Die energy-saving temperature control system for waste heat recovery

Abstract

The invention belongs to the technical field of industrial die energy saving, and provides a die energy-saving temperature control system for waste heat recovery, which is composed of four parts, namely a heat exchange module, a waste heat storage unit, an intelligent temperature control module and a circulating pipeline, and all the parts cooperate with one another to realize efficient recovery and storage of die waste heat and precise intelligent control of die temperature; the die waste heat is quickly captured through the efficient heat exchange module, efficient recovery and accurate distribution of the waste heat are achieved in combination with the high-density heat storage unit and the intelligent temperature control module, the energy utilization efficiency is remarkably improved, the production cost is reduced, the product quality is improved through accurate temperature control, and the product quality is improved. The thermal stress of the mold caused by temperature fluctuation is reduced, so that the service life of the mold is prolonged, and meanwhile, the system is high in adaptability and can be flexibly applied to various mold scenes.

Description

Technical Field

[0001] The present invention belongs to the technical field of industrial mold energy saving, and in particular relates to a mold energy-saving temperature control system with waste heat recovery. Background Art

[0002] In the manufacturing industry, molds are the core equipment in the production process and are widely used in processes such as injection molding, die-casting, and stamping. Traditional molds generate a large amount of heat energy during operation, especially during the high-temperature molding stage, when the mold temperature can reach 150-300°C. Currently, the industry generally uses water cooling or oil cooling systems to force cooling of molds, but these cooling methods have two significant drawbacks: first, the heat energy contained in the high-temperature cooling medium generated during the cooling process (the water temperature can reach 80-90°C) is directly discharged into the environment, resulting in huge energy waste; second, the mold needs to consume a large amount of electricity to be reheated before the next production cycle, forming an energy paradox of "cooling first and then heating".

[0003] Existing mold temperature control systems face the following technical bottlenecks: First, the heat recovery rate of conventional cooling systems is less than 20%, with most of the excess heat dissipated through cooling towers or heat exchangers. Second, traditional heat storage technologies, such as sensible heat storage (e.g., water tank storage), have a low energy density (<100kJ / kg), which cannot meet the intermittent operation requirements of industrial molds.

[0004] To this end, those skilled in the art have proposed a mold energy-saving temperature control system with waste heat recovery to solve the problems raised in the background art. Summary of the Invention

[0005] In order to solve the above technical problems, the present invention develops a mold energy-saving temperature control system that integrates efficient heat exchange, high-density heat storage and intelligent control, which is of great significance to promoting the green transformation of the manufacturing industry and reducing production costs.

[0006] To achieve the above object, the present invention adopts the following technical solutions:

[0007] A waste heat recovery mold energy-saving temperature control system consists of four major components: a heat exchange module, a waste heat storage unit, an intelligent temperature control module, and a circulation pipeline. These components work together to achieve efficient recovery and storage of mold waste heat and precise intelligent control of mold temperature. Specifically, it includes:

[0008] The heat exchange module, integrated into the mold cooling system, includes a parallel heat pipe array and a microchannel heat exchanger to capture the high-temperature waste heat generated by the mold. The heat pipe array consists of 6-12 groups of copper-based graphene-coated heat pipes with a diameter of 6-10 mm, radially arranged in the mold's high-temperature zone at equal intervals of 15-20 mm. The microchannel heat exchanger has an S-shaped circuitous flow channel with a width of 0.5-1.2 mm and a depth of 1.0-1.5 mm. The channel wall is equipped with a nanoporous enhanced heat transfer structure.

[0009] The waste heat storage unit is connected to the heat exchange module via a pipeline and adopts a composite energy storage structure of phase change material (PCM) and sensible heat storage medium. The phase change material is a modified inorganic salt mixture with a melting point of 150-300°C. Its composition, by mass fraction, includes: 40-55% sodium nitrate; 30-45% potassium nitrate; 5-10% nano-alumina; and 2-5% carbon fiber reinforcement. The sensible heat storage medium is a honeycomb ceramic matrix with a porosity of 60-70% and a pore size distribution of 0.5 to 2 mm, and is impregnated with a molten salt high-temperature heat transfer fluid.

[0010] The intelligent temperature control module includes a temperature sensor network, a fuzzy PID controller, and a PLC for dynamically adjusting waste heat distribution. The temperature sensor network includes:

[0011] 4 mold cavity temperature measurement points are arranged 2 to 5 mm away from the mold cavity surface;

[0012] Two temperature measurement points of the heat storage unit are embedded in the PCM layer and the sensible heat medium layer respectively;

[0013] 2 pipeline temperature measurement points, located at the inlet and outlet of the heat exchange module;

[0014] The fuzzy PID controller uses the input variable temperature deviation e(t) and its rate of change ec(t) to output the variable regulating valve opening u(t). The fuzzy rule base contains 25 IF-THEN rules, and the membership function adopts Gaussian distribution.

[0015] Circulation piping system, including insulation main line and branch loop, realizes the directional transmission of heat energy within the system;

[0016] The circulation piping system comprises:

[0017] Quick-switching valve group can switch between mold preheating mode and auxiliary heating mode;

[0018] Anti-corrosion and heat-insulated pipelines with anodized aluminum protective layer on the inner wall;

[0019] Frequency conversion centrifugal pump, flow rate adjustment range 0.5~5m 3 / h.

[0020] Furthermore, the heat exchange module is directly integrated into the mold cooling system, manufactured from highly efficient thermally conductive materials and featuring optimized flow paths. The module contains multiple parallel heat pipe arrays and microchannel heat exchangers. The heat pipes in the heat pipe array have extremely high thermal conductivity, enabling rapid heat transfer from the mold surface. The microchannel heat exchanger further improves heat transfer efficiency by increasing the heat transfer area and optimizing the fluid flow path. During mold operation, heat from the high-temperature mold surface is transferred to the heat pipe array via the highly efficient thermally conductive material. The working fluid in the heat pipe absorbs heat in the evaporation section, transforms into a gaseous state, and rapidly flows to the condensation section, where it transfers heat to the cooling medium in the microchannel heat exchanger. After cooling, the working fluid flows back to the evaporation section, repeating this cycle for efficient heat transfer. The cooling medium in the microchannel heat exchanger absorbs heat, raising its temperature. It then flows through a circulation pipeline into a waste heat storage unit or participates in subsequent temperature control. Thanks to its multiple parallel design, the heat exchange module can rapidly capture waste heat from multiple locations within the mold simultaneously, achieving over 40% higher heat transfer efficiency than conventional designs.

[0021] Furthermore, the waste heat storage unit utilizes a composite energy storage method that combines phase change material (PCM) with sensible heat storage. The PCM is a modified inorganic salt PCM with a melting point between 150°C and 300°C. This PCM undergoes a phase change process when absorbing or releasing heat, absorbing or releasing a large amount of latent heat, resulting in an energy storage density 2-3 times that of traditional thermal storage media.

[0022] Furthermore, the sensible heat storage part can use solid materials with higher specific heat capacity, such as ceramics. Storage structure: A special heat exchange structure is designed inside the waste heat storage unit to exchange heat with the high-temperature cooling medium output by the heat exchange module. When the high-temperature cooling medium flows into the waste heat storage unit, the heat is first transferred to the phase change material, causing it to undergo a phase change and store heat. After the phase change material reaches the upper limit of the phase change temperature, the excess heat is absorbed and stored by the sensible heat storage part. When the stored waste heat needs to be utilized, the heat is transported to the mold or other parts that need heat through the circulation pipeline.

[0023] The intelligent temperature control module is equipped with a network of high-precision temperature sensors located at key locations throughout the mold, enabling real-time monitoring of temperature changes across the mold. The sensors transmit the collected temperature data to a programmable logic controller (PLC) in real time.

[0024] Further control algorithms: Based on the fuzzy PID control algorithm, the PLC calculates the deviation between the current mold temperature and the set temperature and the rate of change of the deviation based on temperature data fed back by the temperature sensor. Using fuzzy inference rules, the PID controller parameters are adjusted online to achieve precise control of the mold temperature. For example, when the mold temperature deviation is large and the rate of change is high, the PLC increases the control output to quickly adjust the mold temperature. When the temperature approaches the set value, the PLC decreases the control output to avoid temperature overshoot.

[0025] Furthermore, waste heat distribution: The PLC intelligently controls the valves and pumps in the circulation pipeline based on the temperature requirements of various parts of the mold and the heat storage status of the waste heat storage unit, achieving reasonable waste heat distribution. For example, when the temperature of a certain part of the mold is low, the PLC controls the transfer of heat from the waste heat storage unit to that part, heating the mold through the heating device. When the overall mold temperature is too high, the cooling device controls the use of the low-temperature coolant in the circulation pipeline to cool the mold, while recovering excess heat to the waste heat storage unit.

[0026] The circulation piping layout: The circulation piping connects the heat exchange module, waste heat storage unit, and various temperature control areas of the mold, forming a complete circulation system. The piping is wrapped with thermal insulation to reduce heat loss during transmission.

[0027] Furthermore, after the heat exchange module captures the mold's residual heat, the heat-carrying cooling medium flows through a circulation pipeline into a residual heat storage unit for heat storage or directly transported to the mold's heated area. During mold temperature control, the cooling medium circulates through the circulation pipeline according to the instructions of the intelligent temperature control module, achieving heat transfer and mold temperature regulation. Simultaneously, the pumps and valves in the circulation pipeline are controlled by the intelligent temperature control module to ensure that the cooling medium flows along the specified path and flow rate.

[0028] A mold energy-saving temperature control method for waste heat recovery is applicable to the above-mentioned mold energy-saving temperature control system for waste heat recovery, comprising the following steps:

[0029] S1. Real-time temperature collection of mold, heat storage unit, and pipeline through the temperature sensor network;

[0030] S2. Fuzzy PID controller calculates the optimal heat energy distribution plan;

[0031] S3.PLC controls the regulating valve and pump to distribute the waste heat proportionally to: mold preheating circuit (60-80% waste heat); workshop auxiliary heating circuit (20-40% waste heat).

[0032] Furthermore, in step S2, a machine learning model based on historical production data is used to predict the temperature control curve, and the training features include: thermal conductivity of mold material; product molding cycle time; and ambient temperature and humidity parameters.

[0033] Compared with the prior art, the present invention has the following beneficial effects:

[0034] The present invention discloses a mold energy-saving temperature control system integrating efficient heat exchange, high-density heat storage and intelligent control, which is of great significance for promoting the green transformation of the manufacturing industry and reducing production costs.

[0035] The present invention solves the problem of high efficiency and energy saving: the efficient design of the heat exchange module can quickly capture the waste heat of the mold, the high energy storage density design of the waste heat storage unit and the reasonable distribution of waste heat by the intelligent temperature control module greatly improve the energy utilization efficiency, reduce the consumption of external energy, and reduce production costs.

[0036] This invention solves the problem of precise temperature control: the intelligent temperature control module is based on the fuzzy PID control algorithm and a high-precision temperature sensor network, which can monitor and regulate the temperature of various parts of the mold in real time and accurately, effectively improving product quality and reducing product defects caused by temperature fluctuations.

[0037] The present invention solves the problem of extending the life of the mold: the stable temperature environment reduces the thermal stress of the mold caused by temperature changes, thereby extending the service life of the mold and reducing the cost of mold replacement and maintenance.

[0038] The present invention solves the problem of strong adaptability: the system of the present invention is applicable to various types of molds and can be flexibly adjusted and optimized according to the working characteristics and temperature requirements of different molds. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 Schematic diagram of the mold energy-saving temperature control system for waste heat recovery of the present invention.

[0040] In the picture:

[0041] 100. Heat exchange module; 110. Parallel heat pipe array; 120. Microchannel heat exchanger; 200. Waste heat storage unit; 300. Intelligent temperature control module; 310. Temperature sensor network; 311. Mold cavity temperature measurement point; 312. Heat storage unit temperature measurement point; 313. Pipeline temperature measurement point; 320. Fuzzy PID controller; 330. PLC; 400. Circulation pipeline system; 410. Insulation main line; 420. Branch loop; 430. Quick switching valve group; 440. Variable frequency centrifugal pump. DETAILED DESCRIPTION

[0042] In order to more clearly illustrate the overall concept of the present invention, a detailed description is given below in an exemplary manner in conjunction with the accompanying drawings.

[0043] In the following description, many specific details are set forth to facilitate a full understanding of the present application. However, the present invention may also be implemented in other ways different from those described herein. Therefore, the scope of protection of the present invention is not limited to the specific embodiments disclosed below.

[0044] In the description of the present invention, it should be understood that the terms "center", "up", "down", "ascending", "descending", "top", "side", "bottom", "front", "back", "left", "right", "vertical", "horizontal", "top", "inside", "outside", "axial", "radial", "circumferential", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore cannot be understood as limiting the present invention.

[0045] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. Throughout the description of this application, "plurality" means two or more, unless otherwise specifically defined.

[0046] In the present invention, unless otherwise expressly specified or limited, terms such as "mounted," "connected," "connect," and "fixed" should be understood broadly. For example, they may refer to fixed connection, detachable connection, or integration; mechanical connection, electrical connection, or communication; direct connection or indirect connection through an intermediate medium; and internal communication between two components or interaction between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0047] In the present invention, unless otherwise clearly specified and limited, a first feature "above" or "below" a second feature may be that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in an appropriate manner in any one or more embodiments or examples.

[0048] Example: The present invention provides a mold energy-saving temperature control system with waste heat recovery, such as Figure 1 As shown, it comprises four parts: a heat exchange module 100, a waste heat storage unit 200, an intelligent temperature control module 300 and a circulation pipeline system 400.

[0049] Specifically, the heat exchange module 100 uses a copper alloy with high thermal conductivity as the base material for manufacturing the heat pipe array 110 and the microchannel heat exchanger 120. Its thermal conductivity is significantly improved compared to ordinary metal materials, and it can transfer heat quickly. For the working fluid in the heat pipe, according to the working temperature range of the mold, an organic working fluid with a boiling point in a suitable range is selected, such as acetone, to ensure that gas-liquid phase change heat transfer can be carried out efficiently at the residual heat temperature of the mold. For the flow channel design of the microchannel heat exchanger 120, computer-aided design (CAD) software is used for simulation analysis to optimize the flow channel shape and size. The flow channel width is set between 0.5 and 2 mm, and the height is between 1 and 3 mm. By increasing the tortuosity and surface area of ​​the flow channel, the heat transfer between the cooling medium and the heat pipe is fully exchanged.

[0050] Specifically, the heat pipe array is manufactured using precision machining techniques to ensure the heat pipe diameter is controlled within ±0.05 mm, ensuring stable flow and heat transfer of the working fluid within the pipe. Vacuum brazing is used in the welds of the heat pipes to improve weld strength and sealing, preventing fluid leakage.

[0051] Specifically, the microchannel heat exchanger 120 is manufactured using a micromachining technique that combines photolithography and chemical etching. A precise microchannel pattern is first drawn on a copper alloy plate using photolithography. Chemical etching then removes unwanted areas to form the microchannel structure. After fabrication, the microchannels undergo rigorous cleaning and degreasing to prevent impurities from affecting the flow of the cooling medium and heat transfer efficiency.

[0052] Specifically, during the mold cooling system design phase, the installation location for the heat exchange module 100 is reserved. Multiple sets of prefabricated parallel heat pipe arrays 110 are then arranged and installed according to the heat distribution on the mold surface, ensuring that the evaporation sections of the heat pipes fit closely to the mold surface. Thermal grease is used to fill the small gap between the two to enhance heat conduction.

[0053] Specifically, install the microchannel heat exchanger 120 so that its condensing section is connected to the condensing end of the heat pipe array. Connect the cooling medium inlet and outlet pipes. The cooling medium inlet pipe is connected to the low-temperature medium inlet of the mold cooling system, and the outlet pipe is connected to the waste heat storage unit 200 or the inlet of a subsequent temperature control link. This ensures that the entire heat exchange module 100 and the mold cooling system form a complete and efficient waste heat capture cycle.

[0054] Specifically, the phase change material (PCM) used in the waste heat storage unit 200 is selected and processed. Modified inorganic salt PCMs with a melting point between 150°C and 300°C are purchased from the market, such as a specially doped potassium nitrate-sodium nitrate eutectic. Purity testing is performed on the purchased PCM to ensure a purity of at least 99% to ensure the stability of its energy storage performance.

[0055] Specifically, the phase-change material is pre-treated, with its particles refined to an average size of 50-100 microns through ball milling and other methods. This increases the contact area between the phase-change material and the heat transfer medium, improving heat transfer efficiency during the phase change process. The pre-treated phase-change material is then encapsulated in a custom-made metal container made of stainless steel, which offers excellent high-temperature and corrosion resistance. The container wall is designed to be 2-3 mm thick, ensuring structural strength while minimizing heat transfer obstruction.

[0056] Specifically, a high-specific-heat-capacity ceramic material, such as alumina ceramic, is selected as the primary material for the sensible heat storage component. The amount and shape of the ceramic material are determined based on the space available within the waste heat storage unit 200 and the energy storage requirements. The ceramic material is processed into blocks or columns to facilitate optimal layout within the storage unit.

[0057] Specifically, a metal heat sink made of aluminum is embedded within the sensible heat storage material. This increases the surface area of ​​the heat sink, enhancing the heat exchange between the sensible heat storage material, the phase change material, and the external heat transfer medium. A high-temperature adhesive bonds the heat sink to the ceramic material, ensuring a stable and reliable thermal connection even in high-temperature environments.

[0058] Specifically, the waste heat storage unit 200's housing features a double-layer structure: an inner layer of high-temperature-resistant stainless steel and an outer layer of fiberglass-reinforced plastic (GFRP) with excellent thermal insulation. The space between the two layers is filled with insulation material, such as rock wool, with a thickness of 5 to 10 centimeters to effectively reduce heat loss.

[0059] Specifically, the metal container encapsulating the phase change material and the processed sensible heat storage material are placed inside the storage unit in a specific arrangement. A heat exchange coil is installed inside the storage unit. The heat exchange coil is made of copper tubes with a diameter of 10 to 20 mm. The shape and layout of the coil are optimized to increase the contact area with the phase change material and the sensible heat storage material, improving the efficiency of heat storage and release. The inlet and outlet of the heat exchange coil are respectively connected to the cooling medium outlet of the heat exchange module 100 and the circulation pipeline system 400 controlled by the intelligent temperature control module 300, realizing heat storage and output.

[0060] Specifically, the intelligent temperature control module 300 uses high-precision thermocouple temperature sensors, which offer a measurement accuracy of ±0.5°C and meet the requirements for precise temperature monitoring of all mold components. The number and placement of temperature sensors are determined based on the mold structure and the distribution of key temperature monitoring points. Temperature sensors are typically evenly distributed across the mold core, cavity, and gate to ensure comprehensive and accurate monitoring of temperature changes across all mold components.

[0061] In detail, when installing the temperature sensor, first drill a suitable mounting hole on the mold. The diameter of the mounting hole is slightly larger than the probe diameter of the temperature sensor. Then insert the probe of the temperature sensor into the mounting hole and use high-temperature sealant to fix and seal it to prevent the high-temperature medium inside the mold from leaking and affecting the measurement accuracy of the sensor. At the same time, ensure good thermal contact between the sensor and the mold.

[0062] Specifically, the intelligent temperature control module 300 includes a temperature sensor network 310, a fuzzy PID controller 320, and a PLC 330 for dynamically adjusting waste heat distribution. The temperature sensor network 310 includes:

[0063] Four mold cavity temperature measuring points 311 are arranged 2 to 5 mm away from the mold cavity surface;

[0064] Two heat storage unit temperature measurement points 312 are embedded in the PCM layer and the sensible heat medium layer respectively;

[0065] Two pipeline temperature measurement points 313 are located at the inlet and outlet of the heat exchange module;

[0066] The fuzzy PID controller 320 outputs the variable regulating valve opening u(t) through the input variable temperature deviation e(t) and its change rate ec(t). The fuzzy rule base contains 25 IF-THEN rules, and the membership function adopts Gaussian distribution.

[0067] As can be seen from the above, the intelligent temperature control module 300 monitors the temperature of the mold, heat storage unit and pipeline in real time through the temperature sensor network 310 it contains (including 4 mold cavity temperature measurement points 311 arranged 2 to 5 mm from the mold cavity surface, 2 heat storage unit temperature measurement points 312 embedded in the PCM layer and the sensible heat medium layer respectively, and 2 pipeline temperature measurement points 313 located at the inlet and outlet of the heat exchange module), and transmits the data to the fuzzy PID controller 320 and PLC330. The latter dynamically adjusts the waste heat distribution based on the fuzzy PID control algorithm to ensure that the mold temperature is accurate and stable, which not only improves energy utilization efficiency, but also ensures product quality and extends the service life of the mold.

[0068] Specifically, a PLC330 with stable performance and fast computing speed was selected as the core control unit of the intelligent temperature control module 300. The PLC330 was programmed using programming languages ​​such as ladder diagrams or structured text based on the system's control requirements. During the programming process, a fuzzy PID control algorithm was implemented to process temperature data collected by the temperature sensor in real time, calculate the deviation between the current mold temperature and the set temperature, and the rate of change of the deviation. A dynamic weight factor α(t) was also defined, whose value was adjusted based on the temperature deviation e(t) and the rate of change of the deviation ec(t). The formula is as follows:

[0069] a(t)=f(e(t),ec(t)); where f is a function designed based on actual needs, used to increase the control response speed when the temperature deviation is large and to reduce the control fluctuation when the temperature is close to the set value.

[0070] Based on fuzzy inference rules, the proportional (P), integral (I), and differential (D) parameters of the PID controller are adjusted online. For example, when the temperature deviation is large and the rate of change is high, the P parameter is increased to speed up the control output response. When the temperature approaches the set point, the P parameter is decreased while the I parameter is appropriately increased to eliminate the system's steady-state error and prevent temperature overshoot. By continuously debugging and optimizing the PLC330 program, the intelligent temperature control module 300 can accurately and stably control the mold temperature.

[0071] Specifically, the control logic for the intelligent distribution of waste heat is programmed in the PLC330 program in the waste heat intelligent distribution control. Based on the temperature information of each part of the mold fed back by the temperature sensor and the heat storage status of the waste heat storage unit 200, the PLC330 controls the operating status of the electric valve and water pump in the circulation pipeline system 400. When the temperature of a certain part of the mold is lower than the set value, the PLC330 controls the electric valve to open, and the high-temperature medium in the waste heat storage unit 200 is transported to that part through the circulation pipeline, and the mold is heated by the heating device; when the overall temperature of the mold is too high, the PLC330 controls the water pump to increase the flow of the cooling medium, and at the same time, the excess heat is recovered to the waste heat storage unit 200 through the circulation pipeline. Through this intelligent distribution method, efficient utilization of waste heat and precise control of mold temperature are achieved.

[0072] Specifically, the circulation piping material selection and design are as follows: the main body of the circulation piping is manufactured from seamless steel pipe. The wall thickness of the steel pipe is selected based on the system operating pressure and temperature, generally between 3 and 5 mm, to ensure the strength and sealing of the pipe. For the pipes connecting to high-temperature components such as the heat exchange module 100 and the waste heat storage unit 200, high-temperature resistant alloy steel pipes, such as 316L stainless steel pipes, are used to improve the corrosion resistance and reliability of the pipes in high-temperature environments.

[0073] Specifically, the pipe diameter is designed and calculated based on the cooling medium's flow rate and velocity. The cooling medium's flow rate in the pipe is controlled between 1 and 3 m / s to ensure good heat transfer and minimal flow resistance. Based on the calculations, the main pipe diameter is determined to be between 50 and 100 mm, and the branch pipe diameter is adjusted accordingly based on the specific flow requirements.

[0074] Specifically, the connections between pipes are made using a combination of welding and flange connections. For locations that require frequent disassembly and maintenance, such as the interfaces with the heat exchange module 100 and the waste heat storage unit 200, flange connections are used to facilitate installation and maintenance. For other pipe connections, argon arc welding is used to ensure weld quality and tightness.

[0075] Specifically, after the pipeline is installed, the entire circulation pipeline is insulated. The insulation material is a 3-5 cm thick aluminum silicate fiber mat, which is heat-resistant and has excellent thermal insulation properties. The aluminum silicate fiber mat is tightly wrapped around the pipeline surface and then protected with galvanized iron sheets or fiberglass cloth to prevent damage to the insulation material and reduce heat loss during transmission.

[0076] Specifically, during the installation and commissioning of the circulating pump and valves, select a circulating pump of appropriate power based on the designed flow and head requirements of the circulating pipeline. The circulating pump is installed at the inlet of the circulating pipeline to ensure that it can provide sufficient power for the cooling medium to circulate throughout the system. Pressure gauges and check valves are installed at the inlet and outlet of the circulating pump to monitor the pump's operating status and prevent backflow of the medium.

[0077] Specifically, electric control valves and shut-off valves are installed in the circulation pipeline. These control valves are controlled by the PLC 330 in the intelligent temperature control module 300, automatically adjusting the flow of the cooling medium in the pipeline based on mold temperature and residual heat distribution requirements. Shut-off valves are installed where the pipeline needs to be shut off to facilitate system maintenance and overhaul. After installation, the circulation pump and valves are debugged to ensure they are functioning properly and meet the system's control requirements.

[0078] In detail, the circulation piping system 400 includes an insulated main circuit 410 and a branch circuit 420 to achieve directional transmission of heat energy within the system;

[0079] The circulation piping system 400 includes:

[0080] The quick-switching valve group 430 can switch between the mold preheating mode and the auxiliary heating mode;

[0081] Anti-corrosion and heat-insulated pipelines with anodized aluminum protective layer on the inner wall;

[0082] Frequency conversion centrifugal pump 440, flow adjustment range 0.5~5m 3 / h.

[0083] As can be seen from the above, the circulation piping system 400 realizes the directional transmission of heat energy within the system through the insulation main line 410 and the branch circuit 420. The quick switching valve group 430 contained therein can flexibly switch between the mold preheating mode and the auxiliary heating mode. The corrosion-resistant insulation pipeline (with an anodized aluminum protective layer on the inner wall) effectively reduces heat loss and extends the service life of the pipeline. The variable frequency centrifugal pump 440 is used to heat the mold through the 0.5-5m 3 / h flow adjustment range, precisely controlling the heat energy transfer efficiency. This design not only improves the flexibility and efficiency of heat energy utilization, but also significantly enhances the durability and stability of the system.

[0084] Working principle: The high-temperature waste heat generated by the mold is captured by the heat exchange module 100 (including a parallel heat pipe array 110 and a microchannel heat exchanger 120) integrated in the mold cooling system. The waste heat is transmitted through a circulation pipeline to the waste heat storage unit 200, which adopts a composite structure of phase change material and sensible heat storage medium, for storage. The intelligent temperature control module 300 (including a temperature sensor network 310, a fuzzy PID controller 320 and a PLC 330) monitors the temperature of the mold, the heat storage unit and the pipeline in real time, dynamically adjusts the waste heat distribution, and distributes the waste heat to the mold preheating circuit or the workshop auxiliary heating circuit as needed, thereby realizing precise and intelligent control of the mold temperature and efficient recovery and utilization of waste heat.

[0085] To sum up: The present invention quickly captures the waste heat of the mold through the high-efficiency heat exchange module 100, and combines the high-density heat storage unit and the intelligent temperature control module 300 to achieve efficient recovery and precise distribution of waste heat. It not only significantly improves energy utilization efficiency and reduces production costs, but also improves product quality through precise temperature control, reduces the thermal stress of the mold caused by temperature fluctuations, thereby extending the service life of the mold. At the same time, the system has strong adaptability and can be flexibly applied to a variety of mold scenarios.

[0086] Through the above specific implementation methods, a mold energy-saving temperature control system for waste heat recovery can be successfully constructed, realizing efficient recovery and utilization of mold waste heat and precise intelligent control of mold temperature, achieving the invention purpose of energy saving, improving product quality and extending mold life.

[0087] The various embodiments in this specification are described in a progressive manner. Similar parts between the various embodiments can be referred to in conjunction with each other. Each embodiment focuses on the differences between the other embodiments. In particular, the system embodiments are generally similar to the method embodiments, so the description is relatively simple. For relevant parts, refer to the description of the method embodiments.

[0088] The foregoing is merely an embodiment of the present invention and is not intended to limit the present invention. It will be apparent to those skilled in the art that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention are intended to be included within the scope of the claims of the present invention.

[0089] The embodiments of the present invention are provided for the purpose of illustration and description. Although the embodiments of the present invention have been shown and described above, it can be understood that the above embodiments are exemplary and cannot be understood as limitations on the present invention. Any changes, modifications, replacements and variations of the above embodiments by ordinary technicians in this field within the scope of the present invention should be included in the scope of protection of the present invention.

Claims

1. A mold energy-saving temperature control system with waste heat recovery, characterized in that: include: A heat exchange module (100), integrated into the mold cooling system, comprises a parallel heat pipe array (110) and a microchannel heat exchanger (120), and is used to capture high-temperature waste heat generated by the operation of the mold; The waste heat storage unit (200) is connected to the heat exchange module (100) via a pipeline and adopts a composite energy storage structure of phase change material and sensible heat storage medium; An intelligent temperature control module (300), comprising a temperature sensor network (310), a fuzzy PID controller (320) and a PLC (330), for dynamically adjusting waste heat distribution; The circulation pipeline system (400) includes a heat-insulating main pipeline (410) and a branch loop (420), which realizes the directional transmission of heat energy within the system.

2. The mold energy-saving temperature control system with waste heat recovery according to claim 1, characterized in that: The parallel heat pipe array (110) is composed of 6-12 groups of copper-based graphene-coated heat pipes, with a heat pipe diameter of Φ6-10 mm, and is radially arranged in the high-temperature zone of the mold at equal intervals of 15-20 mm.

3. The mold energy-saving temperature control system with waste heat recovery according to claim 1, characterized in that: The microchannel heat exchanger (120) has an S-shaped circuitous flow channel with a flow channel width of 0.5 to 1.2 mm and a depth of 1.0 to 1.5 mm, and a nano-porous enhanced heat transfer structure is provided on the flow channel wall.

4. The mold energy-saving temperature control system with waste heat recovery according to claim 1, characterized in that: The phase change material is a modified inorganic salt mixture with a melting point of 150-300° C. The composition thereof comprises, by mass fraction, 40-55% sodium nitrate, 30-45% potassium nitrate, 5-10% nano-aluminum oxide, and 2-5% carbon fiber reinforcement.

5. The mold energy-saving temperature control system with waste heat recovery according to claim 1, characterized in that: The sensible heat storage medium is a honeycomb ceramic matrix with a porosity of 60-70% and a pore size distribution of 0.5-2 mm, and is impregnated with a molten salt high-temperature heat transfer fluid.

6. The mold energy-saving temperature control system with waste heat recovery according to claim 1, characterized in that: The temperature sensor network (310) comprises: Four mold cavity temperature measuring points (311) are arranged 2 to 5 mm away from the mold cavity surface; Two heat storage unit temperature measurement points (312), respectively embedded in the PCM layer and the sensible heat medium layer; Two pipeline temperature measuring points (313) are located at the inlet and outlet of the heat exchange module (100).

7. The mold energy-saving temperature control system with waste heat recovery according to claim 1, characterized in that: The fuzzy PID controller (320) outputs a variable regulating valve opening u(t) through input variables temperature deviation e(t) and its change rate ec(t); the fuzzy rule base includes 25 IF-THEN rules, and the membership function adopts Gaussian distribution.

8. The mold energy-saving temperature control system with waste heat recovery according to claim 1, characterized in that: The circulation piping system (400) comprises: A fast switching valve group (430) can switch between a mold preheating mode and an auxiliary heating mode; Anti-corrosion and heat-insulated pipelines with anodized aluminum protective layer on the inner wall; Frequency conversion centrifugal pump (440), flow adjustment range 0.5~5m 3 / h.

9. A mold energy-saving temperature control method with waste heat recovery, characterized by: A mold energy-saving temperature control system for waste heat recovery according to any one of claims 1 to 8, comprising the following steps: S1. Real-time acquisition of mold, heat storage unit and pipeline temperature through the temperature sensor network (310); S2. The fuzzy PID controller (320) calculates the optimal heat energy distribution scheme; S3.PLC (330) controls the regulating valve and pump to distribute the waste heat proportionally to: mold preheating circuit; workshop auxiliary heating circuit.

10. The mold energy-saving temperature control method for waste heat recovery according to claim 9, characterized in that: In step S2, a machine learning model based on historical production data is used to predict the temperature control curve. The training features include: thermal conductivity of mold material; product molding cycle time; and ambient temperature and humidity parameters.

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