Real-time monitoring device for molten metal in die and die-casting forming system

Abstract

The invention discloses a real-time monitoring device for molten metal in a die and a die-casting forming system, and belongs to the technical field of die-casting casting. The real-time monitoring device comprises a data processing module, a display module and a plurality of monitoring needles capable of being arranged in a cavity; a plurality of designated positions are arranged in the cavity, the monitoring needles are arranged at the designated positions and used for monitoring whether molten metal appears at the designated positions or not and generating monitoring information, and the monitoring information comprises the time point when the molten metal is detected at the designated positions; the data processing module receives the monitoring information collected by the monitoring needles, sorts the specified positions according to the time sequence of the time points corresponding to the specified positions, and connects the specified positions in sequence to generate a molten metal flowing track; the display module is electrically connected with the data processing module and used for displaying the flow track of the molten metal. According to the real-time monitoring system for the molten metal in the mold, the molten metal in the mold can be monitored, so that a worker can know the flowing condition of the molten metal, and the die-casting process is further optimized.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of die casting, and particularly relates to a device for monitoring molten metal in a mold in real time and a die casting system. BACKGROUND

[0002] Pressure casting is a casting method in which molten alloy is filled into a mold cavity under high pressure and high speed, and the alloy is cooled and solidified under high pressure to form a casting. The pressure casting process is a process of dynamically balancing process factors such as pressure, speed and time by organically combining and comprehensively using three elements of a die casting machine, a mold and a die casting alloy. Aluminum alloy has become a key material in the fields of automobiles and medical devices due to its good mechanical properties, low density and corrosion resistance.

[0003] Aluminum alloy die casting can produce castings with thin walls, complex shapes, clear outlines, stable dimensions and small machining allowances. However, the formation of pores in the castings cannot be avoided. In actual production, the formation of pores is related to the filling process of the aluminum liquid. When the aluminum liquid fills too fast, air is entrapped and pores are formed. When the aluminum liquid fills too slowly, the temperature drops and cold shut is easily produced. Therefore, the position of the aluminum liquid in the mold can be monitored to optimize the die casting process and the quality of the castings.

[0004] In actual production, the filling process of the aluminum liquid is simulated by using mold flow software, and the position of the aluminum liquid is calculated theoretically. However, it is difficult to access the inside of the cavity, and the actual temperature change and the flow of the aluminum liquid cannot be accurately obtained, which affects the optimization of the die casting process.

[0005] Therefore, there is a need for a device for monitoring molten metal in a mold cavity in real time to observe the flow of the molten metal and optimize the die casting process. SUMMARY

[0006] In view of one or more of the above defects or improvement needs of the prior art, the present application provides a device for monitoring molten metal in a mold in real time and a die casting system, wherein a monitoring needle is arranged at a needle mounting position in the mold to monitor the flow trajectory of the molten metal in the mold, thereby assisting an operator to optimize the die casting process.

[0007] To achieve the above-mentioned purpose, the present application provides a device for monitoring molten metal in a mold in real time, which comprises a data processing module, a display module and a plurality of monitoring needles that can be arranged in a cavity. The cavity is provided with a plurality of specified positions, and the monitoring needles are arranged at the specified positions to monitor whether the molten metal appears at the specified positions and generate monitoring information, which includes the time point at which the molten metal is detected at the specified position. The data processing module is electrically connected with each monitoring needle, and is used for receiving monitoring information collected by each monitoring needle, sorting each specified position according to time sequence of time points corresponding to the positions, and sequentially connecting to generate a metal melt flow trajectory. The display module is electrically connected with the data processing module, and is used for displaying the metal melt flow trajectory.

[0008] As a further improvement of the application, the monitoring needle comprises a needle body and a temperature sensor arranged at a first end of the needle body. The needle body is provided with a through hole penetrating through two end faces of the needle body, a signal cable is arranged in the through hole, one end of the signal cable is connected with the temperature sensor, and the other end of the signal cable is connected with the data processing module, so as to transmit temperature information collected by the temperature sensor to the data processing module.

[0009] As a further improvement of the application, the temperature sensor is arranged in the through hole, and the temperature sensor is arranged close to the first end of the needle body, so that an opening is formed at the first end of the needle body, and the metal melt can enter the opening to contact the temperature sensor.

[0010] As a further improvement of the application, the monitoring needle further comprises a pressure sensor, The fixed end of the pressure sensor is fixedly connected with the mold, and the sensing end of the pressure sensor abuts against the second end of the needle body, so as to detect the pressure of the metal melt on the needle body.

[0011] As a further improvement of the application, the monitoring needle further comprises an integrated joint, one end of the integrated joint is connected with the pressure sensor and the signal cable respectively, and the other end of the integrated joint is connected with the data processing module, so as to transmit the temperature information and the pressure information to the data processing module after integration.

[0012] As a further improvement of the application, the temperature sensor is a thermocouple probe. and / or, The signal cable is provided with a high-temperature-resistant sealing layer on the outer periphery.

[0013] As a further improvement of the application, the display module is a fixed display terminal and / or a handheld display terminal.

[0014] As another aspect of the application, a die casting system is also provided, which comprises the mold internal metal melt real-time monitoring device and a die casting device. The die casting device comprises a fixed mold and a movable mold, a mold cavity is formed after the fixed mold and the movable mold are combined, a mold needle mounting position is arranged on the movable mold, and the monitoring needle is mounted on the mold needle mounting position, so that the metal melt in the mold cavity is monitored in a die casting process.

[0015] As a further improvement of the present application, it further comprises a simulation module for constructing a metal melt trajectory simulation model. The simulation module is electrically connected with the data processing module, for receiving the monitoring information and importing the monitoring information collected by each monitoring needle into the simulation model for simulation, so as to optimize the simulation result.

[0016] As a further improvement of the present application, it further comprises a scanning module and an analysis module electrically connected with the scanning module, the scanning module scans the product formed by die casting and transmits the scanning information of the product to the analysis module, The analysis module analyzes the scanning information to obtain product defect information. The analysis module is electrically connected with the data processing module, for receiving the monitoring information, The analysis module compares the monitoring information with the product defect information to confirm the influencing factors of product defects, so as to optimize the die casting process.

[0017] The above technical features can be combined with each other as long as they do not conflict with each other.

[0018] Overall, compared with the prior art, the above technical solutions conceived by the present application have the following beneficial effects: (1) The mold internal metal melt real-time monitoring device of the present application monitors the metal melt flow in the mold through the monitoring needle, and the monitoring needle can transmit the monitoring information to the data processing module, the data processing module sorts the specified positions according to the time sequence of their corresponding time points and connects them in turn, and generates the metal melt flow trajectory, which is then displayed by the display module, so that the staff can understand the metal melt flow in the cavity and optimize the subsequent die casting process according to the metal melt flow; (2) The mold internal metal melt real-time monitoring device of the present application is provided with a temperature sensor and a pressure sensor corresponding to the needle body, so that the temperature of the metal melt and the pressure generated thereby can be collected, facilitating the analysis of the die casting process by the staff; (3) The die casting forming system of the present application sets the needle body structure of the monitoring needle and the pin structure to the same structure to meet the requirements of the die casting process, so as to ensure that the die casting process proceeds normally while the metal melt in the mold is monitored; (4) The die casting forming system of the present application constructs a metal melt trajectory simulation model through the simulation module, inputs the monitoring information into the simulation model, and performs simulation to further optimize the simulation result; (5) The die casting system of the present application compares product defects with monitoring information through the analysis module to confirm product defect influencing factors, thereby facilitating the staff to further optimize the die casting process on this basis. BRIEF DESCRIPTION OF DRAWINGS

[0019] Fig. 1 is the overall structure schematic diagram of the die casting system in the embodiment of the present application; Fig. 2 is the sectional view of the monitoring needle in the embodiment of the present application; Fig. 3 is the mold structure schematic diagram applied in the embodiment of the present application; In all the drawings, the same reference signs represent the same technical features, specifically: 1, monitoring needle;101, needle body;102, temperature sensor;103, signal cable;104, pressure sensor;105, high-temperature-resistant sealing layer;106, integrated joint;2, data processing module;3, display module;4, simulation module;5, scanning module;6, analysis module;7, moving die;8, needle mounting position;9, inner runner. DETAILED DESCRIPTION

[0020] In order to make the purpose, technical scheme and advantages of the present application more clear, the present application is further described in detail below in combination with the drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and not to limit the present application. In addition, the technical features involved in each embodiment of the present application described below can be combined with each other as long as there is no conflict.

[0021] In the description of the present application, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like indicate the orientation or positional relationship shown in the drawings, which is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, therefore it cannot be understood as a limitation of the present application.

[0022] In addition, the terms "first", "second" are only for description purpose and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features limited by "first", "second" can explicitly or implicitly include at least one of the features. In the description of the present application, the meaning of "multiple" is at least two, for example, two, three, etc., unless otherwise specifically limited.

[0023] In the present application, unless otherwise clearly specified and limited, the terms "mounting", "connecting", "connecting", "fixing" and the like should be understood broadly, for example, it can be fixed connection, or detachable connection, or integrated; it can be mechanical connection, or electrical connection; it can be direct connection, or indirect connection through intermediate medium, it can be the internal communication of two elements or the interaction relationship between two elements, unless otherwise clearly limited. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0024] In the present application, unless otherwise clearly specified and limited, the first feature is "on" or "under" the second feature, which can be direct contact between the first and second features, or indirect contact between the first and second features through intermediate medium. Moreover, the first feature "above", "over" and "on" the second feature can be directly above or obliquely above the first feature, or only indicate that the horizontal height of the first feature is higher than that of the second feature. The first feature "below", "under" and "under" the second feature can be directly below or obliquely below the first feature, or only indicate that the horizontal height of the first feature is less than that of the second feature.

[0025] Embodiment: Please refer to Figs. 1-3 The mold internal molten metal real-time monitoring device in the preferred embodiment of the present application comprises a data processing module 2, a display module 3 and a plurality of monitoring needles 1. Among them, the monitoring needle 1 can be arranged in the internal cavity of the mold, and arranged at a specified position in the cavity. A plurality of specified positions are arranged in the cavity, and the specified positions are arranged one by one with the monitoring needles 1, so that the monitoring needle 1 can monitor the specified position in the cavity to obtain the monitoring information of the specified position, wherein the monitoring information includes the time point when the molten metal is detected. The data processing module 2 is electrically connected with each monitoring needle 1 respectively, for receiving the monitoring information and processing the monitoring information, sorting each specified position in the time sequence of the time point in the corresponding monitoring information, and connecting in turn to generate the molten metal flow trajectory. The display module 3 is electrically connected with the data processing module 2, for displaying the molten metal flow trajectory.

[0026] Further, the monitoring needle 1 comprises a needle body 101 and a temperature sensor 102 arranged at the first end of the needle body 101, the temperature sensor 102 can collect the temperature information at the position thereof, and the needle body 101 is provided with a through hole penetrating through both ends thereof, a signal cable 103 is arranged in the through hole, one end of the signal cable 103 is connected with the temperature sensor 102, and the other end thereof can be connected with the data processing module 2, so as to transmit the temperature information collected by the temperature sensor 102 to the data processing module 2, the data processing module 2 can compare the real-time transmitted temperature information, and determine whether the metal melt flows through the position according to whether the temperature changes, so as to confirm whether the metal melt appears at the position.

[0027] Further preferably, the temperature sensor 102 is arranged inside the through hole of the needle body 101, and is arranged close to the first end of the needle body 101, so that the first end of the needle body 101 is formed with an opening, and the metal melt can flow into the opening and contact the temperature sensor 102, so that the temperature sensor 102 can collect the temperature of the metal melt.

[0028] Further, after the die casting operation is completed, the metal melt is cooled in the opening and forms residues, and then traces are left on the die casting, which can be removed by finishing in the later period.

[0029] Further, the pressure sensor 104 is further arranged at the second end of the needle body 101, the pressure sensor 104 comprises a fixed end and a sensing end, wherein the fixed end of the pressure sensor 104 is fixedly connected with the movable die 7, and the sensing end thereof abuts against the second end of the needle body 101, and the sensing end can limit the position of the needle body 101, so as to ensure that the position of the needle body 101 in the axial direction is certain, when the metal melt flows through the needle body 101, the pressure sensor 104 can detect the pressure of the metal melt applied to the needle body 101.

[0030] Further preferably, the type needle mounting position 8 on the movable die 7 is a stepped hole, wherein the small-diameter end of the stepped hole can pass through the needle body 101, and the large-diameter end of the stepped hole is provided with the pressure sensor 104, and the fixed end of the pressure sensor 104 can be fixedly connected with the step surface of the stepped hole, and the sensing end thereof abuts against the needle body 101.

[0031] In another preferred embodiment, a limiting plate is arranged corresponding to the type needle mounting position 8, after the needle body 101 is installed, the pressure sensor 104 is installed, so as to arrange the pressure sensor 104 between the limiting plate and the needle body 101, thereby realizing pressure detection.

[0032] Further, the monitoring needle 1 further comprises an integrated joint 106, one end of the integrated joint 106 is connected with the pressure sensor 104 and the signal cable 103 respectively, and the other end is connected with the data processing module 2, the integrated joint 106 can integrate and transmit the pressure information and the temperature information to the data processing module 2.

[0033] Further, the temperature sensor 102 is a thermocouple probe, which can be in contact with the metal melt to collect the temperature signal of the metal melt and convert the temperature signal into an electric signal to be sent to the data processing module 2, thereby realizing temperature information collection, and the signal cable 103 is preferably a thermocouple lead.

[0034] Further, the outer periphery of the signal cable 103 is provided with a high-temperature-resistant sealing layer 105, which can be arranged on the inner peripheral wall surface of the needle body 101, used to isolate the influence of the metal melt temperature on the signal, and also can prevent the metal melt from entering the through hole from the gap between the temperature sensor 102 and the needle body 101, so as to isolate the internal cavity of the needle body 101 from the cavity and protect the signal cable 103. Preferably, the high-temperature-resistant sealing layer 105 is made of insulating ceramic material.

[0035] Further, the data processing module 2 encodes each monitoring needle 1 and associates each monitoring needle 1 with the point position monitored by it, so that the data processing module 2 can determine whether there is metal melt at the point position according to the real-time change data collected by the monitoring needle 1, and sort the point positions according to the time sequence of detecting the metal melt at different point positions, and then connect them in this order to construct the metal melt flow trajectory.

[0036] Further, the display module 3 is a fixed display terminal and / or a handheld display terminal, wherein the fixed display terminal is a computer display screen or a display screen of a numerical control center, and the handheld display terminal can be a mobile phone or a tablet computer, so as to display the metal melt trajectory flow diagram, thereby facilitating personnel to view.

[0037] Further preferably, the data processing module 2 can also construct a cavity model according to the cavity structure, determine the positions of the point positions monitored by the monitoring needles 1 in the cavity model, and correspondingly generate the metal melt flow trajectory, and fit the metal melt trajectory with the cavity model to ensure that the metal melt flow trajectory coincides with the cavity, and when multiple metal melt injection ports are used for metal melt injection at the same time, the metal melt flow trajectory can be optimized according to the positional relationship of the point positions, helping the staff to understand the metal melt flow situation in the cavity.

[0038] As another aspect of the present application, a die casting system is also provided, which comprises a die casting device and a die cavity internal metal melt real-time monitoring device, and the die casting device comprises a mold; The mold comprises a fixed mold and a movable mold 7, and a needle mounting hole is formed on the movable mold 7 corresponding to the needle mounting hole, and the space between the movable mold 7 and the fixed mold is a cavity after the movable mold 7 and the fixed mold are combined, and the monitoring needle 1 is installed in the needle mounting hole, and the external structure of the needle body 101 is the same as that of the traditional needle structure to meet the different molding requirements of the die casting process.

[0039] Further, the monitoring needle 1 replaces the needle installation, and under the premise of ensuring normal die casting work, the metal melt trajectory in the cavity of the mold can also be monitored, and under this premise, the point setting of the monitoring needle 1 depends on the design of the needle installation position, and in the case of fewer needles arranged in the cavity (for example, one or two), the overall structure is smaller or not complex, and the cold shut phenomenon does not occur in the die casting process, so when considering the case of too fast or too slow filling of the metal melt, the needle structure arranged in the cavity is also more, so by replacing the needle with the monitoring needle 1, the metal melt trajectory can be well monitored.

[0040] Further, the die casting system further comprises a simulation module 4, which is used to build a metal melt trajectory simulation model and input the monitoring data of the monitoring points into the trajectory simulation model for simulation and further optimization of the simulation results.

[0041] At the same time, the monitoring information of multiple casting processes can be summarized into a data set, and the data set can be imported into the trajectory simulation model for multiple practices to improve the trajectory simulation accuracy of the trajectory simulation model.

[0042] On the other hand, the monitoring needle 1 does not monitor all points, so when simulating in the metal melt trajectory simulation model, the monitoring information (including time, temperature and pressure value) of the corresponding points can be input into the metal melt trajectory simulation model, and then the simulation results can be optimized. Further, the metal melt trajectory simulation model can be built by using existing mold flow software.

[0043] Further, the metal melt is preferably an aluminum alloy melt, and the type of metal melt needs to be determined when simulating and generating the metal melt trajectory.

[0044] Further, the die casting system further comprises a scanning module 5 and an analysis module 6, the scanning module 5 can scan the product (i.e. the die casting) formed by die casting, and the scanning information of the product can be transmitted to the analysis module 6, the analysis module 6 analyzes the scanning information to obtain the defect information of the product, so that the analysis module 6 can compare the monitoring information with the defect information of the product, especially the defect position and the related monitoring information collected by the corresponding points, to determine the influencing factors of the product defects, and then the die casting process can be optimized.

[0045] In one embodiment, the scanning module 5 detects that there is a cold shut phenomenon at a certain position of the product, and the analysis module 6 finds that the time point of the molten metal appearing at this position is later than the time point of the molten metal appearing at the surrounding positions by comparing the position information and the problem condition with the monitoring information, so as to determine that the defect at this position is caused by the smooth filling of the molten metal.

[0046] In another embodiment, the scanning module 5 can also detect other problems of the product, and the analysis module 6 can find the influencing factors by comparing the pressure data and the temperature data in the monitoring information with the problems of the product.

[0047] Further, the real-time monitoring method and subsequent application of the die casting system include the following steps: S1, the fixed mold and the movable mold 7 are closed to form a cavity between them, and the monitoring needle 1 is installed on the movable mold 7, so that the needle body 101 of the monitoring needle 1 is arranged in the cavity; S2, the metal melt is injected into the cavity through the ingate 9 to perform the die casting process; S3, the data processing module 2 receives the monitoring information collected by each monitoring needle 1 in real time, and feeds back to the operator through the display module 3; S4, when the monitoring needle 1 contacts the metal melt, the monitoring information uploaded by the monitoring needle 1 changes, and the data processing module 2 determines that the metal melt appears at this position, and forms the metal melt flow trajectory after the die casting process is completed; S5, the data collected by each monitoring needle 1 is input into the simulation module 4, and the simulation result is optimized; S6, the die casting part is scanned, and the defect information of the die casting part is compared with the data set collected by the monitoring needle 1 to find the influencing factors and optimize the die casting process.

[0048] Those skilled in the art can easily understand that the above description is only a preferred embodiment of the present application, and is not used to limit the present application, and any modification, equivalent replacement and improvement made within the spirit and principle of the present application should be included in the protection scope of the present application.

Claims

1. A real-time monitoring device for molten metal inside a mold, characterized in that, It includes a data processing module, a display module, and multiple monitoring needles that can be installed in the cavity; The cavity has multiple designated locations, and the monitoring needle is arranged at the designated locations to monitor whether molten metal appears at the designated locations and generate monitoring information, including the time point at which molten metal is detected at the designated locations. The data processing module is electrically connected to each of the monitoring needles and is used to receive the monitoring information collected by each of the monitoring needles, sort each of the designated positions according to the time sequence of their corresponding time points, and connect them in sequence to generate the flow trajectory of molten metal. The display module is electrically connected to the data processing module and is used to display the flow trajectory of the molten metal.

2. The real-time monitoring device for molten metal inside the mold according to claim 1, wherein, The monitoring needle includes a needle body and a temperature sensor disposed at the first end of the needle body; The needle body has through holes extending through both ends. A signal cable is threaded through the through holes. One end of the signal cable is connected to the temperature sensor, and the other end is connected to the data processing module to transmit the temperature information collected by the temperature sensor to the data processing module.

3. The real-time monitoring device for molten metal inside the mold according to claim 2, wherein, The temperature sensor is disposed in the through hole and is located near the first end of the needle body, so that an opening is formed at the first end of the needle body, and the molten metal can enter the opening and come into contact with the temperature sensor.

4. The real-time monitoring device for molten metal inside the mold according to claim 2 or 3, wherein, The monitoring needle also includes a pressure sensor. The fixed end of the pressure sensor is fixedly connected to the mold, and its sensing end abuts against the second end of the needle body to detect the pressure of the molten metal on the needle body.

5. The real-time monitoring device for molten metal inside the mold according to claim 4, wherein, The monitoring needle also includes an integrated connector, one end of which is connected to the pressure sensor and the signal cable respectively, and the other end is connected to the data processing module to integrate the temperature and pressure information and transmit it to the data processing module.

6. The real-time monitoring device for molten metal inside the mold according to claim 2 or 3, wherein, The temperature sensor is a thermocouple probe; And / or, The signal cable is provided with a high-temperature resistant sealing layer on its outer periphery.

7. The real-time monitoring device for molten metal inside the mold according to any one of claims 1 to 3, wherein, The display module is a fixed display terminal and / or a handheld display terminal.

8. A die-casting system, characterized in that, The device includes a real-time monitoring device for molten metal inside the mold as described in any one of claims 1 to 7, and also includes a die-casting device; The die-casting device includes a fixed mold and a moving mold. The fixed mold and the moving mold are closed to form a cavity. The moving mold has a pin mounting position for mounting the monitoring pin to monitor the molten metal inside the cavity during the die-casting process.

9. The die-casting system according to claim 8, wherein, It also includes a simulation module for building a simulation model of the trajectory of molten metal; The simulation module is electrically connected to the data processing module and is used to receive the monitoring information and import the monitoring information collected by each monitoring needle into the simulation model for simulation to optimize the simulation results.

10. The die-casting system according to claim 8 or 9, wherein, It also includes a scanning module and an analysis module electrically connected to the scanning module. The scanning module scans the die-cast product and transmits the scanned information of the product to the analysis module. The analysis module analyzes the scanned information to obtain product defect information; The analysis module is electrically connected to the data processing module and is used to receive the monitoring information. The analysis module compares the monitoring information with the product defect information to identify the influencing factors of product defects, so as to optimize the die-casting process.

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