Casting management system and casting method

Abstract

The invention relates to a casting management system and a casting method.The casting management system comprises a product information management module used for recording product basic information and customer requirements and sending the product basic information and the customer requirements to a quality engineer node; the early-stage quality planning module is used for recording quality planning data obtained by a quality engineer according to product basic information and customer requirements and sending the quality planning data to the technical engineer node; the early process planning module is used for recording process planning data formulated by a technical engineer according to the quality planning data; and the process design module is used for recording a process design scheme formulated by the technical engineer according to the process planning data and sending the scheme to the corresponding execution node. According to the method and the system, the process control nodes are increased, and detailed strategy making and parameter analysis are performed, so that online data can more effectively guide the work of a production field, the dependence on paper files is reduced, the information transmission accuracy is improved, and the process design level and the production efficiency of the whole casting system are improved.

Description

Technical Field

[0001] The present application relates to the field of intelligent casting technology, and in particular to a casting management system and a casting method. Background Art

[0002] Digital and intelligent manufacturing has become an important direction for the transformation and upgrading of the manufacturing industry. In the casting industry, especially in the production of steel castings, process design is the key link between product design and actual manufacturing. Its scientificity, standardization and feasibility directly affect product quality and production efficiency.

[0003] However, the online process design process for casting systems currently on the market generally has many problems, making it difficult to meet the needs of modern manufacturing for efficiency, precision, and knowledge management. The existing online process design process is relatively simple, lacking clear design logic and standardized operating procedures, resulting in an unclear sequence of process design, which can easily lead to design omissions or duplication of work, and inability to effectively monitor key process links, affecting the controllability and consistency of the entire process. In addition, the online process parameter design is relatively simple, with insufficient parameter coverage, making it difficult to fully guide on-site production practices. In actual operations, there is still a high degree of reliance on paper documents and experience-based judgments, and a failure to effectively transform process knowledge into digital assets, which limits the accumulation, inheritance, and reuse of process knowledge.

[0004] Therefore, there is an urgent need for a casting management solution that can systematically and standardizedly integrate process design processes, improve parameter integrity, strengthen process control, and realize digital management of the entire process. Summary of the Invention

[0005] This application overcomes the problems in the existing technology such as relatively simple process, unclear process design sequence, few process control nodes, and insufficient guidance of process parameters, and provides a casting management system through which the standardization and digitization of the design process of the casting process line is realized.

[0006] A casting management system, comprising:

[0007] Product information management module, used to record basic product information and customer requirements and send them to the quality engineer node;

[0008] The early quality planning module is used to record the quality planning data obtained by the quality engineer based on the basic product information and customer requirements, and send it to the technical engineer node;

[0009] The early process planning module is used to record the process planning data formulated by technical engineers based on the quality planning data;

[0010] The process design module is used to record the process design plan formulated by the technical engineer based on the process planning data and send the plan to the corresponding execution node.

[0011] Preferably, the early process planning module includes:

[0012] A casting planning unit, used to record the casting strategy formulated by the casting engineer based on the quality planning data;

[0013] Heat treatment planning unit, used to record the structural difficulties and special requirements determined by the heat treatment engineer based on the quality planning data;

[0014] A welding planning unit, used to record the final welding parameters obtained by the welding engineer based on the quality planning data;

[0015] Digital model management unit, used to input digital model data of products.

[0016] Preferably, the welding planning unit includes:

[0017] An equivalent calculation subunit, configured to calculate the welding equivalent value of the material according to the composition requirements in the quality planning data;

[0018] The welding analysis subunit is used to provide welding temperature recommendations and material weldability analysis results for welding material selection based on the welding equivalent value, and send the results to the welding engineer node; the welding engineer sets welding parameters based on the material weldability analysis results, and the welding analysis subunit generates a Schaeffler phase diagram.

[0019] Preferably, the process design module includes: a process design subunit, which is used to record the process design plan formulated by the technical engineer according to the process planning data, and send the plan to the corresponding execution node; wherein the nodes include casting process node, simulation node, sand box tooling node, chemical composition node, smelting process node, boxing process node, cutting process node, heat treatment process node, welding process node, coating process node, packaging process node, NDT node, MPP node and material BOM node;

[0020] The task execution management unit is used to monitor the task execution status of each process node;

[0021] Quality monitoring unit, used to monitor key quality control points in the production process;

[0022] The feedback optimization unit is used to collect data feedback from the actual production process, and compare and analyze it with the reference process planning data to obtain a process optimization plan.

[0023] Preferably, the casting management system further comprises: an operation instruction module, configured to output corresponding operation instruction data to each node, wherein the operation instruction data comprises an operation instruction book.

[0024] Preferably, the casting management system further comprises: a knowledge base module for storing product information, quality planning data, process planning data and operation instruction records in each project.

[0025] A second aspect of the present application further provides a casting method, comprising:

[0026] The marketing department records basic product information and customer requirements in the product information management module and sends them to the quality engineer node;

[0027] The quality engineer records the quality planning data formulated according to the basic product information and customer requirements in the preliminary quality planning module and sends it to the technical engineer;

[0028] The technical engineer records the process planning data formulated according to the quality planning data in the preliminary process planning module;

[0029] The technical engineer records the process design plan formulated according to the process planning data in the process design module and sends it to the corresponding node for execution.

[0030] Preferably, the technical engineer records the process planning data obtained based on the quality planning data in the preliminary process planning module, including:

[0031] The casting engineer records the casting strategy developed based on the quality planning data in the preliminary process planning module;

[0032] The heat treatment engineer records the structural difficulties and special requirements determined based on the quality planning data in the preliminary process planning module;

[0033] The welding engineer records the final welding parameters developed based on the quality planning data in the advance process planning module.

[0034] Preferably, the welding engineer records the final welding parameters obtained according to the quality planning data in the preliminary process planning module, including:

[0035] The welding engineer sets the final welding parameters in the welding planning unit according to the welding equivalent value calculated by the equivalent calculation subunit and the material weldability analysis result calculated by the welding analysis subunit.

[0036] Preferably, the casting method further comprises:

[0037] On-site operators obtain the operation guidance data of the corresponding node through the operation guidance module.

[0038] This application adds more process control nodes on the original basis and conducts detailed strategy formulation and parameter analysis, so that online data can more effectively guide the work on the production site. This reduces the dependence on paper documents and improves the accuracy of information transmission. At the same time, it also promotes the transformation of empirical knowledge into digitalization and standardization, and improves the process design level and production efficiency of the entire casting system. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 1 is a structural diagram of a casting management system 100 provided in an embodiment of the present application;

[0040] Figure 2 103 is a schematic diagram of the structure of the early process planning module 103 provided in an embodiment of the present application;

[0041] Figure 3 104 is a schematic diagram of the structure of the process design module 104 provided in an embodiment of the present application;

[0042] Figure 4 This is an example diagram of a heat treatment curve provided in an embodiment of the present application;

[0043] Figure 5 This is an example diagram of an NDT node provided in an embodiment of the present application;

[0044] Figure 6 Schematic diagram of the casting method provided in the embodiment of the present application;

[0045] Figure 7 This is a flow chart for the online design of steel casting process provided in an embodiment of the present application. DETAILED DESCRIPTION

[0046] In order to more clearly illustrate the technical solution of the present application, the present application is further described in detail below in conjunction with specific embodiments. Please note that the embodiments described below are exemplary and are only used to explain the present application, and should not be understood as limiting the present application.

[0047] The technical solution provided in this application is particularly suitable for casting systems and their online process design in the steel casting industry, realizing the online design process specification of steel casting processes, achieving a complete online system platform for process design, and realizing efficient and accurate production management.

[0048] Please refer to Figure 1 , Figure 1This is a structural diagram of a casting management system 100 provided in an embodiment of the present application. The casting management system includes a product information management module 101, an advanced quality planning module 102, an advanced process planning module 103, a process design module 104, an operation guidance module 105 and a knowledge base module 106.

[0049] The product information management module 101 is used to record basic product information and customer requirements and send them to the quality engineer node.

[0050] The product information management module 101 is primarily for the marketing department. After signing a contract with a customer and understanding their needs, the marketing department will enter the basic product information and requirements obtained from the customer. This information may include product code, product name, product model, product drawing number, product material, material brand, delivery status, drawing weight, industry classification, etc. In addition, an attachment option can be set in the product information management module to upload relevant attachments provided by the customer, such as drawings, sales contracts, technical agreements, etc., to ensure that all relevant information can be easily accessed and used in subsequent processes.

[0051] After the information is entered, the product information management module can automatically distribute the above information, attachments, etc. to the target nodes of the quality department, technical department and other departments, such as the quality engineer node. It can also be uploaded by marketing department personnel and actively clicked in the module for distribution and push.

[0052] The early quality planning module 102 is used to record the quality planning data obtained by the quality engineer based on the basic product information and customer requirements, and send it to the technical engineer node.

[0053] Quality engineers interpret the contents of documents such as technical agreements provided by customers. They can digitally record customer requirements for composition, performance, non-destructiveness, dimensions, metallographic structure, and heat treatment into the system using templates provided within the system and modules. After quality engineers enter product quality planning data into the system, the task is passed to the technical engineer node. Subsequent process node designs can reference this quality planning data, reducing the need for technical engineers to reinterpret documents, ensuring the accuracy of input parameters, and improving process design efficiency.

[0054] The preliminary process planning module 103 is used to record the process planning data developed by the technical engineer based on the quality planning data. The technical engineer performs preliminary process planning, and the nodes include casting planning nodes, heat treatment planning nodes, welding planning nodes, digital model management nodes, etc.

[0055] Furthermore, different nodes can be handled by engineers who handle the corresponding tasks, e.g. Figure 2As shown in the structural diagram of the advance process planning module 103, the tasks at different nodes of the advance process planning module 103 can be set as a casting planning unit 1031, a heat treatment planning unit 1032, a welding planning unit 1033 and a digital model management unit 1034.

[0056] The casting planning unit 1031 is used to record the casting strategy formulated by the casting engineer based on the quality planning data. After downloading the attachment provided by the customer, the casting engineer enters the product's structural difficulties, dimensional tolerances, dimensional measurement strategies, line formation strategies, shrinkage and compensation process strategies, pouring strategies and key issues into the system, and formulates a casting process strategy, including but not limited to determining the design of the pouring system, the selection of sand molds, the mold cooling method, etc., and using simulation tools to simulate the molding process of the casting, predict possible problems (such as shrinkage holes, cracks, etc.), and propose corresponding solutions. Specific casting parameters such as temperature, pressure, time, etc. can also be set based on product characteristics and customer requirements to ensure that the final product quality meets the standards.

[0057] The heat treatment planning unit 1032 is used to record the structural difficulties and special requirements determined by the heat treatment engineer based on the quality planning data. Based on the quality planning data, the heat treatment engineer identifies the structural difficulties (such as complex shapes, uneven thickness, etc.) and special requirements (such as hardness, strength, toughness, etc.) that the casting may encounter during the heat treatment process, and formulates a detailed heat treatment process plan, including heating curves, holding time, cooling methods, etc., to ensure that the casting meets the required performance indicators. It is also possible to introduce the component requirements and performance requirements of the prior quality planning, analyze the requirements, conduct industry comparisons, determine whether there are special requirements, etc., select appropriate heat treatment equipment according to the process requirements, and make necessary configuration adjustments to meet specific process requirements.

[0058] The welding planning unit 1033 is used to record the final welding parameters obtained by the welding engineer based on the quality planning data. The welding engineer introduces the composition requirements of the preliminary quality planning. The system automatically calculates the equivalent weight and material weldability analysis using preset formulas. The welding engineer sets the welding temperature and selects the welding material based on the results of the automatic calculation of the material weldability analysis. The Schaeffler diagram is automatically generated. The Schaeffler diagram uses the chemical composition of the base metal and the added welding material, combined with the molten weld dilution rate, to estimate the chemical composition of the weld metal and further determine the microstructure of the weld metal.

[0059] Furthermore, the welding planning unit 1033 may also include: an equivalent calculation subunit and a welding analysis subunit, which are preset with corresponding calculation formulas. For example, the equivalent calculation formula is:

[0060] Carbon equivalent = C + Mn / 6 + (Cr + Mo + V) / 5 + (Ni + Cu) / 15;

[0061] Chromium equivalent = Cr + Mo + 1.5*Si + 0.5*Nb;

[0062] Nickel equivalent = Ni + 30*C + 30*N + 0.5*Mn.

[0063] The equivalent calculation subunit is used to calculate the material's welding equivalent value based on the composition requirements in the quality planning data. The equivalent calculation subunit also compares the calculated equivalent value with the customer's equivalent value entered into the system. If the calculated equivalent value is not within the customer's range, the system will prompt a heat treatment engineer to adjust the chemical composition until the calculated equivalent value is within the customer's range.

[0064] The welding analysis subunit is used to perform material weldability analysis based on the welding equivalent value, etc.:

[0065] Crack sensitivity coefficient = C + Si / 30 + (Mn + Cu + Cr) / 20 + Ni / 60 + Mo / 15 + V / 10 + 5B;

[0066] Reheat crack sensitivity empirical formula = Cr + Cu + 2Mo + 5Ti + 7Nb + 10V-2;

[0067] Hot crack sensitivity index = [C(S+P+Si / 25+Ni / 100)] / (3Mn+Cr+Mo+V)*1000;

[0068] In the above-mentioned equivalent calculation formula and material weldability analysis formula, C refers to carbon, Cr refers to chromium, Cu refers to copper, Mo refers to molybdenum, Nb refers to carbon niobium, Ti refers to titanium, V refers to vanadium, Mn refers to manganese, and Si refers to silicon.

[0069] The welding analysis subunit provides welding temperature recommendations and material weldability analysis results for welding material selection, and sends them to the welding engineer node. The welding engineer then sets welding parameters based on these results. Furthermore, the welding analysis subunit provides visualization support, automatically generating visualization tools such as Schaeffler phase diagrams, helping welding engineers more intuitively understand material properties and improving scientific decision-making. Finally, detailed welding procedure documentation can be automatically generated for on-site operators to reference and implement, ensuring standardized and controllable welding processes.

[0070] The digital model management unit 1034 is used to input digital model data for products. Casting engineers upload simulated product drawings, enter modeling weights, and upload modeling information, such as digital model files, modeling records, and digital model marking files. This ensures that all relevant nodes can easily access and use this data. It also records historical information for each modification, ensuring that the latest and most accurate data is always used. The digital model management unit provides accurate basic data for subsequent process design, improving design accuracy and feasibility.

[0071] After the above module node design is completed and approved, the process design can be started. The process design module 104 is used to record the process design plan formulated by the technical engineer based on the process planning data and send the plan to the corresponding execution node. Figure 3 The process design module 104 is a schematic structural diagram shown in FIG. 1 . The process design module 104 may include a process design subunit 1041 , a task execution management unit 1042 , a quality monitoring unit 1043 , and a feedback optimization unit 1044 :

[0072] The process design subunit 1041 is used to record the process design plan developed by the technical engineer based on the process planning data (such as casting strategy, heat treatment parameters, welding parameters, etc.) and send it to the corresponding node for execution. Covering multiple key nodes: The process design plan covers various process nodes from casting to final packaging, including but not limited to:

[0073] Casting process node: determine the design of the pouring system, mold selection, etc.

[0074] Simulation node: Use computer simulation technology to predict the flow, cooling and other conditions during the casting process.

[0075] Sand box tooling node: prepare the required tooling fixtures.

[0076] Chemical composition node: Ensure that the raw materials meet the requirements.

[0077] Melting process node: controls the temperature, time and other parameters during the melting process.

[0078] Boxing process node: determine the best time and method for demolding castings.

[0079] Cutting process node: formulate a specific plan for casting cutting.

[0080] Heat treatment process node: set heating curve, holding time and cooling method.

[0081] Welding process node: formulate welding parameters and welding sequence.

[0082] Coating process node: Select appropriate coating and coating method.

[0083] Packaging process node: determine the packaging materials and packaging methods.

[0084] NDT node: Perform non-destructive testing to ensure product quality.

[0085] MPP node: perform mechanical performance testing.

[0086] Material BOM node: Manage the bill of materials and ensure the supply of all raw materials.

[0087] Among them, at specific processing nodes, corresponding curve graphs and reference graphs can also be automatically generated. For example, at the heat treatment process design node, after the engineer fills in the heat treatment temperature section temperature, heating / cooling rate, holding time, and temperature deviation, the system automatically generates a heat treatment curve graph based on the filled content, such as Figure 4 The heat treatment curve example shown is shown in the figure. The heat treatment temperature parameters are sent to the heat treatment furnace under the data acquisition platform. After confirmation by the on-site personnel, heat treatment is started according to the parameters. The heat treatment curve is synchronized with the on-site heat treatment section for heat treatment curve viewing.

[0088] For example Figure 5 The NDT node example diagram shown above is the NDT process node design flaw detection graphic standard. After uploading the product picture, the flaw detection position is marked. After the NDT process design is completed, the process is synchronized with the production site. The quality flaw detection personnel conduct flaw detection according to the flaw detection position given by the process, eliminating the transmission of paper documents and ensuring the long-term storage, timeliness and accuracy of data. Figure 5 The positions indicated by numbers 1, 2, and 3 are the target positions for flaw detection.

[0089] In the above-mentioned process design subunit 1041, by configuring detailed process nodes, the uncertainty and trial and error times in production are reduced, standardized operation guidelines are provided, the dependence on the operator's experience is reduced, and production efficiency is improved.

[0090] The task execution management unit 1042 is used to monitor the task execution status of each process node. It can track the task execution status of each node in real time and record the task status (e.g., completed, in progress, pending, etc.). Furthermore, tasks can be assigned to corresponding execution nodes based on the process design plan, and task schedules and priorities can be set. When a task is delayed or anomalies occur, an automatic warning is issued to notify relevant personnel so that timely measures can be taken. By monitoring task progress in real time, the task execution management unit 1042 ensures that each link is carried out as planned, improving overall controllability. During the monitoring process, problems in task execution can be promptly identified and resolved, reducing the risk of delays.

[0091] Quality Monitoring Unit 1043 is used to monitor key quality control points in the production process. It can set up multiple key quality control points throughout the production process, collect quality inspection data from each node, and conduct real-time analysis (such as raw material inspection, intermediate process inspection, and finished product inspection) to ensure that quality at every stage meets standards. When quality issues are detected, it can also automatically generate reports, notify relevant responsible personnel, and provide improvement suggestions. Through Quality Monitoring Unit 1043, a complete quality traceability system has been established, capable of tracking the production process of each product, facilitating subsequent quality problem investigation.

[0092] The feedback optimization unit 1044 is used to collect data feedback from the actual production process and compare and analyze it with the reference process planning data to obtain a process optimization plan. Various data from the actual production process (such as process parameters, quality inspection results, etc.) can be collected and compared with the reference process planning data for analysis, problems in the production process (such as unreasonable process parameters, equipment failure, etc.) can be identified, and the causes can be analyzed in depth; based on the analysis results, specific optimization suggestions (such as adjusting process parameters, replacing equipment, etc.) are generated and fed back to the relevant departments. Successful optimization plans can be stored in the knowledge base for subsequent project calls and reuse, forming a virtuous cycle. Through the feedback optimization unit 1044, the production process can be continuously optimized, which reduces unnecessary resource waste, improves product quality and production efficiency; knowledge accumulation and reuse can also speed up the start-up of new projects and promote technological innovation.

[0093] Furthermore, the casting management system 100 may also include an operation instruction module 105 for outputting corresponding operation instruction data to each node, wherein the operation instruction data includes an operation instruction. The operation instruction includes nodes such as casting instruction, smelting instruction, boxing instruction, cutting instruction, and heat treatment instruction. After uploading the operation instruction and the attachments in the process design, the corresponding operation instruction and attachments are displayed on the process by selecting the process and the on-site work report page. The operation instruction module 105 can automatically issue the operation instruction when the task reaches the specified node, or configure corresponding buttons on the human-machine display interface and human-machine interaction interface of each node so that engineers and on-site personnel can actively obtain it.

[0094] Furthermore, the casting management system 100 may also include a knowledge base module 106 for storing basic product information, customer requirements, quality planning data, process planning data, and work instruction records for each project. This facilitates the accumulation and sharing of process knowledge, breaking the traditional reliance on paper documents and experience.

[0095] Through such an automated task distribution mechanism, it can be ensured that all relevant departments can obtain the required information at the first time and quickly carry out the corresponding work, thereby improving the execution efficiency and accuracy of the entire project.

[0096] The technical solution provided in this embodiment adds more process control nodes to the existing system, providing more detailed planning for the task processing process. The new process not only considers basic process parameters but also incorporates in-depth design and analysis based on specific customer needs and industry standards. By digitizing and entering detailed product information, quality requirements, and process planning results into the system, online data can more effectively guide on-site production work. This reduces reliance on paper documents, improves the accuracy and efficiency of information transmission, and promotes the digital and standardized transformation of empirical knowledge.

[0097] Based on the same inventive concept, this application also provides a casting method, please refer to Figure 6 The schematic diagram of the casting method shown, and Figure 7 The steel casting process line design flow chart is shown. The casting method includes the following steps:

[0098] S601: The marketing department records basic product information and customer requirements in the product information management module and sends them to the quality engineer node.

[0099] like Figure 7 Lane 1 shown in: Product Entry. As the first line of direct contact with customers, the marketing department is responsible for collecting and recording basic product information and special customer requirements. This information includes but is not limited to product name, model, specification, material, delivery status, drawing weight, etc. In addition, it also includes customers' special requirements for product quality (such as hardness, strength, surface finish, etc.) and any other specific technical protocols or standards to ensure that all customer needs are recorded accurately and accurately, reducing misunderstandings and errors in subsequent links. Afterwards, the marketing department staff can upload it and actively click in the system (product information management module) to distribute and push it to the target nodes of the quality department, technical department and other departments; or it can be sent automatically by the system.

[0100] S602: The quality engineer records the quality planning data formulated according to the basic product information and customer requirements in the preliminary quality planning module and sends it to the technical engineer.

[0101] like Figure 7 Lane 2, shown in Figure 2: Advanced Quality Planning. Based on basic product information and customer requirements provided by the marketing department, quality engineers develop detailed advanced quality planning data. This includes determining quality control points, testing methods, and acceptance criteria.

[0102] The quality engineer interprets the contents of the documents such as the technical agreement provided by the customer, and enters the customer's composition requirements, performance requirements, lossless requirements, size requirements, metallographic requirements, heat treatment requirements, etc. according to the template provided by the system. After the quality engineer enters the product's quality requirement data into the system, the subsequent process node design will reference the preliminary quality planning data, reducing the need for technical department engineers to interpret the documents again, ensuring the accuracy of the input parameters, and improving process design efficiency. After the preliminary quality planning is completed and reviewed, it can begin as follows Figure 7 Shown in lane three.

[0103] S603: The technical engineer records the process planning data developed based on the quality planning data in the preliminary process planning module.

[0104] like Figure 7 Lane 3, shown in Figure 3: Advanced Process Planning. Technical engineers develop detailed process planning data based on the quality planning data provided by the quality engineer. This includes determining the specific parameters and technical requirements for each process step.

[0105] For example, technical engineers conduct preliminary process planning, and the nodes include casting planning, heat treatment planning, welding planning, and digital model management. At the casting planning node, after the casting engineer downloads the attachments provided by the customer and interprets them, he enters the product's structural difficulties, dimensional tolerances, dimensional measurement strategies, line formation strategies, shrinkage process strategies, pouring strategies, and key issues into the system, and then references them for subsequent casting process design. At the heat treatment planning node, the heat treatment engineer enters the structural difficulties, introduces the composition requirements and performance requirements of the preliminary quality planning, analyzes the requirements, compares the industry, and determines whether there are special requirements. The system designs an equivalent formula, and automatically calculates the equivalent by referencing the upper and lower limits of the composition. The calculated equivalent result is compared with the equivalent given by the customer entered into the system. If the calculated equivalent value is not within the customer range, the system will give a prompt, and the heat treatment engineer will need to adjust the chemical composition until the calculated equivalent value is within the range given by the customer. At the welding planning node, the welding engineer introduces the component requirements of the preliminary quality planning. The system automatically calculates the equivalent and material weldability analysis through preset formulas. The welding engineer sets the welding temperature and selects the welding material based on the results of the automatic calculation of the material weldability analysis, and automatically generates the Schaeffler phase diagram.

[0106] S604: The technical engineer records the process design plan developed according to the process planning data in the process design module and sends it to the corresponding node for execution.

[0107] like Figure 7Lane 4, shown in Figure 4, is Process Design. Based on the process design plan developed by technical engineers, corresponding nodes are executed. These nodes include, but are not limited to, casting process nodes, simulation nodes, sand box tooling nodes, chemical composition nodes, smelting process nodes, boxing process nodes, cutting process nodes, heat treatment process nodes, welding process nodes, coating process nodes, packaging process nodes, NDT nodes, MPP nodes, and material BOM nodes.

[0108] For example, in heat treatment process design, the system automatically generates a heat treatment curve based on the heat treatment temperature, heating / cooling rates, holding time, and temperature deviation. The heat treatment temperature parameters are then passed to the heat treatment furnace under the data acquisition platform. After confirmation by on-site personnel, heat treatment begins according to the parameters. The heat treatment curve is synchronized with the on-site heat treatment section for viewing.

[0109] NDT process nodes are designed according to the flaw detection graphic standard. After uploading the product pictures, the flaw detection positions are marked. After the NDT process design is completed, the process is synchronized with the production site. The quality flaw detection inspection personnel conduct flaw detection according to the flaw detection positions given by the process, and the transmission of paper documents is abolished to ensure the long-term storage, timeliness and accuracy of the data.

[0110] Furthermore, it also includes: on-site operators obtain the operation guidance data of the corresponding node through the operation guidance module. Figure 7 Lane 5 contains nodes such as casting instructions, smelting instructions, boxing instructions, cutting instructions, and heat treatment instructions. After uploading the operation instructions and attachments in the process design, select the process and the on-site work report page, and the corresponding operation instructions and attachments will be displayed for the process.

[0111] The above-mentioned embodiment provided in this application starts from the input of product information by the marketing department to the final formation of a detailed process design plan and guidance of the entire production process. Each step clearly defines the responsible role, realizes the online design process specification of steel casting process, and achieves the complete online system platform for process design. The process parameter coverage rate is high, which can effectively guide on-site production and eliminate the transmission of paper documents. The process design specification is highly versatile, and the process design process and data can be realized online according to the online process design ideas, reducing the exchange and transmission of offline data information, and promoting the transformation of corporate experience and knowledge into digitalization and standardization.

[0112] It should be noted that the casting method provided in this embodiment can refer to the introduction of the casting management system 100 and any optional embodiment thereof, and the casting method provided in this embodiment and the embodiments of the casting management system 100 can be referenced to each other, which will not be repeated in this embodiment.

[0113] Although the embodiments of the present application 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 application. Ordinary technicians in this field can change, modify, replace and modify the above embodiments within the scope of the present application. At the same time, for ordinary technicians in this field, according to the ideas of the present application, there will be changes in the specific implementation methods and application scopes.

Claims

1. A casting management system, characterized in that: include: Product information management module, used to record basic product information and customer requirements and send them to the quality engineer node; The early quality planning module is used to record the quality planning data obtained by the quality engineer based on the basic product information and customer requirements, and send it to the technical engineer node; The early process planning module is used to record the process planning data formulated by technical engineers based on the quality planning data; The process design module is used to record the process design plan formulated by the technical engineer based on the process planning data and send the plan to the corresponding execution node.

2. The casting management system according to claim 1, characterized in that: The advanced process planning module includes: The casting planning unit is used to record the casting strategy formulated by the casting engineer based on the quality planning data; the heat treatment planning unit is used to record the structural difficulties and special requirements determined by the heat treatment engineer based on the quality planning data; A welding planning unit, used to record the final welding parameters obtained by the welding engineer based on the quality planning data; Digital model management unit, used to input digital model data of products.

3. The casting management system according to claim 2, characterized in that: The welding planning unit further includes: An equivalent calculation subunit, configured to calculate the welding equivalent value of the material according to the composition requirements in the quality planning data; The welding analysis subunit is used to provide welding temperature recommendations and material weldability analysis results for welding material selection based on the welding equivalent value, and send the results to the welding engineer node; the welding engineer sets welding parameters based on the material weldability analysis results, and the welding analysis subunit generates a Schaeffler phase diagram.

4. The casting management system according to claim 1, characterized in that: The process design module includes: a process design subunit, which is used to record the process design plan formulated by the technical engineer based on the process planning data and send the plan to the corresponding execution node; the nodes include casting process node, simulation node, sand box tooling node, chemical composition node, smelting process node, boxing process node, cutting process node, heat treatment process node, welding process node, coating process node, packaging process node, NDT node, MPP node and material BOM node; The task execution management unit is used to monitor the task execution status of each process node; Quality monitoring unit, used to monitor key quality control points in the production process; The feedback optimization unit is used to collect data feedback from the actual production process, and compare and analyze it with the reference process planning data to obtain a process optimization plan.

5. The casting management system according to claim 1, characterized in that: Also includes: The operation guidance module is used to output corresponding operation guidance data to each node, wherein the operation guidance data includes an operation instruction book.

6. The casting management system according to claim 1, characterized in that: Also includes: The knowledge base module is used to store basic product information, customer requirements, quality planning data, process planning data and operation instruction records described in each project.

7. A casting method based on the casting management system according to any one of claims 1 to 6, characterized in that: include: The marketing department records basic product information and customer requirements in the product information management module and sends them to the quality engineer node; The quality engineer records the quality planning data formulated according to the basic product information and customer requirements in the preliminary quality planning module and sends it to the technical engineer; The technical engineer records the process planning data formulated according to the quality planning data in the preliminary process planning module; The technical engineer records the process design plan formulated according to the process planning data in the process design module and sends it to the corresponding node for execution.

8. The casting method according to claim 7, characterized in that The technical engineer records the process planning data obtained based on the quality planning data in the preliminary process planning module, including: The casting engineer records the casting strategy formulated based on the quality planning data in the preliminary process planning module; the heat treatment engineer records the structural difficulties and special requirements determined based on the quality planning data in the preliminary process planning module; The welding engineer records the final welding parameters developed based on the quality planning data in the advance process planning module.

9. The casting method according to claim 7, characterized in that: The welding engineer records the final welding parameters obtained based on the quality planning data in the preliminary process planning module, including: The welding engineer sets the final welding parameters in the welding planning unit according to the welding equivalent value calculated by the equivalent calculation subunit and the material weldability analysis result calculated by the welding analysis subunit.

10. The casting method according to claim 7, characterized in that: Also includes: On-site operators obtain the operation guidance data of the corresponding node through the operation guidance module.

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