Intelligent cooling control system for temperature field of large mold

Abstract

This invention relates to the field of low-pressure casting technology and provides an intelligent cooling control system for the temperature field of large molds. The system includes a sensing module, a PLC controller, an execution module, and a human-machine interface module. The sensing module further includes flow sensors and pressure sensors installed at the inlets of corresponding independent cooling circuits. The execution module includes a multi-channel independent adjustment unit, a high-response proportional control valve, a cooling medium pre-cooling device, a medium delivery pump, and a heat exchanger. The input end of the cooling medium pre-cooling device is connected to the outlet of each group of independent cooling circuits via a medium pipeline, and its output end is connected to the input end of the heat exchanger. This system monitors the temperature of multiple key points of the mold in real time and dynamically adjusts the flow rate and temperature of each group of independent cooling circuits based on artificial intelligence algorithms. This achieves precise, uniform, and efficient control of the mold temperature field, effectively eliminating hot spots, improving product quality, reducing production cycle time, and saving energy.

Description

Technical Field

[0001] This invention relates to the field of low-pressure casting technology, and more specifically, to an intelligent cooling control system for the temperature field of large molds. Background Technology

[0002] Low-pressure casting is a precision casting method in which molten metal is smoothly filled into the mold cavity from bottom to top through riser pipes and gating under relatively low pressure, and then solidified under pressure. After low-pressure casting is completed, pressure relief and cooling are required. The traditional cooling method for large molds (such as car bumpers, dashboards, and large die-casting molds) is to directly input the cooling medium into the cooling channel inside the mold.

[0003] However, due to the different heat dissipation conditions in different areas of the mold, traditional cooling methods result in large temperature differences on the surface of the cavity, causing defects such as product warping, shrinkage marks, and high internal stress. Traditional cooling methods are based on PID control at a single temperature measurement point, which has a slow response and cannot cope with the complex thermal dynamic changes during production. Traditional cooling systems usually operate at high power and lack the ability to adjust on demand, failing to achieve precise, uniform, and efficient control of the mold temperature field, resulting in energy waste. At the same time, for the circulating cooling of the cooling medium, the high-temperature medium after heat exchange inside the mold is directly input into the heat exchanger for heat exchange and cooling without adding a pre-cooling device during the transportation process, which increases the workload of the heat exchanger. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the present invention aims to provide an intelligent cooling control system for the temperature field of large molds. By monitoring the temperature of multiple key points of the mold in real time, and dynamically adjusting the flow rate and temperature of each independent cooling circuit based on artificial intelligence algorithms, the system achieves precise, uniform, and efficient control of the mold temperature field. This replaces the traditional method of controlling single-point temperature, enabling control of the entire temperature field, effectively eliminating hot spots, improving product quality, reducing production cycle time, and saving energy.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] A large-scale mold temperature field intelligent cooling control system includes a sensing module, a PLC controller, an execution module, and a human-machine interface module. The PLC controller's input terminal is electrically connected to the sensing module, and its output terminal is electrically connected to the execution module. The sensing module includes multiple sets of high-temperature resistant and impact-resistant thermocouples embedded at key thermal nodes of the mold, forming a dense temperature detection network for collecting temperature data within the mold's three-dimensional space. The sensing module also includes flow sensors and pressure sensors installed at the inlets of corresponding independent cooling circuits to detect the real-time status of the cooling medium. The PLC controller includes a data acquisition unit and a data processing unit. The data processing unit operates... AI intelligent control algorithm; the AI ​​intelligent control algorithm includes a temperature field reconstruction model, a model predictive control subunit, and an adaptive adjustment subunit; the model predictive control subunit uses the thermodynamic model of the built-in mold in the algorithm to predict the temperature change trend in the future and calculate the optimal control strategy in advance; the execution module includes a multi-channel independent adjustment unit, a high-response proportional control valve, a cooling medium precooling device, a medium delivery pump, and a heat exchanger; the input end of the cooling medium precooling device is connected to the outlet of each group of independent cooling loops through a medium pipeline, and its output end is connected to the input end of the heat exchanger; the output end of the heat exchanger is connected to the inlet of each group of independent cooling loops through a medium delivery pump.

[0007] The invention is further configured such that: the data acquisition unit is used to acquire data from each group of thermocouples, flow sensors, and pressure sensors, and continuously upload the data to the PLC controller; the multi-channel independent adjustment unit includes multiple cooling control devices adapted to the independent cooling channels corresponding to the mold; the high-response proportional regulating valve is used to precisely control the cooling water flow rate of each independent cooling circuit; and the PLC controller sends control commands to each group of high-response proportional regulating valves to dynamically adjust the flow rate and pressure of the corresponding independent cooling circuit.

[0008] The present invention is further configured such that: the cooling control device includes a substrate layer, a flow channel layer, and a cover plate layer; the substrate layer is an aluminum alloy plate used for installation and heat dissipation; the flow channel layer is a stainless steel plate, with internal flow channels adapted to the corresponding individual cooling circuit and a valve cavity for installing a high-response proportional regulating valve milled by a CNC machining center; the cover plate layer is a transparent polycarbonate plate.

[0009] The present invention is further configured such that: the temperature field reconstruction model is based on each set of thermocouple data, and through digital twin technology, it constructs and updates the temperature field cloud map of the mold in virtual space in real time, intuitively displaying "hot spots" and "cold spots"; the adaptive adjustment subunit is used to learn the molding cycle of different products and different materials, and automatically optimize the control parameters.

[0010] The present invention is further configured such that the human-computer interaction module is used to display temperature field cloud map, status of each cooling circuit, historical curves and alarm information.

[0011] The present invention is further configured such that: the cooling medium precooling device includes an outer conical shell, a middle conical shell, and an inner conical shell arranged coaxially; the top of the outer conical shell is threadedly connected to the top of the middle conical shell; the bottom of the inner conical shell is threadedly connected to the bottoms of the middle conical shell and the outer conical shell respectively; a fixing seat is screwed to the top of the outer conical shell; an exhaust fan is fixedly installed on the top of the fixing seat; and a spray device is installed above the fixing seat.

[0012] The present invention is further configured such that: the outer conical shell, the middle conical shell, and the inner conical shell are all hollow structures; a threaded inner tube is fixed to the top of the outer conical shell; a threaded outer tube communicating with the interior of the outer conical shell is fixed to the top of the outer conical shell; the bottom surface of the threaded outer tube is open; a threaded sleeve that is threaded into the interior of the threaded outer tube is fixed to the top of the middle conical shell; the interior of the threaded sleeve communicates with the interior of the outer conical shell, and its top is open; an outer ring seat is connected to the bottom of the middle conical shell; a communicating groove is formed on the inner wall of the outer ring seat near its bottom.

[0013] The invention is further configured as follows: a threaded cylinder communicating with the interior is fixed to the top of the inner conical shell; the threaded cylinder is threadedly connected to the threaded inner tube; a drain pipe communicating with the threaded cylinder is fixed to the top of the inner conical shell; an inner ring seat is connected to the bottom of the inner conical shell; a support seat is fixed to the outer wall of the inner ring seat; an outer ring seat is threaded between the inner ring seat and the support seat; a guide groove is formed near the top of the outer wall of the inner ring seat; a screw is fixed to the top of the threaded cylinder; a fastening nut is threaded onto the screw; a stud is fixed to the top of the fixed seat and threadedly connected to the threaded inner tube; an insertion hole is formed inside the stud to engage with the screw; and inspection ports are symmetrically formed on the periphery of the fixed seat.

[0014] The invention is further configured such that: a plurality of hollow guide shrouds communicating with the interior are uniformly fixed from top to bottom on the outer wall of the outer conical shell; a plurality of guide pipes are uniformly fixed through the interior of the hollow guide shrouds; a branch pipe is provided connecting one end of the hollow guide shroud to the interior of the outer conical shell; a plurality of medium inlet pipes are provided near the bottom of the outer wall of the outer conical shell; each medium inlet pipe is connected to the outlet of a corresponding independent cooling circuit; an annular partition is fixed inside the outer conical shell near the other end of the hollow guide shrouds; the medium inlet pipes, the outer conical shell, each set of hollow guide shrouds, the middle conical shell, the interior of the inner conical shell, and the drain pipe form a cooling medium transport channel.

[0015] The invention is further configured such that: a warm water outlet pipe is uniformly fixed on the inner bottom surface of the support base; several connecting pipes are obliquely inserted through the outer wall of the middle conical shell near its top and the outer wall of the inner conical shell near its bottom; a liquid collection chamber connected to the corresponding connecting pipe is fixed on the inner wall of the inner conical shell near its bottom; a cold water inlet pipe is connected to the bottom of the liquid collection chamber; a cooling water conveying channel is formed between the cold water inlet pipe, the outer wall of the inner conical shell and the inner wall of the middle conical shell, the outer wall of the middle conical shell and the inner wall of the outer conical shell, and the warm water outlet pipe; a base is fixed at the bottom of the inner conical shell; a medium transfer cavity is formed between the inner wall of the inner conical shell and the base; and a conveying pipe connected to the inlet of the heat exchanger is connected to the bottom surface of the base.

[0016] The advantages of this invention are:

[0017] 1. This invention monitors the temperature of multiple key points of the mold in real time and dynamically adjusts the flow and temperature of each independent cooling circuit based on artificial intelligence algorithms. This achieves precise, uniform, and efficient control of the mold temperature field, replacing the traditional method of controlling single-point temperature. It controls the entire temperature field, effectively eliminates hot spots, improves product quality, reduces production cycle time, and saves energy.

[0018] 2. The cooling medium precooling device of the present invention consists of an outer conical shell, a middle conical shell and an inner conical shell arranged coaxially, forming a cooling medium conveying channel and a cooling water conveying channel with opposite conveying directions, so as to precool the high temperature medium after heat exchange. The precooled high temperature medium is then conveyed to the heat exchanger for heat exchange and cooling, which reduces the workload of the heat exchanger and improves the circulation cooling efficiency. Attached Figure Description

[0019] Figure 1 This is a framework diagram of the intelligent cooling control system for the temperature field of large molds according to the present invention.

[0020] Figure 2 This is a framework diagram of the AI ​​intelligent control algorithm of the present invention.

[0021] Figure 3 This is a flowchart illustrating the cooling zone process of the large mold according to the present invention.

[0022] Figure 4 This is a schematic diagram of the cooling medium precooling device of the present invention.

[0023] Figure 5 For the present invention Figure 4 Enlarged view of region A.

[0024] Figure 6 For the present invention Figure 4 Enlarged view of region B.

[0025] Figure 7This is a schematic diagram of the cooling control device of the present invention.

[0026] Figure 8 This is a cross-sectional view of the external conical shell of the present invention.

[0027] Figure 9 For the present invention Figure 8 A structural diagram from a frontal viewpoint.

[0028] Figure 10 This is a cross-sectional view of the central conical shell of the present invention.

[0029] Figure 11 For the present invention Figure 10 A structural diagram from a frontal viewpoint.

[0030] Figure 12 This is a cross-sectional view of the internal conical shell of the present invention.

[0031] Figure 13 For the present invention Figure 12 A structural diagram from a frontal viewpoint.

[0032] Figure 14 This is a schematic diagram of the structure of the fixing base of the present invention.

[0033] In the diagram: 1. Cooling medium precooling device; 2. Cooling control device; 3. Substrate layer; 4. Flow channel layer; 5. Cover plate layer; 6. Outer conical shell; 7. Middle conical shell; 8. Inner conical shell; 9. Fixing seat; 10. Threaded inner tube; 11. Threaded outer tube; 12. Threaded sleeve; 13. Outer ring seat; 14. Connecting groove; 15. Threaded cylinder; 16. Drain pipe; 17. Inner ring seat; 18. Support seat; 19. Guide groove; 20. Screw; 21. Fastening nut; 22. Stud; 23. Insertion hole; 24. Inspection port; 25. Hollow guide shroud; 26. Guide pipe; 27. Branch pipe; 28. Medium inlet pipe; 29. ​​Warm water outlet pipe; 30. Connecting pipe; 31. Liquid collection chamber; 32. Cold water inlet pipe; 33. Base; 34. Conveying pipe; 35. Annular partition. Detailed Implementation

[0034] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0035] It should be noted that, unless otherwise specified, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0036] In this invention, unless otherwise stated, the directional terms such as "up" and "down" generally refer to the directions shown in the accompanying drawings, or to the vertical, perpendicular, or gravitational direction; similarly, for ease of understanding and description, "left" and "right" generally refer to the left and right shown in the accompanying drawings; "inner" and "outer" refer to the inner and outer contours of each component itself, but the above directional terms are not intended to limit this invention.

[0037] Example 1, please refer to Figures 1-14 The present invention provides the following technical solutions:

[0038] The intelligent cooling control system for the temperature field of large molds specifically includes a sensing module, a PLC controller, an execution module, and a human-machine interface module. The input terminal of the PLC controller is electrically connected to the sensing module, and its output terminal is electrically connected to the execution module. The sensing module includes multiple sets of high-temperature resistant and impact-resistant thermocouples embedded at key thermal nodes of the mold, forming a dense temperature detection network for collecting temperature data in the three-dimensional space of the mold. The sensing module also includes flow sensors and pressure sensors installed at the inlets of corresponding independent cooling circuits for detecting the real-time status of the cooling medium.

[0039] The PLC controller includes a data acquisition unit and a data processing unit. The data processing unit runs an AI intelligent control algorithm. The AI ​​intelligent control algorithm includes a temperature field reconstruction model, a model predictive control subunit, and an adaptive adjustment subunit. The model predictive control subunit uses the thermodynamic model of the built-in mold in the algorithm to predict the temperature change trend in the future and calculate the optimal control strategy in advance.

[0040] The execution module includes a multi-channel independent control unit, a high-response proportional control valve, a cooling medium precooling device 1, a medium transfer pump, and a heat exchanger. The input end of the cooling medium precooling device 1 is connected to the outlet of each group of independent cooling circuits via a medium pipeline, and its output end is connected to the input end of the heat exchanger. The output end of the heat exchanger is connected to the inlet of each group of independent cooling circuits via the medium transfer pump.

[0041] Working principle of this embodiment:

[0042] By monitoring the temperature of multiple key points of the mold in real time and dynamically adjusting the flow and temperature of each independent cooling circuit based on artificial intelligence algorithms, precise, uniform and efficient control of the mold temperature field is achieved. This replaces the traditional method of controlling single-point temperature, enabling control of the entire temperature field, effectively eliminating hot spots, improving product quality, reducing production cycle and saving energy.

[0043] The cooling medium precooling device 1 consists of an outer conical shell 6, a middle conical shell 7, and an inner conical shell 8 arranged coaxially, forming a cooling medium conveying channel and a cooling water conveying channel with opposite conveying directions. This enables the precooling of the high-temperature medium after heat exchange. The precooled high-temperature medium is then conveyed to the heat exchanger for heat exchange and cooling, reducing the workload of the heat exchanger and improving the circulation cooling efficiency.

[0044] Example 2, please refer to Figures 1-14 This second embodiment is an improvement on the first embodiment as follows: Specifically, the data acquisition unit is used to collect data from each group of thermocouples, flow sensors, and pressure sensors, and continuously upload the data to the PLC controller; the multi-channel independent adjustment unit includes multiple cooling control devices 2 adapted to the independent cooling channels corresponding to the mold; the high-response proportional regulating valve is used to precisely control the cooling water flow of each independent cooling circuit; the PLC controller sends control commands to each group of high-response proportional regulating valves to dynamically adjust the flow and pressure of the corresponding independent cooling circuit.

[0045] The thermocouple is directly inserted into the temperature sensing hole of the runner layer and filled with thermal paste, adhering closely to the coolant. For the temperature sensing hole, a blind hole is drilled on the back or side of the mold (non-cavity surface) until it stops 2.5-4.0mm away from the cavity. The blind hole is cleaned to ensure that the bottom of the hole is flat, clean, and free of iron filings and oil. The temperature end of the thermocouple is inserted into the bottom of the hole, and thermal paste is injected into the hole to ensure that the temperature sensing end of the thermocouple is completely covered, expelling air gaps. The filling of the thermal paste improves the heat conduction efficiency.

[0046] The cooling control device 2 includes a substrate layer 3, a flow channel layer 4, and a cover plate layer 5; the substrate layer 3 is an aluminum alloy plate used for installation and heat dissipation; the flow channel layer 4 is a stainless steel plate, with internal flow channels adapted to the corresponding individual cooling circuit and valve chambers for installing high-response proportional control valves milled by a CNC machining center; the cover plate layer 5 is a transparent polycarbonate plate.

[0047] The high-response proportional control valve is threaded inside the valve cavity. The flow sensor is a turbine flow meter installed at the outlet end of the high-response proportional control valve to ensure measurement accuracy. Two sets of pressure sensors are installed at the inlet and outlet of the corresponding high-response proportional control valve to monitor the pressure difference before and after the high-response proportional control valve. The internal flow channel is formed by drilling and milling grooves on a stainless steel plate, replacing the complex external pipe connection, reducing leakage points, and making the overall structure compact and fast-responding.

[0048] The temperature field reconstruction model is based on the thermocouple data of each group. Through digital twin technology, it constructs and updates the temperature field cloud map of the mold in virtual space in real time, intuitively displaying "hot spots" and "cold spots". The adaptive adjustment subunit is used to learn the molding cycle of different products and materials and automatically optimize the control parameters.

[0049] Independent cooling circuits are cooling pipes that are not interconnected with each other at the partitions inside the mold. Each cooling circuit has a corresponding inlet and outlet, and is individually connected to an independent control channel to achieve precise and independent adjustment of the cooling flow and temperature of the circuit area.

[0050] The determination of individual cooling circuits is achieved through mold flow analysis using CAE software. This involves obtaining temperature distribution cloud maps and cooling time analysis of the mold to identify obvious "hot spots" (high-temperature zones) and "cold spots" (low-temperature zones). Cooling zones are divided based on the temperature distribution map, and a continuous hot spot area is designed as an independent cooling circuit. The gate area is the hottest area and requires the strongest cooling, necessitating a separate cooling circuit. Thick-walled areas require strong cooling to prevent shrinkage marks, also requiring a separate cooling circuit. Multiple circuits are designed sequentially for the main body of the product. The final filling area needs to ensure smooth melt filling or fusion, which may require weaker cooling or even heating, necessitating a separate cooling circuit. Spiral heating wires are added sequentially to this cooling circuit. Thermocouples are allocated within the control area of ​​each cooling circuit. The cooling circuits are routed as parallel as possible to the cavity surface and maintained at a constant distance, typically 1.5-2.5 times the diameter of the cooling circuit.

[0051] Thermocouple installation locations: The area near the gate is where the melt first enters, with the highest temperature and pressure; the last filling area (the area where the melt finally reaches and fills the cavity, also known as the weld line area) is most prone to short shots and weld lines due to excessively rapid cooling, requiring close monitoring to ensure sufficient temperature; areas with thick product walls dissipate heat slowly, making them prone to shrinkage marks; the distance between the thermocouple installation location and the cavity surface should be controlled between 2.5-4.0mm. Too close will weaken the cavity strength and cause excessive temperature fluctuations, while too far will result in a delayed response, and the measured value will not accurately reflect the cavity surface temperature; the thermocouple should be installed in the middle of two separate cooling circuits to measure the actual perceived temperature of the mold.

[0052] The human-machine interface module is used to display temperature field cloud map, status of each cooling circuit, historical curves, and alarm information.

[0053] Working principle of this embodiment two:

[0054] Data acquisition: Each group of thermocouples, flow sensors, and pressure sensors continuously uploads data to the PLC controller.

[0055] State Analysis and Prediction: The AI ​​intelligent control algorithm receives data, reconstructs the current mold temperature field, and predicts the temperature change in the next cycle based on the thermodynamic model.

[0056] Optimization decision: The algorithm compares the predicted results with the set target temperature curve to calculate the optimal control quantity (the opening degree of each group of high-response proportional control valves and the pump speed of the medium delivery pump) that makes the temperature of the entire cavity most uniform and closest to the ideal target.

[0057] Precise execution: The PLC controller sends control commands to each group of high-response proportional control valves, dynamically adjusting the flow and pressure of the corresponding independent cooling circuits.

[0058] Continuous iteration: The above process is repeated in each control cycle to form a closed-loop, dynamic, adaptive precision control system.

[0059] This invention employs model predictive control and digital twin technology to achieve a shift from passive response to active prediction. Compared to traditional PID control, this invention significantly improves control accuracy and response speed, reduces reliance on operator experience, supplies cooling energy on demand, avoids overcooling, shortens cooling time, and improves production efficiency.

[0060] Example 3, please refer to Figures 1-14 This embodiment three is an improvement on embodiment two. Specifically, the cooling medium precooling device 1 includes an outer conical shell 6, a middle conical shell 7, and an inner conical shell 8 arranged coaxially. The top of the outer conical shell 6 is threadedly connected to the top of the middle conical shell 7. The bottom of the inner conical shell 8 is threadedly connected to the bottom of the middle conical shell 7 and the bottom of the outer conical shell 6, respectively. A fixing seat 9 is screwed to the top of the outer conical shell 6. An exhaust fan is fixedly installed on the top of the fixing seat 9. A spray device is installed above the fixing seat 9.

[0061] The outer conical shell 6, the middle conical shell 7, and the inner conical shell 8 are all hollow structures. A threaded inner tube 10 is fixed to the top of the outer conical shell 6. A threaded outer tube 11 communicating with the interior of the outer conical shell 6 is fixed to the top of the outer conical shell 6. The bottom surface of the threaded outer tube 11 is open. A threaded sleeve 12 that is threaded into the interior of the threaded outer tube 11 is fixed to the top of the middle conical shell 7. The interior of the threaded sleeve 12 communicates with the interior of the outer conical shell 6, and its top is open. An outer ring seat 13 is connected to the bottom of the middle conical shell 7. A connecting groove 14 is opened on the inner wall of the outer ring seat 13 near its bottom.

[0062] The top of the inner conical shell 8 is fixed with a threaded cylinder 15 communicating with its interior; the threaded cylinder 15 is threadedly connected to the threaded inner tube 10; the top of the inner conical shell 8 is fixed with a drain pipe 16 communicating with the threaded cylinder 15; the bottom of the inner conical shell 8 is connected with an inner ring seat 17; a support seat 18 is fixed to the outer wall of the inner ring seat 17; an outer ring seat 13 is threaded between the inner ring seat 17 and the support seat 18; a guide groove 19 is opened on the outer wall of the inner ring seat 17 near its top; a screw 20 is fixed to the top of the threaded cylinder 15; a fastening nut 21 is threaded onto the screw 20; a stud 22 is fixed to the top of the fixed seat 9 and threadedly connected to the threaded inner tube 10; an insertion hole 23 is opened inside the stud 22 to engage with the screw 20; inspection ports 24 are symmetrically opened on the sides of the fixed seat 9.

[0063] A number of hollow guide shrouds 25, which communicate with the interior of the outer conical shell 6, are uniformly fixed from top to bottom on the outer wall. A number of guide pipes 26 are uniformly fixed through the interior of the hollow guide shrouds 25. A branch pipe 27 is provided between one end of the hollow guide shrouds 25 and the interior of the outer conical shell 6. A number of medium inlet pipes 28 are provided near the bottom of the outer wall of the outer conical shell 6. Each medium inlet pipe 28 is connected to the outlet of the corresponding independent cooling circuit. An annular baffle 35 is fixed at the other end of the interior of the outer conical shell 6 near the hollow guide shrouds 25. The medium inlet pipes 28, the outer conical shell 6, each group of hollow guide shrouds 25, the middle conical shell 7, the interior of the inner conical shell 8, and the drain pipe 16 form a cooling medium transport channel.

[0064] A warm water outlet pipe 29 is uniformly fixed on the inner bottom surface of the support base 18; several connecting pipes 30 are inclinedly installed on the outer wall of the middle conical shell 7 near its top and on the outer wall of the inner conical shell 8 near its bottom; a liquid collection chamber 31 connected to the corresponding connecting pipe 30 is fixed on the inner wall of the inner conical shell 8 near its bottom; a cold water inlet pipe 32 is connected to the bottom of the liquid collection chamber 31; a cooling water conveying channel is formed between the cold water inlet pipe 32, the outer wall of the inner conical shell 8 and the inner wall of the middle conical shell 7, the outer wall of the middle conical shell 7 and the inner wall of the outer conical shell 6, and the warm water outlet pipe 29; a base 33 is fixed on the bottom of the inner conical shell 8; a medium transfer cavity is formed between the inner wall of the inner conical shell 8 and the base 33; a conveying pipe 34 connected to the heat exchanger inlet is connected to the bottom surface of the base 33.

[0065] Working principle of this embodiment three:

[0066] Cooling medium delivery channel: separate cooling circuit medium outlet → medium inlet pipe 28 → outer conical shell 6 (hollow guide shroud 25 from bottom to top) → threaded outer pipe 11 with internal threaded sleeve 12 → middle conical shell 7 → connecting groove 14 on outer ring seat 13 → guiding groove 19 on inner ring seat 17 → inner conical shell 8 → drain pipe 16 → medium transfer chamber → delivery pipe 34 → heat exchanger → independent cooling circuit medium inlet.

[0067] Cooling water delivery channel: cold water inlet pipe 32 → liquid collection chamber 31 → connecting pipe 30 on the inner conical shell 8 → between the outer wall of the inner conical shell 8 and the inner wall of the middle conical shell 7 → connecting pipe 30 on the middle conical shell 7 → between the outer wall of the middle conical shell 7 and the inner wall of the outer conical shell 6 → warm water outlet pipe 29.

[0068] The cooling medium precooling device 1 consists of an outer conical shell, a middle conical shell, and an inner conical shell arranged coaxially, which increases the heat exchange path between the cooling medium and the cooling water and improves the precooling effect of the cooling medium. The cooling medium in the cooling medium conveying channel flows in the opposite direction to the cooling water in the cooling water conveying channel, which further improves the precooling effect of the cooling medium. The outer conical shell, the middle conical shell, and the inner conical shell are screwed together to facilitate the disassembly and cleaning of the outer conical shell, the middle conical shell, and the inner conical shell, thus improving the practicality of the cooling medium precooling device 1.

[0069] By controlling the start of the exhaust fan, air cooling is achieved for the outer conical shell 6 and the hollow guide shroud 25, further improving the cooling effect on the cooling medium flowing inside the outer conical shell 6 and the hollow guide shroud 25. Cooling water is sprayed into the hollow guide shroud 25 at the highest point through the spray device. The cooling water enters the inner surface of the corresponding hollow guide shroud 25 through the guide pipe 26 and then flows into the lower hollow guide shroud 25, and so on, achieving water cooling for the outer wall of the outer conical shell 6 and the inner and outer surfaces of the hollow guide shroud 25, further improving the cooling effect on the cooling medium flowing inside the outer conical shell 6 and the hollow guide shroud 25.

[0070] The high-temperature medium after heat exchange is pre-cooled by the cooling medium pre-cooling device 1. The pre-cooled high-temperature medium is then transported to the heat exchanger for heat exchange and cooling, which reduces the workload of the heat exchanger and improves the circulation cooling efficiency.

[0071] Obviously, the embodiments described above are merely some, not all, embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention.

[0072] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0073] It should be noted that the terms "first," "second," etc., used in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in sequences other than those illustrated or described herein.

[0074] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

[0075] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A large mold temperature field intelligent cooling control system, characterized in that: It includes a sensing module, a PLC controller, an execution module, and a human-machine interface module; the input terminal of the PLC controller is electrically connected to the sensing module, and its output terminal is electrically connected to the execution module. The sensing module includes multiple sets of high-temperature resistant and impact-resistant thermocouples embedded in key thermal nodes of the mold, forming a dense temperature detection network for collecting temperature data in the three-dimensional space of the mold. The sensing module also includes a flow sensor and a pressure sensor installed at the inlet of the corresponding independent cooling circuit, for detecting the real-time status of the cooling medium. The PLC controller includes a data acquisition unit and a data processing unit; the data processing unit runs an AI intelligent control algorithm. The AI ​​intelligent control algorithm includes a temperature field reconstruction model, a model predictive control subunit, and an adaptive adjustment subunit. The model predictive control subunit uses the thermodynamic model of the built-in mold in the algorithm to predict the temperature change trend in the future and calculate the optimal control strategy in advance. The execution module includes a multi-channel independent adjustment unit, a high-response proportional control valve, a cooling medium precooling device (1), a medium delivery pump, and a heat exchanger; the input end of the cooling medium precooling device (1) is connected to the outlet of each group of independent cooling circuits through a medium pipeline, and its output end is connected to the input end of the heat exchanger; the output end of the heat exchanger is connected to the inlet of each group of independent cooling circuits through a medium delivery pump. The cooling medium precooling device (1) includes an outer conical shell (6), a middle conical shell (7), and an inner conical shell (8) arranged coaxially; the top of the outer conical shell (6) is threadedly connected to the top of the middle conical shell (7); the bottom of the inner conical shell (8) is threadedly connected to the bottom of the middle conical shell (7) and the bottom of the outer conical shell (6), respectively. The outer conical shell (6), the middle conical shell (7), and the inner conical shell (8) are all hollow structures. A threaded inner tube (10) is fixed to the top of the outer conical shell (6). A threaded outer tube (11) communicating with the interior of the outer conical shell (6) is fixed to the top of the inner part of the outer conical shell (6). The bottom surface of the threaded outer tube (11) is open. A threaded sleeve (12) that is threaded into the interior of the threaded outer tube (11) is fixed to the top of the middle conical shell (7). The interior of the threaded sleeve (12) communicates with the interior of the outer conical shell (6), and its top is open. An outer ring seat (13) is connected to the bottom of the middle conical shell (7). A communicating groove (14) is opened on the inner wall of the outer ring seat (13) near its bottom. The top of the inner conical shell (8) is fixed with a threaded cylinder (15) communicating with its interior; the threaded cylinder (15) is threadedly connected to the threaded inner tube (10); the top of the inner conical shell (8) is fixed with a drain pipe (16) communicating with the threaded cylinder (15); the bottom of the inner conical shell (8) is connected with an inner ring seat (17); a support seat (18) is fixed on the outer wall of the inner ring seat (17); the outer ring seat (13) is threaded between the inner ring seat (17) and the support seat (18); a guide groove (19) is opened on the outer wall of the inner ring seat (17) near its top. The outer conical shell (6) has several hollow guide hoods (25) uniformly fixed from top to bottom on its outer wall, which are connected to its interior; several guide pipes (26) are uniformly fixed through the interior of the hollow guide hoods (25); a branch pipe (27) is provided between one end of the hollow guide hood (25) and the interior of the outer conical shell (6); several medium inlet pipes (28) are provided near the bottom of the outer wall of the outer conical shell (6); each medium inlet pipe (28) is connected to the outlet of the corresponding independent cooling circuit; an annular partition (35) is fixed at the other end of the interior of the outer conical shell (6) near the hollow guide hood (25); the medium inlet pipes (28), the outer conical shell (6), each set of hollow guide hoods (25), the middle conical shell (7), the inner conical shell (8), and the drain pipe (16) form a cooling medium transport channel; A warm water outlet pipe (29) is uniformly fixed on the inner bottom surface of the support base (18); several connecting pipes (30) are inclinedly installed on the outer wall of the middle conical shell (7) near its top and the outer wall of the inner conical shell (8) near its bottom; a liquid collection chamber (31) connected to the corresponding connecting pipe (30) is fixed on the inner wall of the inner conical shell (8) near its bottom; a cold water inlet pipe (32) is connected to the bottom of the liquid collection chamber (31); a cooling water conveying channel is formed between the cold water inlet pipe (32), the outer wall of the inner conical shell (8) and the inner wall of the middle conical shell (7), the outer wall of the middle conical shell (7) and the inner wall of the outer conical shell (6), and the warm water outlet pipe (29); a base (33) is fixed on the bottom of the inner conical shell (8); a medium transfer cavity is formed between the inner wall of the inner conical shell (8) and the base (33); a conveying pipe (34) connected to the heat exchanger inlet is connected to the bottom surface of the base (33).

2. The intelligent cooling control system for temperature field of large mold according to claim 1, characterized in that: The data acquisition unit is used to collect data from each group of thermocouples, flow sensors and pressure sensors, and continuously upload the data to the PLC controller; the multi-channel independent adjustment unit includes multiple cooling control devices (2) adapted to the independent cooling channels corresponding to the mold; the high-response proportional regulating valve is used to accurately control the cooling water flow of each independent cooling circuit; the PLC controller sends control commands to each group of high-response proportional regulating valves to dynamically adjust the flow and pressure of the corresponding independent cooling circuit.

3. The intelligent cooling control system for temperature field of large mold according to claim 2, characterized in that: The cooling control device (2) includes a substrate layer (3), a flow channel layer (4), and a cover plate layer (5); the substrate layer (3) is an aluminum alloy plate; the flow channel layer (4) is a stainless steel plate, with internal flow channels adapted to the corresponding individual cooling circuit and valve chambers for installing high-response proportional regulating valves milled by a CNC machining center; the cover plate layer (5) is a transparent polycarbonate plate.

4. The intelligent cooling control system for temperature field of large mold according to claim 3, characterized in that: The temperature field reconstruction model is based on the thermocouple data of each group. Through digital twin technology, it constructs and updates the temperature field cloud map of the mold in virtual space in real time, intuitively displaying "hot spots" and "cold spots". The adaptive adjustment subunit is used to learn the molding cycle of different products and materials and automatically optimize the control parameters.

5. The intelligent cooling control system for temperature field of large mold according to claim 4, characterized in that: The human-computer interaction module is used to display temperature field cloud map, status of each cooling circuit, historical curves, and alarm information.

6. The intelligent cooling control system for temperature field of large mold according to claim 5, characterized in that: The top of the outer conical shell (6) is screwed with a fixing seat (9); an exhaust fan is fixedly installed on the top of the fixing seat (9); a spray device is installed above the fixing seat (9).

7. The intelligent cooling control system for temperature field of large mold according to claim 6, characterized in that: The top of the threaded cylinder (15) is fixed with a screw (20); a fastening nut (21) is screwed onto the screw (20); the top of the fixed seat (9) is fixed with a stud (22) that is screwed onto the inner tube (10); the stud (22) has an insertion hole (23) inside that is engaged with the screw (20); and the fixed seat (9) has symmetrical inspection ports (24) on its periphery.

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