lower air port 34 communicate with the molding cavity;

[0083] Connectors 35 are configured on the sides of the upper air port 33 and the lower air port 34 facing away from the molding cavity. The connectors 35 are respectively installed outside the upper mold 31 and the lower mold 32. The connectors 35 communicate the upper air port 33 and the lower air port 34. The connector 35 includes a barometric pressure sensor 36 for detecting gas pressure. The barometric pressure sensor 36 obtains the gas pressure change corresponding to the upper air port 33 or the lower air port 34 of the connector 35.

[0084] In an implementable manner, the upper air vent 33 and the lower air vent 34 are arranged to exhaust air at different positions during the flow of the molten metal. Both the upper air vent 33 and the lower air vent 34 are connected to the molding cavity. When the molten metal is injected into the interior of the molding cavity, some of the air vents 5 are selectively opened or closed according to the flow state of the molten metal, which can ensure stable exhaust.

[0085] Refer to Figures 7-10 As shown, in one embodiment, the monitoring matrix 7 includes:

[0086] A mounting base 71, which is installed inside the upper mold 31 and the lower mold 32. A plurality of cover plates 72 are arranged inside the mounting base 71, and the cover plates 72 are connected to the mounting base 71 by bolts;

[0087] A groove 73 is opened on the inner side of the mounting base 71, and the cover plate 72 is arranged corresponding to the groove 73;

[0088] A temperature sensor 74 is installed inside the groove 73, and the temperature sensor 74 detects the temperatures of the upper mold 31 and the lower mold 32.

[0089] In an implementable manner, during the flow of the molten metal inside the molding cavity, it can change the temperature change on the surface of the mold 3. The temperature change on the surface of the mold 3 corresponds to the flow state of the molten metal inside the molding cavity. Therefore, temperature monitoring can be used to determine the filling front of the molten metal, and the injection pressure and air diversion are adjusted according to the change of the filling front.

[0090] Refer to Figures 7-10 As shown, in one embodiment, the monitoring matrix 7 further includes:

[0091] A support spring 75 is sleeved outside the bolt, and the support spring 75 is used to support the cover plate 72;

[0092] A clamping plate 76 is installed outside the temperature sensor 74. The clamping plate 76 is sleeved outside the bolt and contacts the support spring 75, and the support spring 75 supports the clamping plate 76;

[0093] A guide sleeve 77 is installed on the outer walls of the upper mold 31 and the lower mold 32. The temperature sensor 74 extends into the guide sleeve 77. The guide sleeve 77 is provided with a through hole in the middle, and one end of the guide sleeve 77 contacting the upper mold 31 and the lower mold 32 is funnel-shaped.

[0094] In an implementable manner, the arrangement of the guide sleeve 77 can be used to collect temperature changes, and the temperature sensor 74 is arranged to be able to change its position by telescoping. Through the cooperation of the bolt and the support spring 75, the distance between the temperature sensor 74 at the corresponding position and the surfaces of the upper mold 31 and the lower mold 32 can be adjusted according to the change of the shape of the shaping cavity.

[0095] Refer to Figure 7 and Figures 11-12 As shown, in one embodiment, the control unit 6 includes:

[0096] An electrically controlled valve 61, installed outside the connector 35, which controls the opening and closing of the connector 35;

[0097] An air pipe 65, installed at one end of the electric valve. A switching end 63 is provided at the end of the air pipe 65 away from the electric valve. An exhaust hole 64 and an air tank 62 are arranged on one side of the switching end 63. The switching end 63 switches the connection between the air pipe 65 and the exhaust hole 64 or the air tank 62.

[0098] In an implementable manner, the electrically controlled valve 61 controls the opening and closing of the connector 35. After the molten metal enters the interior of the molding cavity, according to the flow state of the molten metal, the opening and closing of the electrically controlled valves 61 at different positions are adjusted to control the exhaust of the air ports 5 at different positions.

[0099] Among them, when the air ports 5 are all fully open at the same time, the air in the mold 3 is quickly evacuated, and there will be a situation where the local exhaust is too fast. The rapid exhaust forms a large local negative pressure, resulting in: the molten metal being affected by too large an external pressure gradient at the filling front, resulting in turbulence or local oscillation; the too-fast exhaust causes the pressure in the local area to suddenly drop, thereby changing the metal flow direction, causing local filling deficiency or impact effects caused by too-fast flow.

[0100] Refer to Figures 13-15 As shown, in one embodiment, the switching end includes:

[0101] A mounting bracket 631, arranged at one end of the air pipe 65 and connected to the air pipe 65 through a nut. A guide block 632 is arranged inside the mounting bracket 631. A through hole 633 is arranged in the middle of the guide block 632. A magnetic block 634 is arranged on one side of the guide block 632;

[0102] An electromagnet 635, fixed inside the mounting bracket 631. The electromagnet 635 and the magnetic block 634 are configured to control the position of the guide block 632;

[0103] A knob 636, installed outside the guide block 632 and extending outside the mounting bracket 631. The rotation of the knob 636 drives the guide block 632 to rotate and changes the aperture of the through hole 633 communicating with the air pipe 65;

[0104] A top plate 637, arranged inside the mounting bracket 631. The top plate 637 is connected to the air tank 62, the air pipe 65 and the exhaust hole 64 through a hose. A compression spring 638 is arranged on one side of the top plate 637 to support the top plate 637 to fit against the guide block 632.

[0105] In an implementable manner, the switching end is used to switch the communication state with the trachea 65, which can control the communication between the trachea 65 and the gas tank 62 or the exhaust hole 64. When the trachea 65 is in communication with the exhaust hole 64, the gas located inside the molding cavity can be discharged from the position of the trachea 65. When the trachea 65 is in communication with the gas tank 62, the high-pressure gas inside the gas tank 62 can enter the molding cavity through the trachea 65 and the air port 5.

[0106] Due to the setting of the gas tank 62, the communication between the high-pressure gas inside the gas tank 62 and the air port 5 enables the high-pressure gas to enter the molding cavity. By using the high-pressure gas to push the tray outwards, it is convenient to demold the tray during tray demolding, and additional power is applied to the tray demolding.

[0107] In one embodiment, a cooling component is configured outside the mold 3. The cooling component is used to cool the mold 3. The cooling component includes a cooling water channel extending into the mold 3. After the molten metal is injected into the molding cavity, the cooling component cools the mold 3 through the cooling water channel.

[0108] In an implementable manner, the cooling water channel and the air port 5 do not interfere with each other. When the cooling component is working, the cooling medium for cooling the mold 3, which is liquid or gas, flows inside the cooling water channel, thereby taking away the heat inside the mold 3 and enabling the mold 3 to cool quickly.

[0109] In one embodiment, the exhaust port 5 is in communication with the gas pressure supply unit 4. The gas pressure supply unit 4 monitors the total amount of gas discharged from the exhaust port 5, and determines the filling front range by combining the total amount of discharged gas and the temperature changes of the upper mold 31 and the lower mold 32.

[0110] In an implementable manner, by combining the total amount of gas discharged from the exhaust hole 64 and the temperature changes of the upper mold 31 and the lower mold 32 to determine the filling front, the change of the molten metal inside the molding cavity can be further accurately determined. The injection pressure can be adjusted according to the expansion of the filling front to improve the injection efficiency while ensuring the injection effect.

[0111] Among them, since the space of the molding cavity is fixed, the amount of gas inside it is also fixed. By calculating the total amount of gas, the proportion of the molten metal in the molding cavity can be determined.

[0112] The present application also provides an intelligent tray casting control system for the above-mentioned intelligent new energy vehicle tray casting and molding equipment. The control system includes:

[0113] A sensor unit that acquires the temperature data collected by the monitoring matrix 7 and the supply pressure of the gas pressure supply unit 4;

[0114] Programmable Logic Controller: Controls the entire casting process according to preset logic, including the melt injection speed, exhaust sequence, and cooling process;

[0115] Closed-loop Feedback Control: Combines the temperature and pressure data of the sensor unit, and dynamically adjusts pressure, temperature, and other key parameters through real-time feedback to ensure the consistency of the casting process;

[0116] Process Logic Program: Stores control strategies and determines the pressure curves and pouring speeds required for different products and materials;

[0117] Touchscreen Operating System: Operators can directly set and adjust production parameters and observe real-time data through the terminal;

[0118] Remote Monitoring Module: Real-time access to the device status and production situation through mobile devices and remote computers.

[0119] In one embodiment, the control system further includes a data processing unit, and the data processing unit includes:

[0120] Historical Data Storage Module: Records key data during the casting process, including temperature curves and pressure distributions;

[0121] Data Analysis Module: Combines production data analysis systems to predict process fluctuation trends and equipment failures;

[0122] Digital Twin Module: Docks with virtual models using real-time data for process simulation and optimization.

[0123] Combines multi-sensor data and uses digital twin technology to build a real-time dynamic model:

[0124] Temperature Distribution Map, showing the real-time temperature field in mold 3 and identifying high-temperature expansion areas.

[0125] Flow Path Simulation, generating predicted trajectories of molten metal flow and the current front position through data modeling.

[0126] Filling Ratio Curve, showing the ratio of the filled part in different areas of mold 3 in real time.

[0127] Combines the temperature data in mold 3 with the gas discharge volume to analyze the influence of different areas on the flow of molten metal. Uses the CFD computational fluid dynamics model to simulate the metal filling process and predict the path of the front advancement; through the control system algorithm, dynamically calculates the filling ratio according to the expansion speed of the molten metal front and the gas discharge volume in mold 3.

[0128] Although the present invention is disclosed in connection with the above embodiments, it is not intended to limit the present invention. Any person skilled in the art can make various modifications and refinements without departing from the spirit and scope of the present invention. Therefore, the protection scope of the present invention should be defined by the appended claims.

Claims

1. An intelligent new energy vehicle tray casting equipment, comprising a smelting system (1) for heating an aluminum alloy to a molten state, a low-pressure pouring chamber (2) installed at the outlet of the smelting system (1), and a mold (3) connected to the low-pressure pouring chamber (2), characterized in that: A gas pressure supply unit (4) is arranged outside the low-pressure pouring chamber (2), and the pressure supply unit uses high-purity gas to maintain the low-pressure state of the low-pressure pouring chamber (2), and adjusts the injection pressure of the low-pressure pouring chamber (2) according to the change of the filling front of the molten metal inside the mold (3); An air port (5) and a control unit (6) thereof, wherein the air port (5) is arranged in the mold (3) and connects the molding cavity of the mold (3) with the outside of the mold (3), and the air port (5) is evenly spaced along the edge of the molding cavity; The monitoring matrix (7) is installed inside the mold (3) to monitor the temperature change of the molding cavity during the flow of molten metal inside the molding cavity. The control unit (6) determines the opening and closing state of each air port (5) through the filling front of the molten metal flow.

2. The intelligent pallet casting equipment for new energy vehicles according to claim 1 is characterized in that: The mold (3) is composed of an upper mold (31) and a lower mold (32); the molding cavity is located inside the upper mold (31) and the lower mold (32); the air port (5) is composed of an upper air port (33) opened on the side of the upper mold (31) and a lower air port (34) opened on the side of the lower mold (32); the upper air port (33) and the lower air port (34) are both connected to the molding cavity; A connecting head (35) is disposed on the side of the upper air port (33) and the lower air port (34) facing away from the molding cavity. The connecting head (35) is respectively installed on the outer side of the upper mold (31) and the lower mold (32). The connecting head (35) connects the upper air port (33) and the lower air port (34). The connecting head (35) includes an air pressure sensor (36) for detecting gas pressure. The air pressure sensor (36) obtains the air pressure change of the upper air port (33) or the lower air port (34) corresponding to the connecting head (35).

3. The intelligent pallet casting equipment for new energy vehicles according to claim 2 is characterized in that: The monitoring matrix (7) includes: A mounting seat (71) is mounted on the inner side of the upper mold (31) and the lower mold (32), and a plurality of cover plates (72) are arranged inside the mounting seat (71), and the cover plates (72) are connected to the mounting seat (71) by bolts; A groove (73) is provided inside the mounting seat (71), and a cover plate (72) is provided corresponding to the groove (73); The temperature sensor (74) is installed inside the groove (73), and the temperature sensor (74) detects the temperature of the upper mold (31) and the lower mold (32).

4. The intelligent pallet casting equipment for new energy vehicles according to claim 3 is characterized in that: The monitoring matrix (7) also includes: A support spring (75) is sleeved on the outer side of the bolt, and the support spring (75) is used to support the cover plate (72); A card plate (76) is installed on the outside of the temperature sensor (74), the card plate (76) is sleeved on the outside of the bolt and contacts the support spring (75), and the support spring (75) supports the card plate (76); The guide sleeve (77) is installed on the outer wall of the upper mold (31) and the lower mold (32). The temperature sensor (74) extends into the inside of the guide sleeve (77). The guide sleeve (77) is a centrally-through arrangement, and one end of the guide sleeve (77) that contacts the upper mold (31) and the lower mold (32) is a funnel-shaped arrangement.

5. The intelligent pallet casting equipment for new energy vehicles according to claim 4 is characterized in that: The control unit (6) comprises: An electric control valve (61) is installed outside the connector (35), and the electric control valve (61) controls the opening and closing of the connector (35); The air pipe (65) is installed at one end of the electric valve. A switching end (63) is provided at the end of the air pipe (65) away from the electric valve. An exhaust hole (64) and an air tank (62) are arranged on one side of the switching end (63). The switching end (63) switches the air pipe (65) to communicate with the exhaust hole (64) or the air tank (62).

6. The intelligent pallet casting equipment for new energy vehicles according to claim 5 is characterized in that: The switch terminal includes: A mounting frame (631) is arranged at one end of the air pipe (65) and connected to the air pipe (65) via a nut; a guide block (632) is arranged inside the mounting frame (631); a through hole (633) is arranged in the middle of the guide block (632); and a magnetic block (634) is arranged on one side of the guide block (632); The electromagnet (635) is fixed inside the mounting frame (631), and the electromagnet (635) and the magnetic block (634) are configured to control the position of the guide block (632); A knob (636) is mounted on the outside of the guide block (632) and extends to the outside of the mounting frame (631). The knob (636) rotates to drive the guide block (632) to rotate and change the aperture of the through hole (633) communicating with the air pipe (65); The top plate (637) is arranged inside the mounting frame (631). The top plate (637) is connected to the gas tank (62), the gas pipe (65) and the exhaust hole (64) through a hose. A compression spring (638) is arranged on one side of the top plate (637) to support the top plate (637) to fit the guide block (632).

7. The intelligent pallet casting equipment for new energy vehicles according to claim 6 is characterized in that: A cooling component is arranged outside the mold (3), and is used to cool the mold (3). The cooling component includes a cooling water channel extending into the interior of the mold (3). The cooling component cools the mold (3) through the cooling water channel after molten metal is injected into the molding cavity.

8. The intelligent pallet casting equipment for new energy vehicles according to claim 7 is characterized in that: The exhaust port (5) is connected to the gas pressure supply unit (4), and the gas pressure supply unit (4) monitors the total amount of gas discharged from the exhaust port (5), and determines the filling front range in combination with the total amount of gas discharged and the temperature changes of the upper mold (31) and the lower mold (32).

9. An intelligent pallet casting control system, used for the intelligent new energy vehicle pallet casting molding equipment as claimed in any one of claims 1 to 8, characterized in that: The control system includes: A sensor unit for acquiring temperature data collected by the monitoring matrix (7) and supply pressure of the gas pressure supply unit (4); Programmable Logic Controller: Controls the entire casting process according to preset logic, including melt injection speed, exhaust sequence and cooling process; Closed-loop feedback control: Combines temperature and pressure data from sensor units to dynamically adjust pressure, temperature and other key parameters through real-time feedback to ensure consistency of the casting process; Process logic program: store control strategies and determine the pressure curves and pouring speeds required for different products and materials; Touch screen operating system: Operators can directly set and adjust production parameters and observe real-time data through the terminal; Remote monitoring module: Real-time access to equipment status and production conditions via mobile devices and remote computers.

10. The intelligent tray casting control system according to claim 9, characterized in that: The control system also includes a data processing unit, which includes: Historical data storage module, which records key data during the casting process, including temperature curve and pressure distribution; Data analysis module: Combined with the production data analysis system, predict process fluctuation trends and equipment failures; Digital twin module: Use real-time data to connect with virtual models to perform process simulation and optimization.

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