A quality control system for engine head cover aluminum alloy die castings

Abstract

The application discloses an engine cylinder cover aluminum alloy die casting quality control system and relates to the technical field of intelligent control, which comprises a test module, an analysis module and a control module, final assignment is obtained through testing, a first parameter is set, simulation result is obtained through simulation, a second parameter is obtained through regulation and control, and a first mapping relationship is established. The application simulates the casting process, can accurately predict the possible defect position and type, regulates and controls the first parameter, improves the overall quality of the casting, can establish the first mapping relationship between the second parameter and the casting model according to different casting models, provides the most suitable process parameter combination for each casting model, effectively reduces the porosity problem of thick and large parts, virtually verifies the die casting process before production by using the simulation technology, greatly shortens the development cycle of new products, and improves the material utilization rate by accurately controlling various parameters in the casting process.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of intelligent control, and in particular to an engine cylinder cover aluminum alloy die casting quality control system. BACKGROUND

[0002] In recent years, performance optimization of die-cast aluminum alloy is the key to quality control. By adjusting alloy composition, such as adding appropriate amounts of Cu, Mg and other elements, the mechanical properties and process properties of the alloy are improved, the full-automatic die-casting machine adopts a computer management system to realize detection, storage, calculation and recording of the entire die-casting process, and the wide application of large die-casting machine automatic production lines improves production efficiency and casting quality.

[0003] At present, in the Chinese invention patent with the publication number CN118808597A, a die-casting machine control method and control system based on mold cavity monitoring are disclosed. The method obtains the real-time pressure value in the mold cavity during die-casting operation through the pressure sensor arranged at the tail of the ejector pin, compares the real-time pressure value with the corresponding reference pressure value according to the die-casting process, corrects the die-casting parameters based on the difference between the two, so that the two are within the preset error range during subsequent die-casting operation. The die-casting machine control method based on mold cavity monitoring can effectively improve the quality of die-casting products, but in the related technology, the quality of the casting is not comprehensively controlled according to the defect reasons corresponding to each defect, the comprehensiveness of the control is lacking, the corresponding control strategy is not obtained according to the simulation of various parameters, and the mapping relationship is not established, which is not conducive to the economy and rapidity of the control. SUMMARY

[0004] The technical problem solved by the application is that in the related technology, the quality of the casting is not comprehensively controlled according to the defect reasons corresponding to each defect, the comprehensiveness of the control is lacking, the corresponding control strategy is not obtained according to the simulation of various parameters, and the mapping relationship is not established, which is not conducive to the economy and rapidity of the control.

[0005] To solve the above technical problems, the application provides the following technical scheme: an engine cylinder cover aluminum alloy die casting quality control system, comprising a test module, an analysis module and a control module;

[0006] The test module tests the heat treatment furnace insulation performance according to the mold cavity division rule, and values the mold cavity space according to the test result to obtain the final value;

[0007] The analysis module sets a first parameter according to a predetermined casting model and the final value, simulates the casting process according to the first parameter, and obtains a simulation result;

[0008] The control module regulates the first parameter according to the simulation result, obtains the second parameter, and establishes a first mapping relationship between the second parameter and the casting model.

[0009] As a preferred scheme of the engine cylinder cover aluminum alloy die casting quality control system, the cavity division rule comprises:

[0010] 8 corner points and a geometric center point of the heat treatment furnace are acquired, any corner point is taken as a coordinate origin, edges intersecting with the corner point are taken as x, y and z axes, and a three-dimensional coordinate system is constructed;

[0011] The thermocouples are respectively placed in the cylinder workpiece holes at the 8 corner points and the geometric center point, heating is respectively started, the infrared temperature space maps corresponding to the 8 corner points and the geometric center point are respectively acquired, the geometric center point is connected with each corner point respectively, each first subspace structure is constructed, each first subspace structure is first numbered, and the first number is a natural number;

[0012] A three-dimensional space model of the cavity is acquired, the three-dimensional space model of the cavity is spatially divided according to the first subspace structure, a second subspace structure is obtained, and the number of the first subspace structure is corresponded to the second subspace structure.

[0013] As a preferred scheme of the engine cylinder cover aluminum alloy die casting quality control system, the test result is represented as an average value of the amplitude of the second subspace with the same first number, and the logic for testing the heat preservation performance comprises:

[0014] The infrared temperature values of each point in any second subspace after the first numbering are acquired, the infrared temperature values in the second subspace are traversed, the average value of the infrared temperature values in the second subspace is calculated, the average values of the infrared temperature values of each second subspace are traversed, the infrared temperature value of any second subspace is set as a reference value, the assignment of the second subspace is 1, the first ratio of the average value of the infrared temperature values of each second subspace to the reference value is calculated, the first product of the first ratio and 1 is calculated, and the first product is set as the assignment of the corresponding subspace;

[0015] The assignments of the subspaces corresponding to the infrared temperature space maps corresponding to the 8 corner points and the geometric center point are traversed, the average value of the amplitude of the second subspace with the same first number is calculated, and the average value of the amplitude of the second subspace with the same first number is set as the final assignment of the second subspace;

[0016] The final assignment of any two second subspaces is calculated by the quotient operation to obtain a second ratio, the first value and the second value are set as a second ratio threshold, when all the second ratios are less than or equal to the first value, the heat preservation performance is set as a first grade, when there is a second ratio greater than the first value and less than or equal to the second value and there is no second ratio greater than the second value, the heat preservation performance is set as a second grade, when there is a second ratio greater than the second value, the heat preservation performance is set as a third grade, the first grade, the second grade and the third grade are represented in descending order of heat preservation performance.

[0017] As a preferred scheme of the engine cylinder cover aluminum alloy die casting quality control system, the analysis module obtains a predetermined casting model, calls a casting database, inputs the casting model into the casting database, matches the casting parameters corresponding to the casting model, and the casting parameters include preheating temperature, casting temperature, preheating time, casting pressure, casting time, gate low-speed passing speed, gate speed switching time point, gate high-speed passing speed and holding time.

[0018] As a preferred scheme of the engine cylinder cover aluminum alloy die casting quality control system, the setting logic of the first parameter includes:

[0019] The final assignment is obtained, the first product of the final assignment and the casting temperature is calculated, the first product is set as the final casting temperature of the corresponding second subspace, and the final casting temperature, the preheating temperature, the preheating time, the casting pressure, the casting time, the gate low-speed passing speed, the gate speed switching time point, the gate high-speed passing speed and the holding time of each second subspace are set as the first parameter.

[0020] The casting process is simulated according to the first parameter, and a simulation result is obtained, and the simulation result is represented as each sectional view of the finished product.

[0021] As a preferred scheme of the engine cylinder cover aluminum alloy die casting quality control system, the logic of simulating the casting process according to the first parameter includes:

[0022] Use 3D modeling software to create geometric models of the casting, gating system, and core, and convert them into a format suitable for simulation software recognition. Import the created models into the casting simulation software, check the integrity of the models, and identify incomplete cases such as unclosed surfaces and overlapping surfaces. Set the gravity direction, set the mesh size and shape, and mesh the model. Input the density, specific heat capacity, and thermal conductivity of the casting material and the mold material. Input the first parameter, select the first type of boundary condition, which represents the lowest and highest temperature values ​​on the boundary, select the second type of boundary condition, which represents the heat flux density on the boundary, and select the third type of boundary condition, which represents the temperature gradient value on the boundary. Start the simulation calculation to simulate the casting process, obtain various sectional views of the finished product, and analyze the internal defects of the casting based on each sectional view.

[0023] The defects include porosity, cold shuts, undercasting, shrinkage cavities, bubbles, cracks, and looseness.

[0024] As a preferred embodiment of the quality control system for aluminum alloy die-cast parts of engine cylinder head cover according to the present invention, the control module acquires any cross-sectional view, extracts the shape feature quantity of the cross-sectional view and records it as the first feature quantity, retrieves the aluminum alloy die-casting defect database, acquires any defect image in the aluminum alloy die-casting defect database and records it as the standard defect image, and extracts the shape feature quantity of the standard defect image and records it as the second feature quantity.

[0025] The similarity between the first and second features is calculated using the cosine similarity formula. The third value is set as the similarity threshold. The similarity is compared with the third value, and the first operation is performed based on the comparison result.

[0026] As a preferred embodiment of the quality control system for the aluminum alloy die-cast part of the engine cylinder head cover described in this invention, the comparison results include similarity less than the third value and similarity greater than or equal to the third value.

[0027] The first operation includes jumping to the next standard defect image, repeating the similarity calculation and comparison steps, and setting the current finished product to a defect-free state.

[0028] When the similarity is less than the third value, the first operation is set to jump to the next standard defect image, and the similarity calculation and comparison operations are repeated until the similarity is greater than or equal to the third value. Then, the defect situation corresponding to the standard defect image at this time is set as the defect situation of the current finished product.

[0029] When all similarities are traversed and all similarities are less than the third value, the current finished product is set to the defect-free state.

[0030] As a preferred embodiment of the quality control system for aluminum alloy die-cast parts of engine cylinder head covers according to the present invention, the logic of the control module adjusting the first parameter based on the simulation results to obtain the second parameter includes:

[0031] When the current defect of the finished product is porosity, the high-speed passage speed of the gate is adjusted. The first speed is set to the gradient change. The high-speed passage speed of the gate is continuously reduced according to the first speed, and the corresponding defect of the current finished product is continuously acquired until the porosity disappears. The high-speed passage speed of the gate at this time is then saved.

[0032] When the current defect of the finished product is cold shut, the preheating temperature and preheating time are adjusted. The first temperature and the first duration are set as the change gradient of the preheating temperature and the change gradient of the preheating time. The preheating temperature and the preheating time are continuously increased according to the first temperature and the first duration, and the corresponding defect of the current finished product is continuously obtained until the cold shut disappears. The preheating temperature and the preheating time at this time are saved.

[0033] When the current defect of the finished product is undercasting, the low-speed passage speed of the gate is adjusted, the second speed is set to change gradient, the low-speed passage speed of the gate is continuously increased according to the second speed, and the corresponding defect of the current finished product is continuously obtained until the undercasting disappears, and the low-speed passage speed of the gate at this time is saved.

[0034] When the current defect of the finished product is shrinkage cavity, the casting pressure is adjusted. The first pressure is set as the change gradient. The casting pressure is continuously increased according to the first pressure, and the corresponding defect of the current finished product is continuously acquired until the shrinkage cavity disappears. The casting pressure at this time is then saved.

[0035] When the current defect of the finished product is bubbles, the final casting temperature and casting time are adjusted. The second temperature and the second duration are set as the variable gradient of the final casting temperature and the variable gradient of the casting time. The final casting temperature and casting time are continuously reduced according to the second temperature and the second duration, and the corresponding defect of the current finished product is continuously obtained until the bubbles disappear. At this time, the final casting temperature and the casting time are saved.

[0036] When the current defect of the finished product is cracking, the heat preservation time is adjusted, the third duration is set as the change gradient, the heat preservation time is continuously increased according to the third duration, and the corresponding defect of the current finished product is continuously obtained until the cracking disappears, and the heat preservation time at this time is saved.

[0037] When the current defect of the finished product is looseness, the gate speed switching time point is adjusted, the fourth time length is set as the gradient change, the gate speed switching time point is continuously delayed according to the fourth time length, and the corresponding defect of the current finished product is continuously acquired until the looseness disappears, and the gate speed switching time point at this time is saved.

[0038] Set the saved adjusted first parameter as the second parameter.

[0039] As a preferred embodiment of the quality control system for aluminum alloy die-cast parts of engine cylinder head covers according to the present invention, the control module establishes a first mapping relationship between a second parameter and the casting model, inputs the casting model into the first mapping relationship, matches the second parameter corresponding to the casting model, and casts the material of the casting model according to the second parameter.

[0040] The beneficial effects of this invention are as follows: The testing module tests the heat treatment furnace's heat preservation performance and assigns values ​​to the mold cavity space to obtain the final value. The analysis module sets the first parameter based on the final value and simulates the casting process, accurately predicting the location and type of potential defects, such as porosity, shrinkage cavities, and cold shuts. The control module then adjusts the first parameter based on the simulation results to obtain the second parameter, thereby effectively avoiding these defects and improving the overall quality of the casting. It can establish a first mapping relationship between the second parameter and the casting model for different casting models, providing the most suitable combination of process parameters for each model. For example, for engine cylinder head covers with uneven wall thickness and complex shapes, optimizing parameters such as casting temperature, preheating temperature, and casting pressure effectively reduces porosity in thick areas. Using simulation technology to virtually verify the die-casting process before production allows for early detection and resolution of potential problems, avoiding the repeated trials and adjustments required by traditional trial-and-error methods, significantly shortening the new product development cycle. Precise control of various parameters in the casting process reduces the scrap rate caused by defects and improves material utilization. Attached Figure Description

[0041] Figure 1 This is a basic flowchart illustrating a quality control system for an aluminum alloy die-cast part for an engine cylinder head cover, provided as an embodiment of the present invention. Detailed Implementation

[0042] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0043] Example, refer to Figure 1As an embodiment of the present invention, a quality control system for aluminum alloy die-cast parts of engine cylinder head covers is provided, including a testing module, an analysis module and a control module;

[0044] The testing module tests the heat treatment furnace's insulation performance according to the mold cavity division rules, and assigns values ​​to the mold cavity space based on the test results to obtain the final values;

[0045] The analysis module sets the first parameter according to the predetermined casting model and final assignment, and simulates the casting process based on the first parameter to obtain the simulation results;

[0046] The control module adjusts the first parameter based on the simulation results to obtain the second parameter, and establishes a first mapping relationship between the second parameter and the casting model.

[0047] This invention uses a testing module to test the heat treatment furnace's insulation performance and assign values ​​to the mold cavity space to obtain the final values. The analysis module sets the first parameter based on the final values ​​and simulates the casting process, accurately predicting the location and type of potential defects, such as porosity, shrinkage cavities, and cold shuts. The control module then adjusts the first parameter based on the simulation results to obtain the second parameter, effectively avoiding these defects and improving the overall quality of the casting. It can establish a first mapping relationship between the second parameter and the casting model for different casting types, providing the most suitable combination of process parameters for each type of casting. For example, for engine cylinder head covers with uneven wall thickness and complex shapes, optimizing parameters such as casting temperature, preheating temperature, and casting pressure effectively reduces porosity in thick areas. Using simulation technology to virtually verify the die-casting process before production allows for early detection and resolution of potential problems, avoiding the repeated trials and adjustments required by traditional trial-and-error methods, significantly shortening the new product development cycle. Precise control of various parameters during the casting process reduces the scrap rate due to defects and improves material utilization.

[0048] The cavity division rules include:

[0049] Obtain the 8 corner points and geometric center point of the heat treatment furnace, take any corner point as the origin of the coordinate system, and take the edges that intersect with the corner points as the x-axis, y-axis and z-axis to construct a three-dimensional coordinate system;

[0050] Thermocouples are placed in the workpiece holes of the cylinder at the eight corner points and the geometric center point, respectively, and heating is turned on. Infrared temperature space maps corresponding to the eight corner points and the geometric center point are obtained respectively. The geometric center point is connected to each corner point to construct each first subspace structure. Each first subspace structure is assigned a first number, which is a natural number.

[0051] Obtain the three-dimensional spatial model of the mold cavity, divide the three-dimensional spatial model of the mold cavity into two sub-space structures according to the first sub-space structure, and match the number of the first sub-space structure with the number of the second sub-space structure.

[0052] In practice, thermocouples are placed at eight corner points and the geometric center point of the heat treatment furnace to comprehensively monitor the temperature distribution within the entire mold cavity. These key points reflect temperature changes at different locations within the mold cavity, ensuring the comprehensiveness and accuracy of temperature monitoring. Infrared temperature spatial maps corresponding to the eight corner points and the geometric center point are obtained, constructing a three-dimensional temperature distribution map within the mold cavity. This three-dimensional temperature map visually displays the temperature differences at different locations within the mold cavity, providing crucial information for subsequent temperature control and process optimization. Connecting the geometric center point to each corner point constructs various first subspace structures. Based on these first subspace structures, the three-dimensional spatial model of the mold cavity is spatially divided to obtain second subspace structures. This division method divides the mold cavity into multiple subspaces with clearly defined boundaries, enabling more precise temperature control of different regions within the mold cavity. A clear numbering system is established by mapping the numbers of the first and second subspace structures. This numbering system facilitates the identification and management of each subspace, enabling rapid location and adjustment of parameters for specific subspaces during subsequent process control. Precise temperature control and rational space division reduce production interruptions and rework caused by temperature issues, ensuring production continuity and stability, thereby improving production efficiency. This cavity division rule can be flexibly adjusted according to different casting models and process requirements. By changing the placement and number of thermocouples and adjusting the subspace division method, the production needs of different castings can be met.

[0053] The test results are represented as the average amplitude of the second subspace with the same first number. The logic for testing the thermal insulation performance includes:

[0054] Obtain the infrared temperature value of each point in any second subspace after the first number, traverse the infrared temperature values ​​in the second subspace, calculate the average value of the infrared temperature values ​​in the second subspace, traverse the average value of the infrared temperature values ​​in each second subspace, set the infrared temperature value of any second subspace as the reference value, assign it the value of 1, calculate the first ratio of the average value of the infrared temperature values ​​in each second subspace to the reference value, calculate the first product of the first ratio and 1, and set the first product as the value of the corresponding subspace.

[0055] Iterate through the subspaces corresponding to the infrared temperature space map of the 8 corner points and the geometric center point, calculate the average amplitude of the second subspaces with the same first number, and set the average amplitude of the second subspaces with the same first number as the final value of the second subspace.

[0056] The final values ​​of any two second subspaces are divided to obtain the second ratio. The first and second values ​​are set as the threshold of the second ratio. When all second ratios are less than or equal to the first value, the thermal insulation performance is set to the first level. When there is a second ratio greater than the first value and less than or equal to the second value, and no second ratio is greater than the second value, the thermal insulation performance is set to the second level. When there is a second ratio greater than the second value, the thermal insulation performance is set to the third level. The first level, second level, and third level represent the thermal insulation performance in descending order.

[0057] In practice, the average temperature of each second subspace is obtained by calculating the average infrared temperature value in each subspace. This averaging method reduces the impact of individual point temperature anomalies on the overall assessment and improves the accuracy of temperature evaluation. The average temperature of each second subspace is then compared with a reference value (the average temperature of the subspace assigned a value of 1) to obtain the temperature difference of each subspace relative to the reference subspace. This ratio calculation method more intuitively reflects the temperature differences between different subspaces. Based on the magnitude of the second ratio, the thermal insulation performance is divided into three levels: Level 1, Level 2, and Level 3. This grading standard clearly reflects the quality of insulation performance, providing an important basis for subsequent process improvement and quality control. By grading insulation performance, sub-spaces with poor insulation performance can be identified, allowing for targeted process improvements, such as adjusting heating parameters and optimizing airflow within the furnace, to improve overall insulation performance. When quality problems occur, the grading system quickly locates the problematic sub-space, traces its temperature changes, and rapidly identifies the root cause of the problem, enabling appropriate solutions. By assigning a unique number to each sub-space and calculating its final value, temperature monitoring data is managed in a structured manner. This facilitates data storage, retrieval, and analysis, improving the efficiency and accuracy of data management.

[0058] The analysis module obtains the predetermined casting model, retrieves the casting database, inputs the casting model into the casting database, and matches the casting parameters corresponding to the casting model. The casting parameters include preheating temperature, casting temperature, preheating time, casting pressure, casting time, low-speed gate throughput, gate speed switching time point, high-speed gate throughput, and holding time.

[0059] The logic for setting the first parameter includes:

[0060] Obtain the final assignment value, calculate the first product of the final assignment value and the casting temperature, set the first product as the final casting temperature of the corresponding second subspace, and set the final casting temperature, preheating temperature, preheating time, casting pressure, casting time, low-speed gate throughput, gate speed switching time point, high-speed gate throughput and holding time of each second subspace as the first parameter.

[0061] The casting process is simulated based on the first parameter, and the simulation results are represented as various sectional views of the finished product.

[0062] In practice, the final casting temperature of each second subspace is obtained by calculating the first product of the final assigned value and the casting temperature. This calculation method can set the most suitable casting temperature for each subspace based on the differences in the heat preservation performance of different areas within the mold cavity, thereby reducing casting defects caused by uneven temperature, such as shrinkage cavities, porosity, and cold shuts. The first parameter is formed by comprehensively considering parameters such as the final casting temperature, preheating temperature, preheating time, casting pressure, casting time, low-speed gate throughput, gate speed switching time, high-speed gate throughput, and holding time. This comprehensive parameter setting allows for more complete control of the casting process, ensuring casting quality. Simulations provide cross-sectional views of the finished product, allowing for a direct view of the internal temperature distribution, solidification sequence, and defect distribution of the casting. This visualization analysis helps engineers identify potential problems in advance and make optimizations. By predicting and avoiding defects in advance, it reduces production interruptions and rework caused by quality issues, ensuring production continuity and stability. Reasonable setting of parameters such as preheating temperature and holding time avoids unnecessary energy waste and reduces energy consumption during the production process.

[0063] The logic for simulating the casting process based on the first parameter includes:

[0064] Use 3D modeling software to create geometric models of the casting, gating system, and core, and convert them to a format suitable for simulation software recognition. Import the created models into the casting simulation software, check the integrity of the models, and identify incomplete cases such as unclosed surfaces and overlapping surfaces. Set the gravity direction, set the mesh size and shape, and mesh the model. Input the density, specific heat capacity, and thermal conductivity of the casting material and the mold material. Input the first parameter, select the first type of boundary condition, which represents the lowest and highest temperature values ​​on the boundary, select the second type of boundary condition, which represents the heat flux density on the boundary, select the third type of boundary condition, which represents the temperature gradient value on the boundary, start the simulation calculation, simulate the casting process, obtain various sectional views of the finished product, and analyze the internal defects of the casting based on each sectional view.

[0065] Defects include porosity, cold shuts, undercasting, shrinkage cavities, bubbles, cracks, and looseness.

[0066] The control module acquires any sectional view, extracts the shape feature quantity of the sectional view, and records it as the first feature quantity. It then retrieves the aluminum alloy die casting defect database, acquires any defect image from the aluminum alloy die casting defect database, records it as the standard defect image, and extracts the shape feature quantity of the standard defect image, which is recorded as the second feature quantity.

[0067] The similarity between the first and second features is calculated using the cosine similarity formula. The third value is set as the similarity threshold. The similarity is compared with the third value, and the first operation is performed based on the comparison result.

[0068] In practice, precise simulation and optimization reduce internal defects in castings, such as porosity and shrinkage cavities, thereby improving the mechanical properties and durability of the castings. Simulation optimization of temperature distribution ensures uniform internal temperature, reducing stress concentration and cracking caused by temperature differences. Virtual verification of the casting process before production allows for early detection and resolution of potential problems, avoiding the repeated trials and adjustments required by traditional trial-and-error methods and significantly shortening the new product development cycle. This parameter setting logic can be flexibly adjusted according to different casting models and process requirements. By changing the final assignment and casting temperature calculation methods, as well as adjusting other parameters, the production needs of different castings can be met. Simulation results and cross-sectional views provide a clear view of the effects of process improvements, offering data support for process optimization. Simulation technology also predicts potential defects and problems in advance, reducing safety accidents caused by improper operation.

[0069] The comparison results include those with similarity less than the third value and those with similarity greater than or equal to the third value;

[0070] The first operation includes jumping to the next standard defect image, repeating the similarity calculation and comparison steps, and setting the current finished product to a defect-free state.

[0071] When the similarity is less than the third value, the first operation is set to jump to the next standard defect image, and the similarity calculation and comparison operations are repeated until the similarity is greater than or equal to the third value. Then, the defect situation corresponding to the standard defect image at this time is set as the defect situation of the current finished product.

[0072] When all similarities are traversed and all similarities are less than the third value, the current finished product is set to the defect-free state.

[0073] The control module adjusts the first parameter based on the simulation results to obtain the second parameter. The logic includes:

[0074] When the current defect of the finished product is porosity, the high-speed passage speed of the gate is adjusted. The first speed is set to the gradient change. The high-speed passage speed of the gate is continuously reduced according to the first speed, and the corresponding defect of the current finished product is continuously acquired until the porosity disappears. The high-speed passage speed of the gate at this time is then saved.

[0075] When the current defect of the finished product is cold shut, the preheating temperature and preheating time are adjusted. The first temperature and the first duration are set as the change gradient of the preheating temperature and the change gradient of the preheating time. The preheating temperature and the preheating time are continuously increased according to the first temperature and the first duration, and the corresponding defect of the current finished product is continuously obtained until the cold shut disappears. The preheating temperature and the preheating time at this time are saved.

[0076] When the current defect of the finished product is undercasting, the low-speed passage speed of the gate is adjusted, the second speed is set to change gradient, the low-speed passage speed of the gate is continuously increased according to the second speed, and the corresponding defect of the current finished product is continuously obtained until the undercasting disappears, and the low-speed passage speed of the gate at this time is saved.

[0077] When the current defect of the finished product is shrinkage cavity, the casting pressure is adjusted. The first pressure is set as the change gradient. The casting pressure is continuously increased according to the first pressure, and the corresponding defect of the current finished product is continuously acquired until the shrinkage cavity disappears. The casting pressure at this time is then saved.

[0078] When the current defect of the finished product is bubbles, the final casting temperature and casting time are adjusted. The second temperature and the second duration are set as the variable gradient of the final casting temperature and the variable gradient of the casting time. The final casting temperature and casting time are continuously reduced according to the second temperature and the second duration, and the corresponding defect of the current finished product is continuously obtained until the bubbles disappear. At this time, the final casting temperature and the casting time are saved.

[0079] When the current defect of the finished product is cracking, the heat preservation time is adjusted, the third duration is set as the change gradient, the heat preservation time is continuously increased according to the third duration, and the corresponding defect of the current finished product is continuously obtained until the cracking disappears, and the heat preservation time at this time is saved.

[0080] When the current defect of the finished product is looseness, the gate speed switching time point is adjusted, the fourth time length is set as the gradient change, the gate speed switching time point is continuously delayed according to the fourth time length, and the corresponding defect of the current finished product is continuously acquired until the looseness disappears, and the gate speed switching time point at this time is saved.

[0081] Set the saved adjusted first parameter as the second parameter.

[0082] In practice, a third value is set as a similarity threshold to accurately determine the similarity between the finished product and the standard defect image. Only when the similarity is greater than or equal to the third value is the finished product considered to have a defect, thus avoiding misjudgment. When the similarity is less than the third value, the system jumps to the next standard defect image and repeats the similarity calculation and comparison. This image-by-image comparison method ensures that no possible defect type is missed, improving the accuracy of defect identification. When the similarity is greater than or equal to the third value, the system automatically sets the defect situation corresponding to the current standard defect image as the defect situation of the current finished product. This automated classification method can quickly and accurately identify defect types, improving detection efficiency. By setting a similarity threshold, the system can strictly distinguish the similarity between the finished product and the standard defect image, reducing the possibility of misjudgment. Only when the similarity reaches a certain standard, through accurate defect identification and automated defect classification, can the system improve product quality, reduce the scrap rate caused by defects, and thus improve the overall quality control level before considering the finished product as defective, thereby improving the reliability of detection.

[0083] The control module establishes a first mapping relationship between the second parameter and the casting model. By inputting the casting model into the first mapping relationship, the second parameter corresponding to the casting model is matched, and the material of the casting model is cast according to the second parameter.

[0084] In practical implementation, the first mapping relationship allows for the precise matching of the most suitable second parameters for each casting model. These parameters comprehensively consider multiple key factors such as casting temperature, preheating temperature, and casting pressure, ensuring precise control of the casting process and effectively reducing defects caused by unreasonable parameter settings, such as porosity, shrinkage cavities, and cold shuts. The second parameters, optimized based on simulation results, can predict and prevent potential defects before actual casting. By optimizing process parameters through simulation technology, potential defect-causing parameter settings can be identified and adjusted in advance, significantly improving casting quality. When different casting models need to be produced, the system can quickly call the corresponding second parameters based on the casting model, achieving rapid production switching, improving equipment utilization and production efficiency. With the diversification of market demand, enterprises need to produce multiple casting models. Through the first mapping relationship, the system can flexibly adapt to the production needs of different casting models, quickly adjust process parameters, and meet the production mode of multiple varieties and small batches.

[0085] This invention uses a testing module to test the heat treatment furnace's insulation performance and assign values ​​to the mold cavity space to obtain the final values. The analysis module sets the first parameter based on the final values ​​and simulates the casting process, accurately predicting the location and type of potential defects, such as porosity, shrinkage cavities, and cold shuts. The control module then adjusts the first parameter based on the simulation results to obtain the second parameter, effectively avoiding these defects and improving the overall quality of the casting. It can establish a first mapping relationship between the second parameter and the casting model for different casting types, providing the most suitable combination of process parameters for each type of casting. For example, for engine cylinder head covers with uneven wall thickness and complex shapes, optimizing parameters such as casting temperature, preheating temperature, and casting pressure effectively reduces porosity in thick areas. Using simulation technology to virtually verify the die-casting process before production allows for early detection and resolution of potential problems, avoiding the repeated trials and adjustments required by traditional trial-and-error methods, significantly shortening the new product development cycle. Precise control of various parameters during the casting process reduces the scrap rate due to defects and improves material utilization.

[0086] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product implemented on one or more computer-usable storage media containing computer-usable program code. The storage medium is implemented by any type of volatile or non-volatile storage device or a combination thereof, such as Static Random Access Memory (SRAM), Electrically Erasable Programmable Read-Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM), Programmable Red-Only Memory (PROM), Read-Only Memory (ROM), magnetic storage, flash memory, magnetic disk, or optical disk. These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0087] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention should all be covered within the scope of the claims of the present invention.

Claims

1. A quality control system for aluminum alloy die-cast parts of engine cylinder head covers, characterized in that, It includes a testing module, an analysis module, and a control module; The test module tests the heat treatment furnace insulation performance according to the mold cavity division rules, and assigns values ​​to the mold cavity space based on the test results to obtain the final value. The analysis module sets a first parameter based on the predetermined casting model and final assignment, and simulates the casting process based on the first parameter to obtain simulation results; The control module adjusts the first parameter based on the simulation results to obtain the second parameter, and establishes a first mapping relationship between the second parameter and the casting model. The analysis module obtains the predetermined casting model, retrieves the casting database, inputs the casting model into the casting database, and matches the casting parameters corresponding to the casting model. The casting parameters include preheating temperature, casting temperature, preheating time, casting pressure, casting time, low-speed gate throughput, gate speed switching time point, high-speed gate throughput, and holding time. The logic for setting the first parameter includes: Obtain the final assignment value, calculate the first product of the final assignment value and the casting temperature, set the first product as the final casting temperature of the corresponding second subspace, and set the final casting temperature, preheating temperature, preheating time, casting pressure, casting time, low-speed gate throughput, gate speed switching time point, high-speed gate throughput and holding time of each second subspace as the first parameter. The casting process is simulated based on the first parameter to obtain simulation results, which are represented as various sectional views of the finished product. The control module adjusts the first parameter based on the simulation results to obtain the second parameter. The logic includes: When the current defect of the finished product is porosity, the high-speed passage speed of the gate is adjusted. The first speed is set to the gradient change. The high-speed passage speed of the gate is continuously reduced according to the first speed, and the corresponding defect of the current finished product is continuously acquired until the porosity disappears. The high-speed passage speed of the gate at this time is then saved. When the current defect of the finished product is cold shut, the preheating temperature and preheating time are adjusted. The first temperature and the first duration are set as the change gradient of the preheating temperature and the change gradient of the preheating time. The preheating temperature and the preheating time are continuously increased according to the first temperature and the first duration, and the corresponding defect of the current finished product is continuously obtained until the cold shut disappears. The preheating temperature and the preheating time at this time are saved. When the current defect of the finished product is undercasting, the low-speed passage speed of the gate is adjusted, the second speed is set to change gradient, the low-speed passage speed of the gate is continuously increased according to the second speed, and the corresponding defect of the current finished product is continuously obtained until the undercasting disappears, and the low-speed passage speed of the gate at this time is saved. When the current defect of the finished product is shrinkage cavity, the casting pressure is adjusted. The first pressure is set as the change gradient. The casting pressure is continuously increased according to the first pressure, and the corresponding defect of the current finished product is continuously acquired until the shrinkage cavity disappears. The casting pressure at this time is then saved. When the current defect of the finished product is bubbles, the final casting temperature and casting time are adjusted. The second temperature and the second duration are set as the variable gradient of the final casting temperature and the variable gradient of the casting time. The final casting temperature and casting time are continuously reduced according to the second temperature and the second duration, and the corresponding defect of the current finished product is continuously obtained until the bubbles disappear. At this time, the final casting temperature and the casting time are saved. When the current defect of the finished product is cracking, the heat preservation time is adjusted, the third duration is set as the change gradient, the heat preservation time is continuously increased according to the third duration, and the corresponding defect of the current finished product is continuously obtained until the cracking disappears, and the heat preservation time at this time is saved. When the current defect of the finished product is looseness, the gate speed switching time point is adjusted, the fourth time length is set as the gradient change, the gate speed switching time point is continuously delayed according to the fourth time length, and the corresponding defect of the current finished product is continuously acquired until the looseness disappears, and the gate speed switching time point at this time is saved. Set the saved adjusted first parameter as the second parameter.

2. The quality control system for aluminum alloy die-cast parts of engine cylinder head covers as described in claim 1, characterized in that: The cavity division rules include: Obtain the eight corner points and geometric center point of the heat treatment furnace, take any corner point as the origin of the coordinate system, and take the edge that intersects with the corner point as the x-axis, y-axis and z-axis to construct a three-dimensional coordinate system; Thermocouples are placed in the workpiece holes of the cylinder at the eight corner points and the geometric center point, respectively, and heating is turned on. Infrared temperature space maps corresponding to the eight corner points and the geometric center point are obtained respectively. The geometric center point is connected to each corner point to construct each first subspace structure. Each first subspace structure is assigned a first number, where the first number is a natural number. Obtain the three-dimensional spatial model of the mold cavity, divide the three-dimensional spatial model of the mold cavity into two sub-space structures according to the first sub-space structure, and match the number of the first sub-space structure with the number of the second sub-space structure.

3. The quality control system for aluminum alloy die-cast parts of engine cylinder head covers as described in claim 1, characterized in that: The test results are represented as the average amplitude of the second subspace with the same first number. The logic for testing the thermal insulation performance includes: Obtain the infrared temperature value of each point in any second subspace after the first number, traverse the infrared temperature values ​​in the second subspace, calculate the average value of the infrared temperature values ​​in the second subspace, traverse the average value of the infrared temperature values ​​in each second subspace, set the infrared temperature value of any second subspace as the reference value, assign it the value of 1, calculate the first ratio of the average value of the infrared temperature values ​​in each second subspace to the reference value, calculate the first product of the first ratio and 1, and set the first product as the value of the corresponding subspace. Iterate through the subspaces corresponding to the infrared temperature space map of the 8 corner points and the geometric center point, calculate the average amplitude of the second subspaces with the same first number, and set the average amplitude of the second subspaces with the same first number as the final value of the second subspace. The final values ​​of any two second subspaces are divided to obtain a second ratio. The first and second values ​​are set as the threshold of the second ratio. When all second ratios are less than or equal to the first value, the thermal insulation performance is set to the first level. When there is a second ratio greater than the first value and less than or equal to the second value, and no second ratio is greater than the second value, the thermal insulation performance is set to the second level. When there is a second ratio greater than the second value, the thermal insulation performance is set to the third level. The first level, the second level, and the third level represent the thermal insulation performance in descending order.

4. The quality control system for aluminum alloy die-cast parts of engine cylinder head covers as described in claim 1, characterized in that: The logic for simulating the casting process based on the first parameter includes: Use 3D modeling software to create geometric models of the casting, gating system, and core, and convert them into a format suitable for simulation software recognition. Import the created models into the casting simulation software, check the integrity of the models, and identify incomplete cases such as unclosed surfaces and overlapping surfaces. Set the gravity direction, set the mesh size and shape, and mesh the model. Input the density, specific heat capacity, and thermal conductivity of the casting material and the mold material. Input the first parameter, select the first type of boundary condition, which represents the lowest and highest temperature values ​​on the boundary, select the second type of boundary condition, which represents the heat flux density on the boundary, and select the third type of boundary condition, which represents the temperature gradient value on the boundary. Start the simulation calculation to simulate the casting process, obtain various sectional views of the finished product, and analyze the internal defects of the casting based on each sectional view. The defects include porosity, cold shuts, undercasting, shrinkage cavities, bubbles, cracks, and looseness.

5. The quality control system for aluminum alloy die-cast parts of engine cylinder head covers as described in claim 1, characterized in that: The control module acquires any cross-sectional view, extracts the shape feature quantity of the cross-sectional view, and records it as the first feature quantity. It then retrieves the aluminum alloy die-casting defect database, acquires any defect image from the aluminum alloy die-casting defect database, records it as the standard defect image, and extracts the shape feature quantity of the standard defect image, which is recorded as the second feature quantity. The similarity between the first and second features is calculated using the cosine similarity formula. The third value is set as the similarity threshold. The similarity is compared with the third value, and the first operation is performed based on the comparison result.

6. A quality control system for aluminum alloy die-cast parts of engine cylinder head covers as described in claim 5, characterized in that: The comparison results include those with a similarity less than the third value and those with a similarity greater than or equal to the third value; The first operation includes jumping to the next standard defect image, repeating the similarity calculation and comparison steps, and setting the current finished product to a defect-free state. When the similarity is less than the third value, the first operation is set to jump to the next standard defect image, and the similarity calculation and comparison operations are repeated until the similarity is greater than or equal to the third value. Then, the defect situation corresponding to the standard defect image at this time is set as the defect situation of the current finished product. When all similarities are traversed and all similarities are less than the third value, the current finished product is set to the defect-free state.

7. The quality control system for aluminum alloy die-cast parts of engine cylinder head covers as described in claim 1, characterized in that: The control module establishes a first mapping relationship between the second parameter and the casting model. By inputting the casting model into the first mapping relationship, the second parameter corresponding to the casting model is matched, and the material of the casting model is cast according to the second parameter.

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