An intelligent new energy vehicle pallet casting equipment and intelligent system

Abstract

The present invention discloses an intelligent new energy vehicle tray casting and forming equipment and an intelligent system, which relates to the technical field of aluminum alloy die-casting for structural parts. The equipment comprises a smelting system for heating the aluminum alloy to a molten state, a low-pressure pouring chamber installed at the outlet of the smelting system, and a mold connected to the low-pressure pouring chamber; a gas pressure supply unit is configured outside the low-pressure pouring chamber, and the pressure supply unit uses high-purity gas to maintain the low-pressure state of the low-pressure pouring chamber; an air port and its control unit, the air port is arranged in the mold and connects the mold molding cavity with the outside of the mold, and the air port is evenly spaced along the edge of the molding cavity; a monitoring matrix is ​​installed inside the mold to monitor the temperature changes of the molding cavity during the flow of molten metal inside the molding cavity. By monitoring the air flow state inside the mold in real time and dynamically adjusting the pressure, turbulence and bubbles in the metal flow can be reduced, ensuring that the molten metal diffuses smoothly and evenly in the mold.

Description

Technical Field

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

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

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

[0004] Announcement No. CN118437905A discloses a low-pressure casting device for a new energy battery tray, comprising a workbench, a bracket fixedly mounted at the lower end of the workbench, a crucible fixedly mounted at the lower end of the workbench, a demoulding mechanism installed through the center of the workbench, a fixed seat fixedly mounted on all four sides of the upper surface of the workbench, a clamping mechanism installed through the outer side of each fixed seat, columns fixedly mounted on all four corners of the upper surface of the workbench, an upper crossbeam fixedly mounted on the upper end of the column, and mounting plates fixedly mounted on both sides of the bracket; after the clamping mechanism is low-pressure cast, the demoulding mechanism pushes the material away from the workbench. A demoulding mechanism that fits the upper surface of the workbench is used, and after the clamping mechanism is low-pressure cast, the bottom long rod is pushed to demould the tray, thereby improving production efficiency. An exhaust mechanism and a fan are used to form a sealed low-pressure environment for the crucible, avoiding the bubble problem that is easily generated in 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 trapped air may form a local high-pressure area; the dynamic flow state of the air in the mold will form a complex fluid interaction with the flow of molten metal. For example, excessive local air pressure or unstable airflow 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 affect the metal viscosity and solidification rate, thereby indirectly interfering with the expansion and directional solidification process of the molten metal in the cavity.

[0006] When molten metal is injected from one side of the mold, a clear 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 voids or pores during solidification. Therefore, it is extremely important to adjust the exhaust state according to different changes in the filling front. Summary of the Invention

[0007] One of the purposes of the present invention is to provide an intelligent tray casting and molding equipment and an intelligent system for new energy vehicles. After the aluminum alloy is melted, it enters the mold for casting. During the casting process, the airflow changes inside the mold are dynamically adjusted by monitoring the changes in the filling front.

[0008] To achieve the above objectives, the present invention is implemented through the following technical solutions: an intelligent new energy vehicle tray casting and molding equipment, comprising a smelting system for heating aluminum alloy to a molten state, a low-pressure pouring chamber installed at the outlet of the smelting 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 ports and their control units, the air ports being arranged in the mold and connecting the mold molding cavity with the outside of the mold, and the air ports being evenly spaced along the edge of the molding cavity;

[0011] The monitoring matrix is ​​installed inside the mold to monitor the temperature changes of the molding cavity during the flow of molten metal inside the molding cavity. The control unit determines the opening and closing status of each air port through 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 molding cavity is located inside the upper mold and the lower mold, and the gas port is composed of an upper gas port opened on the upper mold side and a lower gas port opened on the lower mold side, and the upper gas port and the lower gas port are both connected to the molding cavity;

[0013] The upper air port and the lower air port are both provided with connecting heads on the side facing away from the molding cavity. The connecting heads are respectively installed on the outside of the upper mold and the lower mold. The connecting heads connect the upper air port and the lower air port. The connecting heads include an air pressure sensor for detecting gas pressure. The air pressure sensor obtains the air pressure changes of the upper air port or the lower air port corresponding to the connecting head.

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

[0015] A mounting base is installed on the inner side of the upper mold and the lower mold, and a plurality of cover plates are arranged inside the mounting base, and the cover plates are connected to the mounting base by bolts;

[0016] A groove is provided on the inner side of the mounting seat, and the cover plate is provided corresponding to the groove;

[0017] The temperature sensor is installed inside the tank and detects the temperature of the upper mold and the lower mold.

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

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

[0020] A card plate is installed on the outside of the temperature sensor. The card plate is sleeved on the outside of the bolt and contacts the support spring. The support spring supports the card plate.

[0021] The guide sleeve is installed on the outer wall of the upper mold and the lower mold. The temperature sensor extends into the inside of the guide sleeve. The guide sleeve is a middle-through setting, and the end of the guide sleeve that contacts the upper mold and the lower mold is a funnel-shaped setting.

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

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

[0024] The air pipe is installed at one end of the electric valve. A switching end is set 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. The switching end switching air pipe is connected to the exhaust hole or the air tank.

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

[0026] The mounting frame is arranged at one end of the air pipe and 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 mounted on the outside of the guide block and extends to the outside of the mounting frame. Rotating the knob drives the guide block to rotate and changes the diameter of the through hole communicating with the air pipe.

[0029] The top plate is arranged inside the mounting frame and is connected to the gas tank, the gas 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 assembly is configured on the outside of the mold, and the cooling assembly is used to cool the mold. The cooling assembly includes a cooling water channel extending into the interior of the mold. The cooling assembly cools the mold after the molten metal is injected into the molding cavity through the cooling water channel.

[0031] In one or more embodiments of the present invention, the exhaust port is connected to a gas pressure supply unit, which monitors the total amount of gas discharged from the exhaust port and determines the filling front range based on the total amount of gas discharged 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 molding equipment, the control system comprising:

[0033] The sensor unit obtains the temperature data collected by the monitoring matrix and the supply pressure of the gas pressure supply unit;

[0034] Programmable Logic Controller: Controls the entire casting process according to preset logic, including melt injection rate, exhaust sequence and cooling process;

[0035] 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 in the casting process.

[0036] Process logic program: stores control strategies and determines the pressure curve and pouring speed required for different products and materials;

[0037] Touch screen operating system: Operators can directly set and adjust production parameters and observe real-time data through the terminal;

[0038] Remote monitoring module: Real-time access to equipment status and production status through mobile devices and remote computers.

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

[0040] Historical data storage module, which records key data during the casting process, including temperature curve and pressure distribution;

[0041] Data analysis module: Combined with the production data analysis system, it predicts process fluctuation trends and equipment failures; Digital twin module: Uses real-time data to connect with the virtual model to perform process simulation and optimization. In one or more embodiments of the present invention, the above.

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

[0043] 1. By real-time monitoring of the air flow state inside the mold and dynamically adjusting the pressure, turbulence and bubbles in the metal flow can be reduced, ensuring that the molten metal diffuses smoothly and evenly in the mold. The optimized flow path not only reduces the risk of defects such as pores, cold shuts, and shrinkage cavities, but also forms a denser microstructure, thereby improving the mechanical properties of the casting. Dynamic pressure adjustment can also ensure more complete metal filling, filling every corner, which is particularly advantageous in complex geometric molds, ensuring the dimensional accuracy and surface finish of the final product.

[0044] 2. Dynamic pressure adjustment can improve filling efficiency based on the diffusion state of the molten metal. It can increase thrust when the flow is slow or encounters resistance, and slow down the flow when it is smooth, thereby improving filling efficiency. Precisely matched pressure control can effectively shorten filling time while avoiding turbulence or impact caused by overly rapid injection. The more efficient filling process directly reduces the waiting time of casting production, helps to improve the overall output capacity of the production line, especially in large-scale production scenarios.

[0045] 3. Dynamic pressure control: By adjusting the gas exhaust and metal flow pressure, the air in the mold and the molten metal flow are coordinated to avoid defects caused by gas retention or improper pressure. Adjusting the exhaust speed can prevent flow instability caused by local vacuum while exhausting air, reducing the defective rate, significantly reducing material waste and later repair costs.

[0046] 4. With the combination of sensors and control systems, multiple data such as mold temperature, gas displacement, and metal flow rate can be collected in real time. Dynamic pressure adjustment makes the casting process more intelligent and flexible. For molds of different shapes, pressure curves are configured to match complex geometries. During the production process, strategies are automatically adjusted to cope with environmental changes. Intelligent operation not only reduces the need for manual intervention.

[0047] Other features and advantages of the present invention will be described in the following description, and part of them will become obvious from the description, or will be understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained by the structures particularly pointed out in the written description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

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

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

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

[0051] Figure 4This is a partial schematic diagram of the present invention Figure 3 ;

[0052] Figure 5 It is a schematic diagram of the lower mold of the present invention;

[0053] Figure 6 This is a schematic diagram of the connection between the lower mold and the control unit of the present invention;

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

[0055] Figure 8 This is a schematic diagram of the connection between the guide sleeve and the temperature sensor of the present invention;

[0056] Figure 9 This is an exploded view of the guide sleeve and temperature sensor of the present invention;

[0057] Figure 10 It is a schematic diagram of the card board structure of the present invention;

[0058] Figure 11 It is a schematic diagram of the structure of the gas tank of the present invention;

[0059] Figure 12 This is a schematic structural diagram of the connector of the present invention;

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

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

[0062] Figure 15 It is an exploded view of the internal structure of the switching end of the present invention.

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

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

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

[0066] 631 mounting frame, 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 slot, 74 temperature sensor, 75 support spring, 76 clamping plate, 77 guide sleeve. DETAILED DESCRIPTION

[0068] The following drawings illustrate various embodiments of the present invention. For clarity, many practical details are included in the following description. However, it should be understood that these practical details are not intended to limit the present invention. In other words, in some embodiments of the present invention, these practical details are optional. Furthermore, features from different embodiments may be interchangeably applicable, where practically possible.

[0069] Unless otherwise defined, all words used herein (including technical and scientific terms) have their ordinary meanings as understood by those skilled in the art. Furthermore, the definitions of the above-mentioned words in commonly used dictionaries should be interpreted in the context of this specification as having the same meanings as those in the relevant field of the present invention. Unless otherwise explicitly defined, these words should not be interpreted as having 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 parallelism can be understood as basic parallelism, allowing for situations where the two sides are not absolutely parallel due to factors such as assembly tolerance, design tolerance, and the influence of structural flatness. Small angle errors are allowed. For example, within an assembly error range of 10 degrees, it can be understood as a parallel relationship.

[0072] Vertical: The vertical defined in this application is not limited to an absolute vertical intersection relationship (angle of 90 degrees). It allows for non-absolute vertical intersection relationships caused by factors such as assembly tolerance, design tolerance, and structural flatness. It allows for errors in a small angle range. For example, the assembly error range of 80 to 100 degrees can be understood as a vertical relationship.

[0073] Floor: The floor defined in this application is not limited to a specific material or location. It only needs to be a platform for supporting the application, and it can be stacked, tilted, and have varying flatness. For example, cement floors, tile floors, work platforms, etc. can all be interpreted as floors.

[0074] The above explanation does not fully include the relationship definitions given in this application, but only represents part of it.

[0075] See Figure 1-4 As shown, the present invention provides an intelligent new energy vehicle pallet casting and molding equipment, which is used for battery pallet casting and molding. When the molten metal enters the mold 3 from the pouring chamber, the exhaust state can be dynamically adjusted according to the filling front.

[0076] The casting molding equipment includes a smelting system 1 for heating 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;

[0077] A gas pressure supply unit 4 is provided 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 changes in the filling front of the molten metal inside the mold 3.

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

[0079] 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 status of each air port 5 through the filling front of the molten metal flow.

[0080] In one feasible method, low air pressure is used to push the melt into the mold 3, and the filling process is carried out slowly and continuously. Under the action of low pressure, the flow turbulence and gas mixing problems are reduced when the metal is filled into the mold, which can effectively reduce internal stress and defects. Through continuous pressure, it is ensured that during the solidification process, there is always enough metal in the low-pressure casting chamber 2 to supplement the solidification shrinkage.

[0081] Among them, after the molten metal enters the molding cavity, it flows to form an obvious filling front. Combined 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, the local gas is more concentrated, forming a local high-pressure or negative pressure area, which affects the smooth filling of the metal. When the filling front expands and diffuses stably and evenly, the overall internal pressure tends to balance, the flow resistance is reduced, and increasing the injection speed can improve the injection efficiency while ensuring the injection effect.

[0082] See Figure 2-6 As shown, in one 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, and 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, and the upper air port 33 and the lower air port 34 are both connected to the molding cavity;

[0083] A connecting head 35 is configured 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 outside 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 changes of the upper air port 33 or the lower air port 34 corresponding to the connecting head 35.

[0084] In one feasible method, the setting of the upper air port 33 and the lower air port 34 can perform exhaust at different positions during the flow of molten metal, and the upper air port 33 and the lower air port 34 are both connected to the molding cavity. When the molten metal is injected into the molding cavity, some air ports 5 are selectively opened or closed according to the flow state of the molten metal, which can ensure the stability of exhaust.

[0085] See Figure 7-10 As shown, in one embodiment, the monitoring matrix 7 includes:

[0086] The mounting base 71 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. The cover plates 72 are connected to the mounting base 71 by bolts.

[0087] A groove 73 is formed inside the mounting base 71 , and a cover plate 72 is provided corresponding to the groove 73 ;

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

[0089] In one feasible method, the temperature change on the surface of the mold 3 can be changed during the flow of the molten metal inside the molding cavity. 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 can be adjusted according to the change of the filling front.

[0090] See Figure 7-10 As shown, in one embodiment, the monitoring matrix 7 further includes:

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

[0092] The 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. The support spring 75 supports the card plate 76.

[0093] 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 guide sleeve 77. The guide sleeve 77 is a centrally-through setting, and the end of the guide sleeve 77 that contacts the upper mold 31 and the lower mold 32 is a funnel-shaped setting.

[0094] In one feasible method, the guide sleeve 77 is set to collect temperature changes, and the temperature sensor 74 is set to be able to telescopically change its position. Through the cooperation of the bolt and the support spring 75, the distance between the temperature sensor 74 at the corresponding position and the surface of the upper mold 31 and the lower mold 32 can be adjusted according to the change of the shape of the molding cavity.

[0095] See Figure 7 as well as Figure 11-12 As shown, in one embodiment, the control unit 6 includes:

[0096] The electrically controlled valve 61 is installed outside the connector 35 and controls the opening and closing of the connector 35;

[0097] The air pipe 65 is installed at one end of the electric valve. A switching end 63 is set 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 be connected with the exhaust hole 64 or the air tank 62.

[0098] In one feasible method, the electric control valve 61 controls the opening and closing of the connector 35. After the molten metal enters the molding cavity, the opening and closing of the electric control valves 61 at different positions are adjusted according to the flow state of the molten metal to control the exhaust of the air ports 5 at different positions.

[0099] Among them, when the air port 5 is fully opened at the same time, the air in the mold 3 is quickly extracted, and there will be a situation of local excessive exhaust. The rapid exhaust forms a large local negative pressure, resulting in: the molten metal is affected by the excessive external pressure gradient at the filling front, resulting in turbulence or local oscillation; the excessive exhaust causes the pressure in the local area to drop suddenly, thereby changing the direction of metal flow, causing local insufficient filling or impact effect due to excessive flow.

[0100] See Figure 13-15 As shown, in one embodiment, the switching end includes:

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

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

[0103] The knob 636 is mounted on the outside of the guide block 632 and extends to the outside of the mounting bracket 631. The knob 636 rotates to rotate the guide block 632 and change the diameter of the through hole 633 connected to the air pipe 65.

[0104] 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 via a hose. A compression spring 638 is arranged on one side of the top plate 637 to support the top plate 637 against the guide block 632 .

[0105] In one feasible method, the switching end is used to switch the connection state with the air pipe 65, which can control the connection between the air pipe 65 and the gas tank 62 or the exhaust hole 64. When the air pipe 65 is connected to the exhaust hole 64, the gas inside the molding cavity can be discharged from the position of the air pipe 65, and when the air pipe 65 is connected to the gas tank 62, the high-pressure gas inside the gas tank 62 can enter the molding cavity through the air pipe 65 and the gas port 5.

[0106] Due to the setting of the gas tank 62, the high-pressure gas inside the gas tank 62 is connected to the gas port 5, which allows the high-pressure gas to enter the molding cavity, and the pallet is pushed outward by the high-pressure gas. When the pallet is demoulded, it is convenient to demould the pallet, and additional power is added to the demoulding of the pallet.

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

[0108] In one feasible method, the cooling water channel and the air port 5 are positioned so as not to interfere with each other. When the cooling assembly is working, the cooling medium used to cool the mold 3: liquid or gas, flows inside the cooling water channel, thereby taking away the heat inside the mold 3 and cooling the mold 3 quickly.

[0109] In one embodiment, the exhaust port 5 is connected to the gas pressure supply unit 4, which monitors the total amount of gas discharged from the exhaust port 5 and determines the filling front range based on the total amount of gas discharged and the temperature changes of the upper mold 31 and the lower mold 32.

[0110] In one feasible method, the filling front is determined by combining the total amount of gas discharged from the exhaust hole 64 and the changes in the temperature of the upper mold 31 and the lower mold 32, which can further accurately predict the changes in the molten metal inside the molding cavity, so as to adjust the injection pressure according to the expansion of the filling front, thereby improving the injection efficiency while ensuring the injection effect.

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

[0112] The present application also provides an intelligent pallet casting control system for the above-mentioned intelligent new energy vehicle pallet casting molding equipment, the control system comprising:

[0113] The sensor unit obtains 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 melt injection rate, exhaust sequence and cooling process;

[0115] 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 in the casting process.

[0116] Process logic program: stores control strategies and determines the pressure curve and pouring speed required for different products and materials;

[0117] Touch screen 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 equipment status and production status through mobile devices and remote computers.

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

[0120] Historical data storage module, which records key data during the casting process, including temperature curve and pressure distribution;

[0121] Data analysis module: Combined with the production data analysis system, it predicts process fluctuation trends and equipment failures;

[0122] Digital twin module: Utilizes real-time data to connect with virtual models for process simulation and optimization.

[0123] Combining multi-sensor data and using digital twin technology to build real-time dynamic models:

[0124] The temperature distribution diagram shows the real-time temperature field inside the mold 3 and identifies the high-temperature extension area.

[0125] Flow path simulation generates the predicted trajectory and current front position of the molten metal flow through data modeling.

[0126] The filling ratio curve shows the proportion of the filled parts in different areas of the mold 3 in real time.

[0127] Temperature data within mold 3 is combined with gas discharge volume to analyze the impact of different regions on molten metal flow. A CFD computational fluid dynamics model is used to simulate the metal filling process and predict the path of the front. A control system algorithm dynamically calculates the fill ratio based on the expansion speed of the molten metal front and the gas discharge volume within mold 3.

[0128] Although the present invention is disclosed in conjunction with the above embodiments, it is not intended to limit the present invention. Anyone familiar with this technology can make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention should be based on the definition of the attached claims.

Claims

1. An intelligent new energy vehicle tray casting and molding 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 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). 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). 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) and the outside of the mold (3), the air port (5) is evenly spaced along the edge of the molding cavity, and 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), and the upper air port (33) and the lower air port (34) are both connected to the molding cavity; The upper air port (33) and the lower air port (34) are both provided with a connector (35) on the side facing away from the molding cavity; A monitoring matrix (7) is installed inside the mold (3) to monitor the temperature change of the molding cavity during the flow of molten metal in the molding cavity, and a control unit (6) determines the opening and closing state of each gas port (5) through the filling front of the molten metal flow; 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).

2. The intelligent new energy vehicle pallet casting equipment according to claim 1 is characterized in that: The connecting head (35) is respectively installed on the outer sides of the upper mold (31) and the lower mold (32). The connecting head (35) is connected to 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 new energy vehicle pallet casting equipment 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), wherein 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 on the inner side of 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 new energy vehicle pallet casting equipment according to claim 3 is characterized in that: The monitoring matrix (7) also includes: A support spring (75) is sleeved on the outside 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 interior of the guide sleeve (77). The guide sleeve (77) is a centrally-through setting, and one end of the guide sleeve (77) that contacts the upper mold (31) and the lower mold (32) is a funnel-shaped setting.

5. The intelligent new energy vehicle pallet casting equipment according to claim 4 is characterized in that: The switch includes: A mounting frame (631) is provided at one end of the air pipe (65) and connected to the air pipe (65) via a nut. A guide block (632) is provided inside the mounting frame (631). A through hole (633) is provided in the middle of the guide block (632). A magnetic block (634) is provided 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).

6. The intelligent new energy vehicle pallet casting equipment according to claim 5 is characterized in that: A cooling assembly is arranged outside the mold (3), and is used to cool the mold (3). The cooling assembly includes a cooling water channel extending into the interior of the mold (3). The cooling assembly cools the mold (3) after molten metal is injected into the molding cavity through the cooling water channel.

7. The intelligent new energy vehicle pallet casting equipment according to claim 6 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 based on the total amount of gas discharged and the temperature changes of the upper mold (31) and the lower mold (32).

8. An intelligent pallet casting control system, used in the intelligent new energy vehicle pallet casting molding equipment according to any one of claims 1 to 7, 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 rate, 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 in the casting process. Process logic program: stores control strategies and determines the pressure curve and pouring speed 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 status through mobile devices and remote computers.

9. The intelligent pallet casting control system according to claim 8, characterized in that: The control system further comprises a data processing unit, which comprises: 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, it predicts process fluctuation trends and equipment failures; Digital twin module: Utilizes real-time data to connect with virtual models for process simulation and optimization.

Images