A new casting method for the guide shell of deep well pump

Abstract

The present invention relates to the field of guide shell casting technology, and in particular to a novel casting method for a guide shell for a deep-well pump, comprising the following steps: obtaining molten iron surface temperature data, pressure data, and infrared images; injecting a first bag of molten iron from a bottom sprue with a first injection parameter, flowing into a bottom runner, then into a bottom ingrown runner, and into a deep-well pump guide shell mold cavity; evaluating whether the heat loss of the first bag of molten iron surface is acceptable, and adjusting the first casting parameter; simultaneously with the first bag of molten iron reaching a preset temperature measurement point, injecting a second bag of molten iron into a top sprue with a second injection parameter; after entering the top sprue, the second bag of molten iron flows sequentially through a top ingrown runner and a top ingrown runner into a dedicated feeding riser; evaluating whether the feeding channel of the dedicated feeding riser is clogged, and adjusting a second preset casting rate; determining whether the heat distribution on the mold cavity surface is uniform based on a thermal dispersion deviation characteristic value, and adjusting the second preset casting temperature. The present invention improves the casting stability of a guide shell for a deep-well pump.

Description

Technical Field

[0001] The invention relates to the technical field of guide shell casting, in particular to a novel casting process method for a guide shell for a deep well pump. Background Art

[0002] In the field of casting production, there are special limitations on the structure of the guide shell for deep well pumps. The casting wall is relatively thin, the built-in blades are spiral, and the product height is relatively high. In the traditional pouring system method, a single-ladle pouring method is adopted. Under the single-ladle pouring process, the molten iron enters from the inner runner located at the bottom of the casting. During the filling process, the molten iron needs to gradually fill the entire complex guide shell cavity, resulting in a long filling time in the pouring process. When the molten iron gradually fills to the top of the casting, due to the early flow and heat loss, the temperature of the uppermost molten iron is significantly reduced. The riser on the top of the casting cannot provide a limited shrinkage compensation effect, and the casting is prone to shrinkage and shrinkage holes.

[0003] Chinese patent application publication number: CN113458330A discloses a large-scale diversion pump housing casting system, including a pouring system, a diversion pump housing cavity and a mud core; the pouring system includes a straight runner, a cross runner connected to the straight runner and an ingedentary connected to the cross runner; the ingedentary includes a first ingedentary, a second ingedentary and a third ingedentary; the first ingedentary is located at the upper end of the diversion pump housing cavity; the second ingedentary is located in the middle of the diversion pump housing cavity.

[0004] However, the existing technology has the following problems: single ladle casting is used, the amount of molten iron shrinkage supplement is insufficient, the molten iron temperature distribution is uneven, and the deep well pump guide shell has shrinkage and shrinkage defects, which leads to low casting stability of the deep well pump guide shell. Summary of the Invention

[0005] To this end, the present invention provides a new casting and pouring process method for a guide shell for a deep well pump, which is used to overcome the problem in the prior art of using single ladle pouring, insufficient molten iron shrinkage supplementation, uneven molten iron temperature distribution, shrinkage and shrinkage cavity defects in the guide shell for the deep well pump, and thus low casting stability of the guide shell for the deep well pump.

[0006] To achieve the above-mentioned object, the present invention provides a novel casting method for a guide shell for a deep well pump, comprising:

[0007] Acquire molten iron surface temperature data within the guide shell cavity of a deep-well pump, obtain pressure data for a dedicated feeding riser, and obtain infrared images of the cavity's outer surface;

[0008] The first bag of molten iron is injected from the bottom sprue according to the first injection parameter, flows into the bottom runner, enters the bottom ingrown channel and flows into the guide shell cavity for the deep well pump;

[0009] determining whether the heat loss of the first ladle of molten iron is qualified based on the liquid surface temperature attenuation coefficient obtained based on the molten iron liquid surface temperature data during the pouring process of the first ladle of molten iron, and adjusting the first pouring parameter according to the difference between the liquid surface temperature attenuation coefficient and a preset liquid surface temperature attenuation coefficient;

[0010] When the first ladle of molten iron reaches the preset temperature measuring point, the second ladle of molten iron is injected into the top sprue with the second injection parameter. After entering the top sprue, the second ladle of molten iron flows through the top runner and the top ingrate in sequence and enters the dedicated feeding riser.

[0011] Determining that a feeding channel of the dedicated feeding riser is clogged based on a pressure decay characterization parameter obtained from the pressure data, and adjusting a second preset pouring rate based on a relative difference between the pressure decay characterization parameter and a preset pressure decay characterization parameter;

[0012] Determining the heat distribution on the cavity surface based on a heat dispersion deviation characteristic value of a first bag of molten iron in a guide shell cavity for a deep well pump during feeding of the dedicated feeding riser by the second bag of molten iron, so as to determine and adjust the second preset pouring temperature according to a ratio of the heat dispersion deviation characteristic value to the first preset heat dispersion deviation characteristic value;

[0013] Under the condition of ensuring uniform heat distribution on the cavity surface, the casting of the guide shell for the deep well pump is completed.

[0014] Furthermore, the unqualified liquid surface heat loss of the first ladle of molten iron is determined based on the comparison result that the liquid surface temperature attenuation coefficient is greater than the preset liquid surface temperature attenuation coefficient, wherein the liquid surface temperature attenuation coefficient is determined based on the initial liquid surface temperature, current liquid surface temperature and pouring time interval of the molten iron liquid surface temperature data during the pouring process of the first ladle of molten iron.

[0015] Furthermore, the process of adjusting the first pouring parameter includes:

[0016] Calculate the difference between the liquid surface temperature attenuation coefficient under the condition that the heat loss of the first ladle of molten iron is unqualified and the preset liquid surface temperature attenuation coefficient;

[0017] Determining to increase the first preset injection temperature based on the comparison result that the difference is less than or equal to the preset difference;

[0018] The increased first preset injection temperature is determined according to the first preset injection temperature and the preset injection temperature adjustment coefficient.

[0019] Furthermore, the process of adjusting the first pouring parameter further includes:

[0020] Calculate the difference between the liquid surface temperature attenuation coefficient under the condition that the heat loss of the first ladle of molten iron is unqualified and the preset liquid surface temperature attenuation coefficient;

[0021] Determining to reduce the first preset pouring rate based on the comparison result that the difference is greater than the preset difference;

[0022] The reduced first preset pouring rate is determined according to the first preset pouring rate and the preset injection rate adjustment coefficient.

[0023] Furthermore, the blockage of the feeding channel of the dedicated feeding riser is determined based on a comparison result that the pressure decay characterization parameter is greater than a preset pressure decay characterization parameter, wherein the pressure decay characterization parameter is determined according to the pressure decay slope and the pressure decay slope threshold.

[0024] Furthermore, the process of adjusting the second preset pouring rate includes:

[0025] Calculating a relative difference between the pressure decay characterization parameter and the preset pressure decay characterization parameter;

[0026] Determining to increase a second preset pouring rate based on a comparison result of the relative difference and a preset relative difference;

[0027] The increased second preset pouring rate is determined according to the second preset pouring rate and the preset rate adjustment coefficient.

[0028] Furthermore, the process of determining the heat distribution on the cavity surface includes:

[0029] Determine the characteristic value of the thermal dispersion deviation of the first bag of molten iron in the guide shell mold cavity for the deep well pump during the feeding process of the dedicated feeding riser under the condition that the feeding channel of the dedicated feeding riser is not blocked;

[0030] Determining that the cavity surface has a low thermal distribution and a low cavity surface temperature based on a comparison result that the thermal dispersion deviation characteristic value is less than or equal to a first preset thermal dispersion deviation characteristic value;

[0031] The thermal dispersion deviation characteristic value is determined according to the average thermal radiation intensity of the cavity surface area and the average intensity threshold.

[0032] Furthermore, the process of determining the heat distribution on the cavity surface further includes:

[0033] Determine the characteristic value of the thermal dispersion deviation of the first bag of molten iron in the guide shell mold cavity for the deep well pump during the feeding process of the dedicated feeding riser under the condition that the feeding channel of the dedicated feeding riser is not blocked;

[0034] Based on the comparison result that the thermal dispersion deviation characteristic value is greater than the first preset thermal dispersion deviation characteristic value, it is determined that the cavity surface has a high thermal distribution and the cavity surface temperature is high.

[0035] Furthermore, the process of adjusting the second preset pouring temperature includes:

[0036] Calculating a ratio of a heat dispersion deviation characteristic value under a condition where the cavity surface temperature is low to a first preset heat dispersion deviation characteristic value;

[0037] Determining to increase the second preset pouring temperature based on the comparison result that the ratio is less than or equal to the preset ratio;

[0038] The increased second preset pouring temperature is determined according to the second preset pouring temperature and the preset temperature increase adjustment coefficient.

[0039] Furthermore, the process of adjusting the second preset pouring temperature also includes:

[0040] Calculating a ratio of a heat dispersion deviation characteristic value under a condition where the cavity surface temperature is high to a first preset heat dispersion deviation characteristic value;

[0041] Determining to reduce the second preset pouring temperature based on the comparison result that the ratio is greater than the preset ratio;

[0042] The reduced second preset pouring temperature is determined according to the second preset pouring temperature and the preset temperature reduction adjustment coefficient.

[0043] Compared with the prior art, the beneficial effect of the present invention lies in that the present invention collects the cavity molten iron liquid surface temperature in real time through a thermocouple and calculates the attenuation coefficient, evaluates the heat loss rate of the first bag of molten iron, monitors the shrinkage riser pressure through a pressure sensor, and judges whether the shrinkage channel is blocked in combination with the pressure decay characterization parameter, adjusts the pouring rate of the second bag to maintain an effective shrinkage pressure, prevents internal shrinkage, analyzes the thermal dispersion deviation characteristic value of the cavity surface based on infrared images, intuitively identifies local overcooling or overheating areas, adjusts the pouring temperature of the second bag to balance the heat distribution, avoids thermal stress concentration or structural segregation caused by excessive surface temperature difference, and improves the internal density and surface quality of the casting. When the first bag of molten iron reaches the preset temperature measuring point, the second bag of molten iron begins to be poured, which is used to supplement the molten iron in the special shrinkage riser and neutralize the temperature of the molten iron in the upper part of the guide shell cavity for deep well pumps. To ensure that there is always sufficient molten iron for shrinkage feeding during the solidification process of the guide shell casting for deep well pumps, two independent pouring and filling systems are adopted, changing the traditional single pouring mode. Two casting ladles are equipped with clear division of labor and orderly collaboration. Special feeding risers are designed to ensure the pouring temperature of the uppermost molten iron and provide sufficient molten iron for feeding, thereby improving product performance and reliability, thereby improving the casting stability of the guide shell casting for deep well pumps.

[0044] Furthermore, the present invention determines whether the heat loss is qualified by the liquid surface temperature attenuation coefficient. If it is unqualified, the first preset injection temperature or the first preset pouring rate is adjusted according to the difference between the liquid surface temperature attenuation coefficient and the preset liquid surface temperature attenuation coefficient, accurately judges the heat loss state, and dynamically adjusts the injection temperature or rate based on the difference to avoid insufficient local temperature during the second bag filling due to excessive heat loss, effectively prevents defects such as shrinkage and cracks, and improves the controllability of the pouring process and the consistency of casting quality.

[0045] Furthermore, the present invention determines whether the shrinkage feeding channel is blocked by the pressure decay characterization parameter. When blocked, the second preset pouring rate is adjusted according to the relative difference between the pressure decay characterization parameter and the preset pressure decay characterization parameter to ensure that the shrinkage feeding pressure is stable, thereby improving the accuracy and objectivity of the blockage detection. For the blockage problem, the second preset pouring rate is dynamically adjusted based on the relative difference, which can not only compensate for the pressure loss caused by the blockage, but also avoid the risk of air entrainment or overflow caused by over-adjustment of the rate, thereby ensuring that the shrinkage feeding channel is unobstructed, ensuring the adaptability of the shrinkage feeding pressure and temperature, fundamentally reducing the occurrence of defects such as pores and shrinkage, and improving the consistency of the internal quality of the casting and the process reliability.

[0046] Furthermore, the present invention judges the thermal distribution state by the thermal dispersion deviation characteristic value, and adjusts the second preset pouring temperature according to the ratio of the thermal dispersion deviation characteristic value to the first preset thermal dispersion deviation characteristic value, thereby improving the detection accuracy of the thermal distribution state, compensating for the temperature deviation to balance the thermal distribution, avoiding thermal stress concentration or structural segregation caused by temperature overadjustment, preventing defects such as shrinkage holes and cracks caused by uneven thermal distribution, improving the surface quality of the casting and the uniformity of the internal structure, and thus improving the casting stability of the guide shell for deep well pumps. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 This is a flow chart of a casting process for a novel guide shell for a deep well pump according to an embodiment of the present invention;

[0048] Figure 2 A flow chart for determining whether the heat loss of the liquid surface is qualified according to an embodiment of the present invention;

[0049] Figure 3 This is a front view of a casting system for a guide shell for a new deep well pump according to an embodiment of the present invention;

[0050] Figure 4 A top view of a casting system for a guide shell for a new deep well pump according to an embodiment of the present invention;

[0051] Figure 5 This is a bottom view of the casting system of the guide shell for the new deep well pump according to the embodiment of the present invention;

[0052] In the figure, 1. Bottom sprue; 2. Bottom runner; 3. Bottom ingrown runner; 4. Top sprue; 5. Top runner; 6. Top ingrown runner; 7. Special feeding riser; 8. Diversion shell cavity for deep well pump. DETAILED DESCRIPTION

[0053] In order to make the objects and advantages of the present invention more clearly understood, the present invention is further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are merely used to explain the present invention and are not intended to limit the present invention.

[0054] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0055] It should be pointed out that the data in this embodiment are obtained by comprehensive analysis and evaluation of the historical test data and the corresponding historical test results of the three months before this test. It can be understood by those skilled in the art that the present invention can determine the above parameters for a single item by selecting the value with the highest proportion as the preset standard parameter based on the data distribution, using weighted summation to use the obtained value as the preset standard parameter, substituting each historical data into a specific formula and using the value obtained by the formula as the preset standard parameter or other selection methods, as long as the present invention can clearly define the different specific situations in the single determination process through the obtained values.

[0056] See also Figure 1 As shown, it is a flow chart of the casting process method of the new deep well pump guide shell according to an embodiment of the present invention.

[0057] The casting method of the novel guide shell for a deep well pump according to the embodiment of the present invention comprises:

[0058] Step S1, inserting a plurality of thermocouples into a dedicated feeding riser to obtain the temperature data of the molten iron surface in the guide shell cavity of a deep well pump and the pressure data of the pressure sensor installed in the dedicated feeding riser, as well as an infrared image of the outer surface of the cavity;

[0059] Step S2, injecting a first bag of molten iron from the bottom sprue with a first injection parameter, flowing into the bottom runner, then into the bottom ingrown gate and into the guide shell cavity for the deep well pump;

[0060] Step S3, determining whether the heat loss of the first ladle of molten iron is qualified based on the liquid surface temperature attenuation coefficient obtained based on the molten iron surface temperature data during the pouring process of the first ladle of molten iron, and adjusting the first pouring parameter according to the difference between the liquid surface temperature attenuation coefficient and a preset liquid surface temperature attenuation coefficient;

[0061] Step S4: When the first ladle of molten iron reaches the preset temperature measurement point, the second ladle of molten iron is injected into the top sprue with the second injection parameter. After entering the top sprue, the second ladle of molten iron flows through the top runner and the top ingrate in sequence and enters the dedicated feeding riser.

[0062] Step S5, determining whether a feeding channel of the dedicated feeding riser is blocked based on a pressure decay parameter obtained from pressure data of the pressure sensor, and adjusting a second preset pouring rate based on a relative difference between the pressure decay parameter and a preset pressure decay parameter;

[0063] Step S6, determining whether the heat distribution on the cavity surface is uniform based on the heat dispersion deviation characteristic value of the first ladle of molten iron in the guide shell cavity of the deep well pump during the feeding process of the dedicated feeding riser by the second ladle of molten iron, and adjusting the second preset pouring temperature according to the ratio of the heat dispersion deviation characteristic value to the first preset heat dispersion deviation characteristic value;

[0064] Step S7: completing the casting of the guide shell for the deep well pump under the condition that the heat distribution on the cavity surface is uniform.

[0065] In the embodiment of the present invention, the infrared image is obtained by an infrared thermal imager.

[0066] Specifically, the present invention uses a thermocouple to collect the temperature of the molten iron surface in the mold cavity in real time and calculates the attenuation coefficient, evaluates the heat loss rate of the first bag of molten iron, monitors the pressure of the feeding riser through a pressure sensor, and determines whether the feeding channel is blocked in combination with the pressure decay characterization parameter, adjusts the pouring rate of the second bag to maintain an effective feeding pressure to prevent internal shrinkage, analyzes the thermal dispersion deviation characteristic value of the mold cavity surface based on infrared images, intuitively identifies local overcooling or overheating areas, adjusts the pouring temperature of the second bag to balance the heat distribution, avoids thermal stress concentration or structural segregation caused by excessive surface temperature difference, and improves the internal density and surface quality of the casting. When the first bag of molten iron reaches the preset temperature measuring point, the second bag of molten iron begins to be poured. Its function is to supplement the molten iron in the special feeding riser and neutralize the temperature of the molten iron in the upper part of the guide shell cavity for the deep well pump. To ensure that there is always sufficient molten iron for shrinkage feeding during the solidification process of the guide shell casting for deep well pumps, two independent pouring and filling systems are adopted, changing the traditional single pouring mode. Two casting ladles are equipped with clear division of labor and orderly collaboration. Special feeding risers are designed to ensure the pouring temperature of the uppermost molten iron and provide sufficient molten iron for feeding, thereby improving product performance and reliability, thereby improving the casting stability of the guide shell casting for deep well pumps.

[0067] Specifically, when pouring a guide shell for a deep well pump, an embodiment of the present invention injects a first bag of molten iron into the bottom sprue with a first pouring parameter, the first bag of molten iron flows into the bottom runner, then into the bottom endocastor, and finally into the cavity of the guide shell for the deep well pump. The first pouring parameter includes a first preset rate, a first preset injection pressure, and a first preset injection temperature.

[0068] In an embodiment of the present invention, the first preset rate range is 10-20 kg / min, preferably 15 kg / min; the first preset injection pressure range is 0.1-0.3 MPa, preferably 0.2 MPa; the first preset injection temperature range is 1350-1450°C, preferably 1400°C.

[0069] It can be understood that the bottom runner is a spoke-shaped annular structure, and the bottom runner can evenly distribute the molten iron flow rate and adjust the flow direction of the molten iron so that the first bag of molten iron can stably enter the bottom runner.

[0070] See also Figure 2 As shown, it is a flow chart of determining whether the liquid surface heat loss is qualified according to an embodiment of the present invention.

[0071] Specifically, in an embodiment of the present invention, under the condition that the first ladle of molten iron is poured into the guide shell cavity for the deep well pump, whether the liquid surface heat loss is qualified is determined based on the comparison result of the liquid surface temperature attenuation coefficient of the molten iron liquid surface temperature data during the pouring process and the preset liquid surface temperature attenuation coefficient;

[0072] When the liquid surface temperature attenuation coefficient is less than or equal to the preset liquid surface temperature attenuation coefficient, it is determined that the liquid surface heat loss is qualified;

[0073] When the liquid surface temperature attenuation coefficient is greater than the preset liquid surface temperature attenuation coefficient, it is determined that the liquid surface heat loss is unqualified.

[0074] In the embodiment of the present invention, the preset liquid surface temperature attenuation coefficient is in the range of 0.5 to 1.5°C / min, preferably 1.0°C / min, but the above value is not limited thereto, and those skilled in the art may also adjust the value according to actual needs.

[0075] In an embodiment of the present invention, the liquid level temperature attenuation coefficient is the result of dividing the difference between the initial liquid level temperature and the current liquid level temperature by the pouring time interval, the initial liquid level temperature is the first preset injection temperature, the pouring time interval is 5s, and the current liquid level temperature is the liquid level temperature at different pouring time intervals.

[0076] It is understandable that the temperature of the first bag of molten iron will drop during the pouring process due to factors such as heat dissipation in the mold cavity and friction of the molten iron flow. If the liquid surface temperature decays too quickly and the heat loss in the surface cavity is too large, it will cause insufficient local temperature when the second bag of molten iron is filled, causing shrinkage or cracks.

[0077] Specifically, in an embodiment of the present invention, when it is determined that the liquid surface heat loss is unqualified, the first preset injection temperature or the first preset pouring rate is adjusted according to the comparison result of the difference between the liquid surface temperature attenuation coefficient and the preset liquid surface temperature attenuation coefficient and the preset difference;

[0078] When the difference is less than or equal to the preset difference, it is determined that the first preset injection temperature is increased to a corresponding value by a preset injection temperature adjustment coefficient of 1.05;

[0079] When the difference is greater than the preset difference, it is determined to reduce the first preset pouring rate to a corresponding value using a preset injection rate adjustment coefficient of 0.97;

[0080] The difference is the difference between the liquid surface temperature attenuation coefficient and the preset liquid surface temperature attenuation coefficient.

[0081] In the embodiment of the present invention, the preset difference value is 0.7, but the above value is not limited thereto, and those skilled in the art may also adjust the value according to actual needs.

[0082] In an embodiment of the present invention, the increased first preset injection temperature is the product of the first preset injection temperature and the preset injection temperature adjustment coefficient, and the preset injection temperature adjustment coefficient is 1.05; the reduced first preset pouring rate is the product of the preset injection rate adjustment coefficient and the first preset pouring rate, and the preset injection rate adjustment coefficient is 0.97. In order to ensure that the adjusted first preset injection temperature and the first preset pouring rate meet actual needs, the adjustment range should not be too large, so the adjustment coefficient is set accordingly to control the adjustment range.

[0083] Specifically, the present invention determines whether the heat loss is qualified by the liquid surface temperature attenuation coefficient. If it is unqualified, the first preset injection temperature or the first preset pouring rate is adjusted according to the difference between the liquid surface temperature attenuation coefficient and the preset liquid surface temperature attenuation coefficient, accurately judges the heat loss state, and dynamically adjusts the injection temperature or rate based on the difference to avoid insufficient local temperature during the second bag filling due to excessive heat loss, effectively prevents defects such as shrinkage and cracks, and improves the controllability of the pouring process and the consistency of casting quality.

[0084] Specifically, in an embodiment of the present invention, under the condition of determining that the heat loss of the liquid surface is qualified or adjusting the first injection parameter, the first bag of molten iron is continuously poured to a preset temperature measuring point, and at the same time the second bag of molten iron begins to be poured. The second bag of molten iron is injected into the top straight runner with the second injection parameter. After entering the top straight runner, the second bag of molten iron flows through the top cross runner and the top inner runner in sequence and enters the special shrinkage feeding riser. The second injection parameter includes a second preset pouring rate, a second preset injection pressure and a second preset injection temperature.

[0085] In an embodiment of the present invention, the second preset pouring rate range is 15-25 kg / min, preferably 20 kg / min; the second preset injection pressure range is 0.5-0.7 MPa, preferably 0.6 MPa; the second preset injection temperature range is 1500-1600°C, preferably 1550°C.

[0086] Specifically, in an embodiment of the present invention, when it is determined that the first ladle of molten iron has reached a preset temperature measurement point and the second ladle of molten iron has begun to be poured, a pressure decay characteristic parameter obtained by pressure data from a pressure sensor provided on the dedicated feeding riser is compared with a preset pressure decay characteristic parameter to determine whether the feeding channel of the dedicated feeding riser is blocked;

[0087] When the pressure decay characteristic parameter is less than or equal to the preset pressure decay characteristic parameter, it is determined that the feeding channel is not blocked;

[0088] When the pressure decay characterization parameter is greater than the preset pressure decay characterization parameter, it is determined that the feeding channel is blocked;

[0089] In the embodiment of the present invention, the preset value of the pressure attenuation characterization parameter is [1.0, 1.2], preferably 1.1, but the above value is not limited thereto, and those skilled in the art can also adjust the value according to actual needs.

[0090] In an embodiment of the present invention, the pressure decay characterization parameter is the ratio of the pressure decay slope to the pressure decay slope threshold, the pressure decay slope threshold is set to 0.03 MPa / s, the pressure decay slope is the difference between the initial value of the second preset injection pressure and the current value of the second preset injection pressure divided by the time interval, and the time interval is set to 3s.

[0091] It is understandable that the function of the feeding riser is to provide continuous feeding for the cavity. If its channel is blocked, it will lead to insufficient feeding pressure, and the gas in the cavity cannot be discharged, eventually forming pores or shrinkage. The embodiment of the present invention collects the riser pressure data through a pressure sensor and calculates the pressure decay slope, which can quantify the degree of channel blockage, avoiding the traditional subjective judgment of observing whether the riser is solidified, and improving the accuracy of blockage detection.

[0092] Specifically, in an embodiment of the present invention, when it is determined that the feeding channel is blocked, the second preset pouring rate is adjusted according to a comparison result of the relative difference between the pressure decay characteristic parameter and the preset pressure decay characteristic parameter and the preset relative difference;

[0093] When the relative difference is less than or equal to the preset relative difference, it is determined to increase the second preset pouring rate to a corresponding value by the first preset rate adjustment coefficient of 1.03;

[0094] When the relative difference is greater than the preset relative difference, it is determined to increase the second preset pouring rate to a corresponding value using a second preset rate adjustment coefficient of 1.07.

[0095] The relative difference is the relative difference between the pressure decay characterization parameter and the preset pressure decay characterization parameter.

[0096] In the embodiment of the present invention, the preset relative difference value is 0.8, but the above value is not limited thereto, and those skilled in the art may also adjust the value according to actual needs.

[0097] In an embodiment of the present invention, the increased second preset pouring rate is the product of the second preset pouring rate and the preset rate adjustment coefficient. The preset rate adjustment coefficient includes the first preset rate adjustment coefficient, which is 1.03, and the second preset pouring rate, which is 1.07. In order to ensure that the adjusted second preset pouring rate meets actual needs, the adjustment range should not be too large, so the corresponding adjustment coefficient is set to control the adjustment range.

[0098] Specifically, the present invention determines whether the shrinkage feeding channel is blocked by the pressure decay characterization parameter. When blocked, the second preset pouring rate is adjusted according to the relative difference between the pressure decay characterization parameter and the preset pressure decay characterization parameter to ensure that the shrinkage feeding pressure is stable, thereby improving the accuracy and objectivity of blockage detection. For the blockage problem, the second preset pouring rate is dynamically adjusted based on the relative difference, which can not only compensate for the pressure loss caused by the blockage, but also avoid the risk of air entrapment or overflow caused by over-adjustment of the rate, thereby ensuring that the shrinkage feeding channel is unobstructed, ensuring the adaptability of the shrinkage feeding pressure and temperature, fundamentally reducing the occurrence of defects such as pores and shrinkage, and improving the consistency of the internal quality of the casting and the process reliability.

[0099] Specifically, in an embodiment of the present invention, under the condition that the feeding channel of the dedicated feeding riser is determined to be unblocked, the heat distribution on the cavity surface is determined to be uniform based on a comparison result of a heat dispersion deviation characteristic value of a first bag of molten iron in the guide shell cavity of a deep well pump during the feeding of the dedicated feeding riser by the second bag of molten iron with a preset heat dispersion deviation characteristic value.

[0100] When the heat dispersion deviation characteristic value is less than or equal to the first preset heat dispersion deviation characteristic value, it is determined that the heat distribution on the cavity surface is uneven and the cavity surface temperature is low;

[0101] When the heat dispersion deviation characteristic value is greater than the first preset heat dispersion deviation characteristic value and less than or equal to the second preset heat dispersion deviation characteristic value, it is determined that the heat distribution on the cavity surface is uniform;

[0102] When the heat dispersion deviation characteristic value is greater than a second preset heat dispersion deviation characteristic value, it is determined that the heat distribution on the cavity surface is uneven and the cavity surface temperature is high.

[0103] In the embodiment of the present invention, the first preset thermal dispersion deviation characteristic value is 0.15, and the second preset thermal dispersion deviation characteristic value is 0.25, but the above values ​​are not limited thereto. Those skilled in the art may also adjust the values ​​according to actual needs.

[0104] In the embodiment of the present invention, the thermal dispersion deviation characteristic value is the ratio of the average thermal radiation intensity of the cavity surface area to the average intensity threshold, and the average intensity threshold is set to 6000W / m 2 The process of extracting the thermal radiation intensity of the cavity surface area is to use an infrared thermal imager to collect infrared images of the cavity surface of the guide shell for deep well pumps. The collection frequency is set to 1Hz to obtain the thermal radiation intensity distribution image of the cavity surface. The collected thermal radiation intensity distribution image is preprocessed, and then the image segmentation algorithm is used to separate the cavity surface area from the background. In the segmented cavity surface area, the thermal radiation intensity value of each point is extracted. The above process is a conventional process and will not be repeated here.

[0105] Specifically, in an embodiment of the present invention, under the condition of determining that the heat distribution is uneven, the second preset pouring temperature is adjusted according to a comparison result of the ratio of the heat dispersion deviation characteristic value to the first preset heat dispersion deviation characteristic value and the preset ratio;

[0106] When the ratio is less than or equal to the preset ratio, it is determined to increase the second preset pouring temperature to a corresponding value by a preset temperature increase adjustment coefficient of 1.12;

[0107] When the ratio is greater than the preset ratio, it is determined to reduce the second preset pouring temperature to a corresponding value by a preset temperature reduction adjustment coefficient of 0.92;

[0108] The preset ratio is a ratio of the thermal dispersion deviation characteristic value to the first preset thermal dispersion deviation characteristic value.

[0109] In the embodiment of the present invention, the preset ratio is set to 1, but the above value is not limited thereto, and those skilled in the art may also adjust the value according to actual needs.

[0110] In an embodiment of the present invention, the increased second preset pouring temperature is the product of the second preset pouring temperature and the preset temperature increase adjustment coefficient, and the preset temperature increase adjustment coefficient is 1.12; the reduced second preset pouring temperature is the product of the second preset pouring temperature and the preset temperature decrease adjustment coefficient, and the preset temperature decrease adjustment coefficient is 0.92. In order to ensure that the adjusted second preset pouring temperature meets actual needs, the adjustment range should not be too large, so the corresponding adjustment coefficient is set to control the adjustment range.

[0111] Specifically, the present invention judges the thermal distribution state by the thermal dispersion deviation characteristic value, and adjusts the second preset pouring temperature according to the ratio of the thermal dispersion deviation characteristic value to the first preset thermal dispersion deviation characteristic value, thereby improving the detection accuracy of the thermal distribution state, compensating for the temperature deviation to balance the thermal distribution, avoiding thermal stress concentration or structural segregation caused by temperature overadjustment, preventing defects such as shrinkage holes and cracks caused by uneven thermal distribution, improving the surface quality of the casting and the uniformity of the internal structure, and thus improving the casting stability of the guide shell for deep well pumps.

[0112] Specifically, in the embodiment of the present invention, a cast deep well pump guide shell is obtained under the condition of ensuring uniform heat distribution.

[0113] See also Figure 3-Figure 5 As shown, Figure 3 This is a front view of a casting system for a guide shell for a new deep well pump according to an embodiment of the present invention; Figure 4 A top view of a casting system for a guide shell for a new deep well pump according to an embodiment of the present invention; Figure 5 This is a bottom view of the casting system of the guide shell for a new deep well pump according to an embodiment of the present invention.

[0114] The embodiment of the present invention also includes a casting system for a novel guide shell for a deep well pump, comprising:

[0115] The bottom sprue 1 is in the shape of a tube extending up and down, and is used to guide the first ladle of molten iron into the bottom runner 2;

[0116] A bottom runner 2, one end of which is connected to the bottom sprue 1, for evenly distributing the flow of the first ladle of molten iron and adjusting the flow direction of the first ladle of molten iron;

[0117] A bottom ingrown 3, one end of which is connected to the bottom runner 2, for injecting the first bag of molten iron into the bottom of the guide shell cavity 8 for the deep well pump;

[0118] A top sprue 4 is provided on the upper portion of the guide shell cavity 8 for the deep well pump and is used to guide the second ladle of molten iron to be injected into the top runner 5;

[0119] A top runner 5, one end of which is connected to the top sprue 4, for distributing the second ladle of molten iron to the top ingrown 6;

[0120] A top runner 6, one end of which is connected to the top runner 5, for injecting the second ladle of molten iron into a dedicated feeding riser 7;

[0121] A dedicated feeding riser 7, which is arranged at the top of the guide shell cavity 8 for the deep well pump and is used to receive the second bag of molten iron in the top sprue 6;

[0122] The guide shell cavity 8 for a deep well pump is used to guide the molten iron to fill and solidify to form the guide shell for a deep well pump.

[0123] Thus far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art may make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will fall within the scope of protection of the present invention.

[0124] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that the present invention is susceptible to various modifications and variations. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A new casting method for a guide shell for a deep well pump, characterized in that: include: Acquire molten iron surface temperature data within the guide shell cavity of a deep-well pump, obtain pressure data for a dedicated feeding riser, and obtain infrared images of the cavity's outer surface; The first bag of molten iron is injected from the bottom sprue according to the first injection parameter, flows into the bottom runner, enters the bottom ingrown channel and flows into the guide shell cavity for the deep well pump; determining whether the heat loss of the first ladle of molten iron is qualified based on the liquid surface temperature attenuation coefficient obtained based on the molten iron liquid surface temperature data during the pouring process of the first ladle of molten iron, and adjusting the first pouring parameter according to the difference between the liquid surface temperature attenuation coefficient and a preset liquid surface temperature attenuation coefficient; When the first ladle of molten iron reaches the preset temperature measuring point, the second ladle of molten iron is injected into the top sprue with the second injection parameter. After entering the top sprue, the second ladle of molten iron flows through the top runner and the top ingrate in sequence and enters the dedicated feeding riser. Determining that a feeding channel of the dedicated feeding riser is clogged based on a pressure decay characterization parameter obtained from the pressure data, and adjusting a second preset pouring rate based on a relative difference between the pressure decay characterization parameter and a preset pressure decay characterization parameter; Determining the heat distribution on the cavity surface based on a heat dispersion deviation characteristic value of a first bag of molten iron in a guide shell cavity for a deep well pump during feeding of the dedicated feeding riser by the second bag of molten iron, so as to determine and adjust the second preset pouring temperature according to a ratio of the heat dispersion deviation characteristic value to the first preset heat dispersion deviation characteristic value; Under the condition of ensuring uniform heat distribution on the cavity surface, the casting of the guide shell for the deep well pump is completed.

2. The casting process of the novel guide shell for deep well pump according to claim 1 is characterized in that: The unqualified heat loss of the first bag of molten iron is determined based on the comparison result that the liquid surface temperature attenuation coefficient is greater than the preset liquid surface temperature attenuation coefficient, wherein, The liquid surface temperature attenuation coefficient is determined according to the initial liquid surface temperature, the current liquid surface temperature and the pouring time interval of the molten iron liquid surface temperature data during the pouring process of the first ladle of molten iron.

3. The casting process of the new deep well pump guide shell according to claim 2 is characterized in that: The process of adjusting the first pouring parameter includes: Calculate the difference between the liquid surface temperature attenuation coefficient under the condition that the heat loss of the first ladle of molten iron is unqualified and the preset liquid surface temperature attenuation coefficient; Determining to increase the first preset injection temperature based on the comparison result that the difference is less than or equal to the preset difference; The increased first preset injection temperature is determined according to the first preset injection temperature and the preset injection temperature adjustment coefficient.

4. The casting process of the novel guide shell for deep well pump according to claim 3 is characterized in that: The process of adjusting the first pouring parameter further includes: Calculate the difference between the liquid surface temperature attenuation coefficient under the condition that the heat loss of the first ladle of molten iron is unqualified and the preset liquid surface temperature attenuation coefficient; Determining to reduce the first preset pouring rate based on the comparison result that the difference is greater than the preset difference; The reduced first preset pouring rate is determined according to the first preset pouring rate and the preset injection rate adjustment coefficient.

5. The casting process of the novel guide shell for deep well pump according to claim 1 is characterized in that: The blocking of the feeding channel of the dedicated feeding riser is determined based on the comparison result that the pressure decay characterization parameter is greater than the preset pressure decay characterization parameter, wherein, The pressure decay characterization parameter is determined according to the pressure decay slope and the pressure decay slope threshold.

6. The casting method of the novel guide shell for deep well pump according to claim 5 is characterized in that: The process of adjusting the second preset pouring rate includes: Calculating a relative difference between the pressure decay characterization parameter and the preset pressure decay characterization parameter; Determining to increase a second preset pouring rate based on a comparison result of the relative difference and a preset relative difference; The increased second preset pouring rate is determined according to the second preset pouring rate and the preset rate adjustment coefficient.

7. The casting method of the novel guide shell for deep well pump according to claim 1 is characterized in that: The process of determining the heat distribution on the cavity surface includes: Determine the characteristic value of the thermal dispersion deviation of the first bag of molten iron in the guide shell mold cavity for the deep well pump during the feeding process of the dedicated feeding riser under the condition that the feeding channel of the dedicated feeding riser is not blocked; Determining that the cavity surface has a low thermal distribution and a low cavity surface temperature based on a comparison result that the thermal dispersion deviation characteristic value is less than or equal to a first preset thermal dispersion deviation characteristic value; The thermal dispersion deviation characteristic value is determined according to the average thermal radiation intensity of the cavity surface area and the average intensity threshold.

8. The casting method of the novel guide shell for deep well pump according to claim 1 is characterized in that: The process of determining the heat distribution on the cavity surface further includes: Determine the characteristic value of the thermal dispersion deviation of the first bag of molten iron in the guide shell mold cavity for the deep well pump during the feeding process of the dedicated feeding riser under the condition that the feeding channel of the dedicated feeding riser is not blocked; Based on the comparison result that the thermal dispersion deviation characteristic value is greater than the first preset thermal dispersion deviation characteristic value, it is determined that the cavity surface has a high thermal distribution and the cavity surface temperature is high.

9. The casting method of the novel guide shell for deep well pump according to claim 7 is characterized in that: The process of adjusting the second preset pouring temperature includes: Calculating a ratio of a heat dispersion deviation characteristic value under a condition where the cavity surface temperature is low to a first preset heat dispersion deviation characteristic value; Determining to increase the second preset pouring temperature based on the comparison result that the ratio is less than or equal to the preset ratio; The increased second preset pouring temperature is determined according to the second preset pouring temperature and the preset temperature increase adjustment coefficient.

10. The casting method of the novel guide shell for deep well pump according to claim 8 is characterized in that: The process of adjusting the second preset pouring temperature also includes: Calculating a ratio of a heat dispersion deviation characteristic value under a condition where the cavity surface temperature is high to a first preset heat dispersion deviation characteristic value; Determining to reduce the second preset pouring temperature based on the comparison result that the ratio is greater than the preset ratio; The reduced second preset pouring temperature is determined according to the second preset pouring temperature and the preset temperature reduction adjustment coefficient.

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