Automatic wire feeder for grain refinement process

Abstract

The invention discloses an automatic wire feeder for a grain refinement process, which relates to the technical field of wire feeders and comprises a mechanical execution system, an electrical control system and a central control unit. The mechanical execution system is sequentially provided with a discharging unit, a wire feeding driving unit and a guiding and feeding unit in the wire advancing direction. The electrical control system comprises a sensing module and a driving module; the central control unit is in communication connection with the sensing module and the driving module, and is configured to adjust a driving instruction in real time through a built-in control model based on a feedback signal of the sensing module, realize self-adaptive closed-loop control in the wire feeding process, monitor and diagnose the running state of equipment, and realize abnormal early warning; by establishing a linkage closed loop of the alloy wire and the molten aluminum state and controlling real-time detection of abnormal conditions, the adding amount of the alloy wire is accurately controlled, the stability of the refining effect of aluminum liquid crystal particles is improved, and therefore the product quality and the production efficiency of aluminum castings are improved.

Description

Technical Field

[0001] This invention relates to the field of wire feeder technology, and in particular to an automated wire feeder for a grain refinement process. Background Technology

[0002] Aluminum alloys, as lightweight and high-strength materials, are widely used in aerospace, rail transportation, automobile manufacturing, and electronic equipment. During the smelting and casting process of aluminum alloys, grain refiners are often added to improve grain structure, enhance mechanical properties, and improve forming quality. One method is melt feeding, where master alloy wires such as Ti-B, Ti-C, and Al-Ti-B are gradually added to the melt through flow channels like grooves. This effectively controls the distribution of grain refiners in the molten metal, promoting grain refinement. However, existing wire feeding processes generally rely on manual experience, typically involving manual feeding or simple motor-driven wire feeders, resulting in significant production instability.

[0003] Traditional manual wire feeding methods typically require operators to manually feed alloy wire into the casting trough based on experience. This is not only labor-intensive but also prone to problems such as uneven feeding, overfeeding, or underfeeding due to poor matching between melt temperature, flow rate, and actual linear consumption, leading to fluctuations in the refining effect. Furthermore, the complex environment of the smelting site and the real-time changes in the flow state of the molten metal make it difficult for manual responses to keep up with system changes. This can result in delayed responses to wire shortages, causing defects such as grain growth and coarse microstructure in the finished product, ultimately affecting the quality of the final casting.

[0004] On the other hand, some motor-driven wire feeding equipment in the industry has attempted to replace manual labor, but most of them are simple mechanical wire feeding mechanisms that lack real-time feedback control mechanisms. The wire feeding speed, clamping state and melt state are out of sync, often resulting in wire breakage, slippage and unstable wire speed. At the same time, most existing wire feeding machines do not have working status monitoring and abnormal alarm functions. When there is a lack of wire or wire jamming, the equipment cannot remind in time, delaying the processing time, causing scrap, and the production cost remains high.

[0005] To address these issues, the industry has largely improved the process by strengthening personnel training, increasing on-site supervision, and upgrading machinery and equipment. However, these measures have not fundamentally solved the problems of insufficient control precision, high reliability, and intelligence in the wire feeding process.

[0006] In summary, the existing technology has at least the following technical problems: Existing wire feeding processes suffer from technical problems such as difficulty in accurately controlling the amount of alloy wire added in real time, low automation and lack of precise control and feedback closed-loop mechanism linked to the melt state, and failure to detect and alert in real time to abnormal wire feeding conditions, resulting in unstable grain refinement effects. Summary of the Invention

[0007] The purpose of this invention is to provide an automated wire feeder for grain refinement process, in order to solve the technical problems of existing wire feeding processes, such as difficulty in real-time and accurate control of the amount of alloy wire added, low degree of automation and lack of precise control and feedback closed-loop mechanism linked with the melt state, failure to detect and prompt abnormal wire feeding conditions in real time, resulting in unstable grain refinement effect.

[0008] The preferred technical solutions among the many technical solutions provided by this invention can produce a variety of technical effects, which are described in detail below.

[0009] To address the aforementioned technical problems, the present invention provides the following technical solution: This invention provides an automated wire feeder for a grain refinement process, comprising a mechanical execution system including a feeding unit, a wire feeding drive unit, and a guiding and feeding unit arranged sequentially along the wire's forward direction; the feeding unit releases the wire, the wire feeding drive unit drives the wire forward, and the guiding and feeding unit guides the wire into the molten aluminum; and an electrical control system including a sensing module for detecting the state of the molten aluminum and the equipment's operating state, and a drive module for driving the wire feeding drive unit; and a central control unit communicatively connected to the sensing module and the drive module; wherein the central control unit is configured to: based on feedback signals from the sensing module, adjust the control commands output to the drive module in real time through a built-in control model to achieve adaptive closed-loop control of the wire feeding process; and monitor and diagnose the equipment's operating state to provide early warning of abnormalities.

[0010] In one embodiment, the central control unit is configured to: receive a feedback signal characterizing the temperature of the molten aluminum as the molten aluminum temperature signal, and compare the molten aluminum temperature signal with preset target process parameters to dynamically adjust the wire feeding speed.

[0011] In one embodiment, the sensing module includes a sensor that monitors the current and / or vibration data of the motor of the wire feeding drive unit; the central control unit is configured to diagnose and provide early warning of at least one abnormality in the wire material, such as wire breakage, slippage, motor overload, or mechanical wear, by analyzing the changing trends of the current and / or vibration data of the motor.

[0012] In one embodiment, the sensing module further includes a quality detection unit; the quality detection unit includes a high-frequency ultrasonic probe and / or a laser-induced breakdown spectroscopy probe, for online detection of grain refinement state and / or key element concentration in molten aluminum.

[0013] In one embodiment, the central control unit is configured to: receive the feedback signal from the quality detection unit as the aluminum liquid quality signal; compare the aluminum liquid quality signal with the target grain size and target element concentration of the preset aluminum liquid quality; and based on the comparison result, dynamically adjust the operating parameters of the wire feeding drive unit through a feedforward-feedback composite control algorithm.

[0014] In one embodiment, the wire feeding drive unit includes at least one feeder, the surface of the pressure roller of the feeder is provided with a ceramic coating with a hardness of not less than HV1200; the wire extends out from the feeder of the wire feeding drive unit and then enters the guiding and feeding unit.

[0015] In one embodiment, the feeding unit includes a wire spool with damping adjustment and a tension buffer mechanism; the wire spool, through damping adjustment, cooperates with the tension buffer mechanism to straighten the wire and provides a negative traction force to cooperate with the positive traction force provided by the wire feeding drive unit to promote the wire to be stably fed into the guiding and feeding unit at a preset speed controlled by the central control unit.

[0016] In one embodiment, the system further includes a human-machine interface module and a communication module, both of which are electrically connected to the central control unit. The human-machine interface module is used to preset parameters for the aluminum liquid state and equipment operating state that the central control unit needs to control in the current production batch. The communication module is used to upload the data detected by the sensing module to a remote manufacturing execution system and record the current parameters for the aluminum liquid state and the equipment operating state. When the central control unit executes the currently preset parameters for the equipment operating state but fails to achieve the preset parameters for the aluminum liquid state, the central control unit, through the communication module, calls the parameters for the equipment operating state in the manufacturing execution system that are similar to the currently preset parameters for the aluminum liquid state as the parameters for real-time control of the drive module.

[0017] In one embodiment, the mechanical actuation system has a dual-channel structure to simultaneously deliver two of the wires into the molten aluminum.

[0018] The beneficial effects of this invention are as follows: (1) It has realized the leap from "extensive experience" to "precise control" in wire feeding process, fundamentally improving product quality and solving the problem of "difficulty in real-time and precise control of alloy wire addition". Through the servo drive module and the precision algorithm of the central control unit, stepless speed regulation in the range of 0.3-5m / min is realized, and the speed control accuracy is as high as ±0.03m / min. This makes the addition of titanium and boron elements in aluminum-titanium-boron wire extremely precise, ensuring their uniform distribution in aluminum liquid, reducing the fluctuation of mechanical properties of aluminum castings, including strength and toughness, by more than 30%, and significantly improving the quality consistency and reliability of high-end aluminum alloy castings applied to new energy vehicles and aerospace components.

[0019] (2) An intelligent closed loop linked with the melt state was constructed, which greatly improved the automation and stability of the production process and solved the problem of "lack of precise control and feedback closed loop mechanism linked with melt state". By breaking through the limitations of traditional open loop control, the sensing module collects key state parameters such as aluminum liquid temperature in real time, and the control model built into the central control unit processes them. It can automatically adjust the wire feeding speed in milliseconds to respond to changes in the melt state. A closed loop control mechanism of "sensing-decision-execution" is formed, so that the wire feeding process is no longer an isolated process, but an adaptive system that is deeply coordinated with the entire casting process. It effectively resists interference in the production process and reduces the scrap rate of aluminum castings caused by process fluctuations from 8%-12% to below 3%.

[0020] (3) Comprehensive abnormal diagnosis and early warning functions have been introduced to ensure the continuity and predictability of production. Through real-time monitoring and data analysis of the operating status of equipment such as motor current and vibration, the central control unit can intelligently diagnose potential faults such as wire breakage, slippage, motor overload and mechanical wear, and provide early warnings. This changes equipment maintenance from "passive maintenance" to "active early warning", reducing unplanned downtime by more than 60%, thereby increasing the mean time between failures (MTBF) to more than 1,500 hours. This not only reduces maintenance costs, but also ensures the continuous and efficient operation of the casting production line, reduces the dependence on the experience of operators, and solves the problem of "failure to detect and prompt abnormal wire feeding conditions in real time".

[0021] In summary, this invention senses and converts the production status of molten aluminum, equipment, and wire into data, and achieves automated and intelligent precise control of the amount of wire fed into the molten aluminum through closed-loop control. This not only overcomes the technical bottlenecks of existing wire feeding processes one by one, but also promotes the transformation and upgrading of aluminum alloy casting processes towards intelligence and digitalization, bringing high-quality, high-efficiency, and high-reliability production line performance to the field of aluminum casting. Attached Figure Description

[0022] To more clearly illustrate the technical solution of the present invention, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the composition of the automated wire feeder of the present invention.

[0024] The accompanying figure is labeled as follows: 1. Mechanical actuator system; 2. Feeding unit; 21. Wire spool; 22. Tension buffer mechanism; 3. Wire feeding drive unit; 31. Motor; 32. Feeder; 4. Guiding and feeding unit; 5. Electrical control system; 6. Sensing module; 7. Driver module; 8. Central control unit; 81. Human-computer interaction module; 82. Communication module; 91. Wire material; 92. Aluminum liquid flow channel. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0026] The specific implementation provides an automated wire feeder for grain refinement, including a mechanical execution system, an electrical control system, and a central control unit. The mechanical execution system is sequentially equipped with a feeding unit, a wire feeding drive unit, and a guiding and feeding unit along the wire feeding direction. The electrical control system includes a sensing module and a drive module. The central control unit is communicatively connected to the sensing module and the drive module and is configured to: adjust the drive commands in real time based on the feedback signal from the sensing module through a built-in control model to achieve adaptive closed-loop control of the wire feeding process, while monitoring and diagnosing the equipment's operating status to achieve abnormal early warning; by establishing a linkage closed loop between the alloy wire and the state of the molten aluminum, and controlling the real-time detection of abnormal conditions, the amount of alloy wire added is precisely controlled, thereby improving the stability of the grain refinement effect of the molten aluminum and improving the product quality and production efficiency of aluminum castings. This effectively solves the technical problems of existing wire feeding processes, such as difficulty in accurately controlling the amount of alloy wire added in real time, low automation level and lack of precise control and feedback closed-loop mechanism linked with the melt state, and failure to detect and prompt abnormal wire feeding conditions in real time, leading to unstable grain refinement effects.

[0027] The first implementation of an automated wire feeder, for example Figure 1As shown, the system includes a mechanical execution system 1, comprising a feeding unit 2, a wire feeding drive unit 3, and a guiding and feeding unit 4 arranged sequentially along the forward direction of the wire 91; the feeding unit 2 is used to release the wire 91, the wire feeding drive unit 3 is used to drive the wire 91 forward, and the guiding and feeding unit 4 is used to guide the wire 91 into the molten aluminum; an electrical control system 5, comprising a sensing module 6 for detecting the state of the molten aluminum and the operating state of the equipment, and a drive module 7 for driving the wire feeding drive unit 3; and a central control unit 8, which is communicatively connected to the sensing module 6 and the drive module 7; wherein, the central control unit 8 is configured to: based on the feedback signal of the sensing module 6, adjust the control commands output to the drive module 7 in real time through a built-in control model to achieve adaptive closed-loop control of the wire feeding process; and monitor and diagnose the operating state of the equipment to achieve abnormal early warning.

[0028] The automated wire feeder of this invention addresses three core problems in existing wire feeding processes: difficulty in real-time and precise control of the alloy wire addition amount, low automation level, lack of precise control and feedback closed-loop mechanism linked to the melt state, and failure to detect and alert to wire feeding anomalies in real time, leading to unstable grain refinement effects. By constructing an intelligent solution consisting of a mechanical execution system 1, an electrical control system 5, and a central control unit 8, it brings several technical benefits, manifested in the following three aspects: achieving a leap from "extensive experience" to "precise and controllable" wire feeding processes, fundamentally improving product quality. This solves the problem of "difficulty in controlling the amount of alloy wire added in real time and with precision"; through the precise algorithm of the servo-driven drive module 7 and the central control unit 8, stepless speed regulation of the wire feeding speed in the range of 0.3-5m / min is achieved, with a speed control accuracy of up to ±0.03m / min; this makes the addition of titanium and boron elements in aluminum-titanium-boron wire extremely precise, ensuring their uniform distribution in the aluminum liquid, reducing the fluctuation of mechanical properties of aluminum castings, including strength and toughness, by more than 30%, and significantly improving the quality consistency and reliability of high-end aluminum alloy castings used in new energy vehicles and aerospace components.

[0029] A smart closed loop linked to the melt state was constructed, significantly improving the automation and stability of the production process and solving the problem of "lack of a precise control and feedback closed-loop mechanism linked to the melt state". By breaking through the limitations of traditional open-loop control, the sensing module 6 collects key state parameters such as aluminum melt temperature in real time, and the control model built into the central control unit 8 processes them. It can automatically adjust the wire feeding speed within milliseconds to respond to changes in the melt state. A closed-loop control mechanism of "sensing-decision-execution" is formed, so that the wire feeding process is no longer an isolated process, but an adaptive system that is deeply coordinated with the entire melting and casting process. It effectively resists interference in the production process and reduces the scrap rate of aluminum castings caused by process fluctuations from 8%-12% to below 3%.

[0030] The introduction of comprehensive anomaly diagnosis and early warning functions ensures the continuity and predictability of production. Through real-time monitoring and data analysis of the operating status of equipment such as motor 31 current and vibration, the central control unit 8 can intelligently diagnose potential faults such as wire breakage, slippage, motor 31 overload, and mechanical wear, and provide early warnings. This transforms equipment maintenance from "passive repair" to "proactive early warning," reducing unplanned downtime by more than 60%, thereby increasing the mean time between failures (MTBF) to more than 1,500 hours. This not only reduces maintenance costs but also ensures continuous and efficient operation of the casting production line, reduces reliance on operator experience, and solves the problem of "failure to detect and alert to abnormal wire feeding conditions in real time."

[0031] In summary, this invention senses and converts the production status of molten aluminum, equipment, and wire 91 into data. Through closed-loop control, it achieves automated and intelligent precise control of the amount of wire 91 fed into the molten aluminum. This not only overcomes the technical bottlenecks of existing wire feeding processes one by one, but also promotes the transformation and upgrading of aluminum alloy casting processes towards intelligence and digitalization, bringing high-quality, high-efficiency, and high-reliability production line performance to the field of aluminum castings.

[0032] As one alternative implementation method: Regarding the key components of the aforementioned feeding unit 2, this implementation is as follows: Figure 1 As shown, the feeding unit 2 includes a wire spool 21 with damping adjustment and a tension buffer mechanism 22; the wire spool 21, through damping adjustment and in conjunction with the tension buffer mechanism 22, straightens the wire 91 and provides negative traction force in conjunction with the positive traction force provided by the wire feeding drive unit 3 to promote the wire 91 to be stably fed into the guide and feed unit 4 at a preset speed controlled by the central control unit 8.

[0033] In application, the damping adjustment of the feeding unit 2 and the tension buffer mechanism 22 work together to form a stable "filament 91 tension servo system". The damping adjustment and the tension buffer mechanism 22 work together to actively maintain a constant small counter-tension force, which precisely counteracts the positive traction force provided by the feeding drive unit 3. This dynamic balance of forces can effectively eliminate the "loosening of the filament" caused by the inertial rotation of the filament spool, as well as the risk of "hard breakage" caused by sudden acceleration, ensuring that the filament 91 is always taut and tension fluctuates during the transition from feeding to driving the filament feeding. This directly solves the problem of instantaneous fluctuation in the amount of element added caused by unstable filament feeding, and provides a stable prerequisite for the high-precision speed control of the downstream feeding drive unit 3, which is the basic guarantee for achieving precise filament feeding throughout the process.

[0034] Damping adjustment can be achieved using a magnetic powder brake or a pneumatic damper, and is electrically connected to the central control unit 8. The central control unit 8 makes real-time fine adjustments based on the set tension value of the wire feeding, realizing intelligent tension adjustment. The tension buffer mechanism 22 adopts a spring slider mechanism with a guide rod. The wire 91 contacts the slider, and the spring provides the slider with a force to resist the wire 91. The displacement of the slider is detected by the sensor and used as a tension feedback signal of the wire 91 for the central control unit 8.

[0035] Regarding the key components of the aforementioned wire feeding drive unit 3, this embodiment, for example... Figure 1 As shown, the wire feeding drive unit 3 includes at least one feeder 32. The surface of the pressure roller of the feeder 32 is provided with a ceramic coating with a hardness of not less than HV1200. After the wire 91 extends out from the feeder 32 of the wire feeding drive unit 3, it enters the guide and feed unit 4.

[0036] In application, the core function of the ceramic-coated pressure roller is to solve the compatibility problem between high-hardness aluminum-titanium-boron wire (hardness HV≥280) and the drive wheel. The high hardness (hardness HV≥1200) and excellent wear resistance of the silicon carbide ceramic coating can effectively resist the micro-cutting and wear of the wire 91, thus avoiding the problems that are prone to occur with traditional steel wheels, such as "excessive indentation leading to damage to the cross-section of the wire 91" or "wheel surface wear leading to decreased friction and slippage".

[0037] The motor 31 of the wire feeding drive unit 3 is a servo motor 31.

[0038] The ceramic-coated pressure roller in the feeder 32, combined with the servo motor 31 and precision reducer, ensures that the wire feeding drive unit 3 can reliably execute the minute speed commands from the central control unit 8, avoids errors from the flexible gap, and converts the precise electrical signal into equally precise mechanical feeding action. Ultimately, it achieves a wire feeding speed control accuracy of ±0.03m / min within the range of 0.3-5m / min, fundamentally ensuring the uniformity and stability of element addition.

[0039] The pressure roller of the feeder 32 has a "V" groove cross-section to better wrap and guide the filament 91.

[0040] Regarding the specific monitoring structure of the sensing module 6 on the wire feeding drive unit 3, this implementation is as follows: Figure 1 As shown, the sensing module 6 includes sensors that monitor the current and / or vibration data of the motor 31 of the wire feeding drive unit 3; The central control unit 8 is configured to diagnose and provide early warning of at least one abnormal condition of the wire 91, such as wire breakage, slippage, motor 31 overload, or mechanical wear, by analyzing the changing trends of the current and / or vibration data of the motor 31.

[0041] When wire breakage occurs, the load on motor 31 of wire feeding drive unit 3 drops sharply, and the current value will be significantly lower than the normal operating range. When slippage or wear of mechanical transmission components occurs, the frictional resistance increases, and the current of motor 31 will rise abnormally and be accompanied by a vibration signal of a specific frequency. After sensing this current and vibration data, the sensing module 6 feeds it back to the central control unit 8. The central control unit 8 identifies these abnormal signs in advance by analyzing the changing trends of these current and vibration data in real time. Working closely with wire feeding drive unit 3 and feeding unit 2, once an abnormality is diagnosed, the system immediately issues an early warning or stops the machine, thereby avoiding continuous ineffective wire feeding in the case of wire breakage or slippage. This directly solves the problem of unqualified aluminum liquid composition caused by the failure to detect wire feeding interruption in time, and greatly reduces quality risks and raw material waste.

[0042] In addition, regarding the direct detection of the aluminum melt structure by the aforementioned sensing module 6, the sensing module 6 also includes a quality detection unit; the quality detection unit includes a high-frequency ultrasonic probe and / or a laser-induced breakdown spectroscopy probe, used to detect the grain refinement state and / or the concentration of key elements in the aluminum melt online.

[0043] The central control unit 8 is configured to: receive feedback signals from the quality detection unit as aluminum liquid quality signals; compare the aluminum liquid quality signals with the preset target grain size and target element concentration of aluminum liquid quality; and based on the comparison results, dynamically adjust the operating parameters of the wire feeding drive unit 3 through a feedforward-feedback composite control algorithm.

[0044] In practical applications, this structure is key to the invention's shift from "process control" to "quality and effect control." The high-frequency ultrasonic probe can detect the grain nucleation and size distribution within the molten aluminum online, while the laser-induced breakdown spectroscopy probe can directly and quantitatively analyze the real-time concentrations of Ti and B elements in the molten aluminum.

[0045] The central control unit 8 uses these signals as the most direct feedback of the process effect, comparing them with preset target values; it constructs a feedforward-feedback composite control loop with the final metallurgical quality as the target: the feedback loop adjusts the wire feeding speed according to the real-time grain size to ensure the effect meets the standard; the feedforward loop predicts future trends based on the real-time element concentration and adjusts the wire feeding parameters in advance to overcome system lag. This collaborative control completely solves the industry pain point that traditional methods can only judge quality after the fact through metallographic inspection and cannot intervene in real time during the production process to ensure the refinement effect.

[0046] The high-frequency ultrasonic probe and the laser-induced breakdown spectroscopy (LIBS) probe can be integrated into a water-cooled protective sleeve. The probe can be automatically moved and positioned at a specific location above the aluminum melt flow channel 92 via a robotic arm or guide rail mechanism to obtain more representative aluminum melt sample data, while avoiding direct impact from the high-temperature aluminum melt and extending the probe's service life.

[0047] Temperature is one of the key parameters for controlling the state of molten aluminum. Regarding the control of molten aluminum temperature and wire feeding speed by the central control unit 8, the central control unit 8 is configured to: receive a feedback signal characterizing the temperature of molten aluminum as the molten aluminum temperature signal, compare the molten aluminum temperature signal with the preset target process parameters, and dynamically adjust the wire feeding speed.

[0048] In application, the temperature of the molten aluminum is a key parameter affecting the reaction rate of the grain refiner and the diffusion rate of elements. The central control unit 8 receives the molten aluminum temperature signal and compares it with the target process parameters, enabling an adaptive "temperature-speed" matching strategy. When the molten aluminum temperature is too high, the dissolution and diffusion of titanium and boron elements will accelerate. To avoid over-reaction and element burn-off, the central control unit 8 will control the drive module 7 to automatically and slightly reduce the wire feeding speed. Conversely, when the temperature is too low, to ensure sufficient element addition, the central control unit 8 will control the drive module 7 to automatically and appropriately increase the speed. Through dynamic detection and dynamic coordination with the feeding unit 2 and the wire feeding drive unit 3, it is ensured that even with normal fluctuations in the molten aluminum temperature throughout the casting process, the amount of alloying elements entering the molten aluminum per unit time remains relatively constant. This solves the problem of inconsistent grain refinement effects caused by temperature changes and ensures the uniformity of the quality of the entire batch of castings.

[0049] The central control unit 8 has multiple preset temperature-feeding speed characteristic curves for different aluminum alloy grades. Operators only need to select the alloy grade, and the central control unit 8 can automatically call up the corresponding curve parameters to achieve one-click precise control, thereby greatly reducing the difficulty of operation and the reliance on skilled workers.

[0050] A second implementation of an automated wire feeder, for example Figure 1 As shown, the difference between this embodiment and the first embodiment is that the mechanical execution system 1 has a dual-channel structure to simultaneously deliver two wires 91 into the molten aluminum.

[0051] In application, the dual-channel structure achieves the dual goals of "speed reduction and quality improvement" and "process optimization" through spatial diversion and coordination. This structure allows two wires 91 to be fed synchronously at a lower, more stable speed, significantly reducing the risk of wire breakage and slippage caused by high-speed feeding of a single wire 91, thus improving system reliability. Furthermore, the two wires 91 can be precisely fed to different key locations in the smelting process; for example, one at the degassing box inlet, where the stirring effect of the degassing rotation promotes initial element diffusion; the other in the casting flow channel, fine-tuning the elements and ensuring final uniformity. This setup, in conjunction with the closed-loop control of the central control unit 8, results in a significantly better combination and distribution uniformity of alloying elements in the molten aluminum compared to single-point addition. It directly solves the technical problem in large-capacity furnaces or high-efficiency production lines where single-wire feeding is forced to increase speed to meet throughput, leading to decreased stability and poor refining effects.

[0052] Furthermore, when more elements need to be added to the molten aluminum, the dual-channel structure can simultaneously deliver two different alloy wires 91 to the molten aluminum, making it convenient to flexibly change the grade of the molten aluminum during production.

[0053] The third implementation of an automated wire feeder, for example Figure 1 As shown, this embodiment differs from the first embodiment in that it also includes a human-machine interaction module 81 and a communication module 82. Both the human-machine interaction module 81 and the communication module 82 are electrically connected to the central control unit 8. The human-machine interaction module 81 is used to preset the parameters of the aluminum liquid state and the equipment operating state parameters that the central control unit 8 needs to control in the current production batch. The communication module 82 is used to upload the data detected by the sensing module 6 to the remote manufacturing execution system and record the parameters of the current aluminum liquid state and the equipment operating state. When the central control unit 8 executes the currently preset equipment operating state parameters but fails to reach the preset aluminum liquid state parameters, the central control unit 8 calls the parameters of the equipment operating state in the manufacturing execution system that are similar to the currently preset aluminum liquid state parameters as the parameters of the real-time control drive module 7 via the communication module 82.

[0054] When applied, the human-computer interaction and communication module 82 transforms a single automated wire feeder from an "automation island" into an "organic component of a digital factory".

[0055] Through data flow, a three-layer collaborative intelligent system of "on-site operation - equipment control - factory management" is constructed; the human-machine interaction module 81 makes the preset and monitoring of process parameters intuitive and convenient, while the communication module 82 continuously uploads real-time production data, such as aluminum liquid temperature, actual wire feeding speed, motor 31 current value and result data, such as the final element concentration of aluminum liquid, to the MES system, realizing complete traceability of the production process.

[0056] Its core intelligence lies in the fact that when the central control unit 8 recognizes that the current process parameters cannot reach the preset aluminum liquid state target, for example, when the wire is fed at the current speed but the Ti element concentration detected by the LIBS probe is consistently low, it will actively send a request to the MES system through the communication module 82 to call the "optimal" equipment parameters corresponding to the "similar" aluminum liquid state in historical successful cases, and automatically apply them to correct the process parameters of the current production batch.

[0057] It flexibly solves the deep-seated problems of traditional automated equipment relying on fixed programs, being unable to learn and optimize from historical experience, and having limited adaptive capabilities to cope with abnormal working conditions. It enables continuous self-optimization of the production process and intelligent decision-making, further helping traditional industries upgrade to digital factories.

[0058] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described.

Claims

1. An automated wire feeder for a grain refinement process, characterized in that, The system includes a mechanical actuation system comprising a feeding unit, a wire feeding drive unit, and a guiding and feeding unit arranged sequentially along the wire's forward direction; the feeding unit is used to release the wire, the wire feeding drive unit is used to drive the wire forward, and the guiding and feeding unit is used to guide the wire into the molten aluminum. And an electrical control system, including a sensing module for detecting the state of the molten aluminum and the operating state of the equipment, and a driving module for driving the wire feeding drive unit; And a central control unit, which is communicatively connected to the sensing module and the drive module; The central control unit is configured to: adjust the control commands output to the drive module in real time based on the feedback signals from the sensing module through a built-in control model to achieve adaptive closed-loop control of the wire feeding process; and monitor and diagnose the operating status of the equipment to achieve abnormal early warning.

2. The automated wire feeder according to claim 1, characterized in that, The central control unit is configured to receive a feedback signal characterizing the temperature of the molten aluminum as the molten aluminum temperature signal, compare the molten aluminum temperature signal with preset target process parameters, and dynamically adjust the wire feeding speed.

3. The automated wire feeder according to claim 1, characterized in that, The sensing module includes sensors that monitor the current and / or vibration data of the motor of the wire feeding drive unit. The central control unit is configured to diagnose and provide early warning of at least one abnormal condition among wire breakage, slippage, motor overload, or mechanical wear by analyzing the changing trends of the motor's current and / or vibration data.

4. The automated wire feeder according to claim 1, characterized in that, The sensing module also includes a quality detection unit; The quality detection unit includes a high-frequency ultrasonic probe and / or a laser-induced breakdown spectroscopy probe, used to detect the grain refinement state and / or the concentration of key elements in the molten aluminum online.

5. The automated wire feeder according to claim 4, characterized in that, The central control unit is configured to receive feedback signals from the quality detection unit as aluminum liquid quality signals. The aluminum melt quality signal is compared with the preset target grain size and target element concentration of the aluminum melt; and based on the comparison result, the operating parameters of the wire feeding drive unit are dynamically adjusted through a feedforward-feedback composite control algorithm.

6. The automated wire feeder according to claim 1, characterized in that, The wire feeding drive unit includes at least one feeder, and the surface of the pressure roller of the feeder is provided with a ceramic coating with a hardness of not less than HV1200. After the filament extends from the feeder of the filament feeding drive unit, it enters the guide and feed unit.

7. The automated wire feeder according to claim 1, characterized in that, The feeding unit includes a wire spool with damping adjustment and a tension buffer mechanism; The spool shaft, through damping adjustment, works in conjunction with the tension buffer mechanism to straighten the filament and provides negative traction force, which, together with the positive traction force provided by the filament feeding drive unit, promotes the stable feeding of the filament to the guide and feed unit at a preset speed controlled by the central control unit.

8. The automated wire feeder according to claim 1, characterized in that, It also includes a human-computer interaction module and a communication module, both of which are electrically connected to the central control unit; The human-machine interaction module is used to preset the parameters of the aluminum liquid state and the equipment operating state that the central control unit needs to control to achieve in the current production batch. The communication module is used to upload the data detected by the sensing module to a remote manufacturing execution system, and to record the parameters of the current state of the molten aluminum and the parameters of the operating state of the equipment. When the parameters of the current preset equipment operating state executed by the central control unit do not reach the preset parameters of the molten aluminum state, the central control unit calls the parameters of the equipment operating state in the manufacturing execution system that are similar to the parameters of the current preset molten aluminum state as the parameters for real-time control of the drive module via the communication module.

9. The automated wire feeder according to claim 1, characterized in that, The mechanical actuation system has a dual-channel structure to simultaneously deliver two of the wires into the molten aluminum.

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