Metal melt flow control method and system and storage medium

Abstract

The invention discloses a metal melt flow control method and system and a storage medium, and belongs to the technical field of metal structural part casting, and the method comprises the steps that at least one flow controller is preset according to the position, the control range and the trigger condition of a target flow control area in a casting mold, the flow controller and a sensor matched with the flow controller are fixed in the casting mold according to preset positions; after the controller and the sensor are installed, the casting mold provided with the flow controller is subjected to pouring operation under preset technological conditions; in the pouring process, the intensity, the frequency and the power-on phase sequence of the three-phase exciting current applied to the flow controller are adjusted in real time, so that a traveling wave magnetic field acting on the metal melt is generated and controlled, and adjustment of the flow of the metal melt in the pouring process is achieved. A non-contact control device is adopted to solve the problem that the local flow of a complex structural part cannot be controlled, the local feeding effect of the aluminum alloy melt is enhanced, and meanwhile the metallurgical quality and the production qualification rate of castings are improved.

Description

Technical Field

[0001] This invention belongs to the field of metal structural component casting technology, and specifically relates to a method, system and storage medium for controlling the flow rate of molten metal. Background Technology

[0002] With the rapid development of industries such as aviation and aerospace, the internal structure of castings is becoming increasingly complex. Castings with various irregular cavities and pipeline structures meet the development trend of integrated functions and overall structure of castings, which significantly increases the complexity of castings and the value of individual castings. At the same time, the quality of metallurgy of such castings greatly affects the process of overall and integrated development of castings.

[0003] The casting process is divided into two stages: filling and solidification. Solidification is generally designed as sequential solidification to avoid defects such as porosity. The filling process requires a smooth flow to avoid splashing, choking, and turbulence. This is relatively easy to achieve in simpler casting designs. However, complex castings often have uneven thicknesses that hinder filling and solidification due to functional requirements. This necessitates significantly reducing or increasing the flow rate at specific locations relative to other locations during the filling process to ensure a smooth overall filling process. In some areas, due to space constraints, the feeding gates or risers may be too small to achieve the required feeding effect. In such cases, the feeding pressure may be increased locally without affecting other locations. Additionally, some locations are prone to splashing, requiring control of the filling speed.

[0004] There are generally two ways to solve the above problems: one is to design a complex gating system, try and fail many times, and finally optimize the gating system. However, this method takes a long time and is difficult to implement for more complex structural castings. The other is to ensure that the gating system as a whole meets the metallurgical quality requirements, and solve the problem of local structural defects by removing defects or welding in the later stage. This method has great uncertainty, and the conditions for removing defects or welding may not be available in some areas. Summary of the Invention

[0005] To address the above problems, the present invention provides a method for controlling the flow rate of molten metal, the method comprising: Based on the location, control range, and triggering conditions of the target flow control area within the mold, at least one flow controller is preset, and the flow controller and its associated sensor are fixed inside the mold at preset positions. After the controller and sensor are installed, the mold equipped with the flow controller is poured under preset process conditions. During the casting process, the intensity, frequency, and energizing phase sequence of the three-phase excitation current applied to the flow controller are adjusted in real time to generate and control the traveling wave magnetic field acting on the molten metal, thereby regulating the flow rate of the molten metal during the casting process.

[0006] Furthermore, the triggering conditions include: The flow controller is activated when the pouring time reaches a preset threshold; or... The flow controller is activated when the melt front reaches a specific location monitored by the sensor; or... The flow controller is activated when the melt temperature, flow rate, or pressure detected by the sensor exceeds a preset range.

[0007] Furthermore, the flow controller includes a traveling wave magnetic field generator, and the assembly of the traveling wave magnetic field generator includes: The original sand gating system in the target flow control area of ​​the mold was replaced with a prefabricated ceramic pipe. One or more traveling wave magnetic field generators are axially spaced along the outer wall of the ceramic tube. A heat insulation layer is provided between the traveling wave magnetic field generator and the outer wall of the ceramic tube; The assembled ceramic tube, insulation layer, and traveling wave magnetic field generator are integrated into the mold.

[0008] Furthermore, the sensor includes at least a temperature sensor for monitoring the melt temperature, a flow field sensor for monitoring the melt surface velocity or pressure, and a positioning sensor for determining the arrival position of the melt front.

[0009] Furthermore, the method also includes a cooling step for the traveling wave magnetic field generator: Cooling channels are integrated around or inside the traveling wave magnetic field generator; A first temperature sensor is embedded in the insulation layer to monitor the temperature of the insulation layer in real time. If the temperature of the first temperature sensor reaches the set cooling threshold, the cooling medium is introduced into the cooling channel to cool the traveling wave magnetic field generator.

[0010] Furthermore, the traveling wave magnetic field generator includes: An electromagnetic coil made of conductive material is configured to generate a traveling wave magnetic field that propagates in a specific direction when a multiphase alternating current is applied. The winding of the electromagnetic coil is made of at least one of hollow wire, enameled wire, and insulated bare wire.

[0011] Furthermore, the control of the traveling wave magnetic field includes: Based on the deviation between the real-time flow rate and the target flow rate fed back by the sensor, the amplitude of the three-phase excitation current is dynamically adjusted to change the magnetic induction intensity of the traveling wave magnetic field. Based on the current flow state of the molten metal and the target control requirements, the frequency of the excitation current is dynamically adjusted to change the moving speed of the traveling wave magnetic field. By changing the energizing sequence of the three-phase currents, the direction of travel of the traveling wave magnetic field is switched, thereby applying a positive thrust or a reverse braking force to the melt.

[0012] Furthermore, the method also includes: Record the monitoring data of each sensor, the control parameters of the excitation current, and the quality data of the final casting during each pouring process; Based on the recorded data, a flow control strategy model is trained using machine learning algorithms to optimize the adjustment strategies for the excitation current intensity, frequency, and phase sequence in subsequent casting processes.

[0013] The present invention also provides a molten metal flow control system, the system comprising a flow control execution module, a casting module, and a control module. The flow control execution module is configured to preset at least one flow controller according to the location, control range and triggering conditions of the target flow control area inside the mold, and fix the flow controller and its matching sensor in the mold at preset positions. The casting module is configured to perform a casting operation on the mold equipped with the flow controller using preset process conditions after the controller and sensor have been installed. The control module is configured to generate and control the traveling wave magnetic field acting on the molten metal during the pouring process by adjusting the intensity, frequency and energizing phase sequence of the three-phase excitation current applied to the flow controller in real time.

[0014] The present invention also provides a computer storage medium storing one or more instructions that, when executed by one or more computers, cause the one or more computers to perform the method described in the present invention.

[0015] Compared with the prior art, the present invention has the following advantages: The present invention provides a method, system, and storage medium for controlling the flow rate of molten aluminum alloy in the casting of thin-walled complex structural parts. It adopts a non-contact control device, which does not contaminate the molten metal; the parameters can be programmed and controlled, and automation can be easily achieved; it solves the problem of uncontrollable local flow rate in complex structural parts, improves the stability of the casting filling process, enhances the local feeding effect of the molten aluminum alloy, and improves the metallurgical quality and production qualification rate of the casting.

[0016] This invention upgrades the control method from "passive flow channel design" to "active melt manipulation" by dynamically and quantitatively controlling the traveling wave magnetic field. By precisely controlling the intensity, frequency, and phase sequence of the excitation current, the melt is controlled to flow at a preset speed and direction, ensuring that the far end and thin-walled areas are fully filled and compensated. By adjusting the control parameters, the filling and compensation schemes can be quickly verified and optimized. Only a few physical tests are needed to lock in the optimal process window, greatly shortening the process cycle.

[0017] This invention ensures that the melt front maintains sufficient heat and kinetic energy to achieve seamless fusion by precisely controlling the shape, speed, and pressure of the melt flow front. It provides continuous and directional feeding pressure throughout the solidification process, "driving" shrinkage cavities from the inside of the casting to the pre-set riser or gating, thereby achieving densification of the casting. Through stable laminar flow guidance, it reduces the impact and tumbling of the melt on the molding sand, thereby reducing the tendency for inclusions and porosity to form.

[0018] This invention achieves one-time casting, avoiding all uncertainties, additional costs, and potential risks associated with post-processing. For casting parts that are structurally enclosed, deeply buried, or cannot be disassembled for inspection during service, the active control capabilities of this invention can directly target these "blind spots," ensuring high-quality molding structure from the source. This is revolutionary for core castings in key fields such as aerospace and energy.

[0019] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures pointed out in the description, claims, and drawings. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 A schematic flowchart of a metal melt flow control method according to an embodiment of the present invention is shown; Figure 2 This shows an overall schematic diagram of the melt flow controller before triggering in Embodiment 1 of the present invention; Figure 3 A partial schematic diagram of the traveling wave magnetic field in Embodiment 1 of the present invention is shown; Figure 4This shows an overall schematic diagram of the melt flow controller after it is triggered in Embodiment 1 of the present invention; Figure 5 A schematic diagram of the metal melt flow control system according to an embodiment of the present invention is shown.

[0022] In the figure: 1. Molten metal; 2. Traveling wave magnetic field generator; 3. First signal sensor; 4. Second signal sensor; 5. First monitoring sensor; 6. Second monitoring sensor; 7. Third monitoring sensor; 8. Controller; 9. Ceramic tube; 10. Insulation layer. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] This invention provides a method for controlling the flow rate of aluminum alloy melt during the forming process of complex structural parts, thereby controlling the flow rate distribution of aluminum alloy melt in the gating system during the forming process.

[0025] Specifically, this paper proposes a process method for controlling the flow rate or speed of molten metal in local areas during the molding of complex structural parts. This method ensures controllable local flow rate and speed, smooth filling process of complex structural parts, avoids splashing due to excessively fast filling speed, poor feeding effect due to insufficient pressure, and backflow caused by excessively fast filling in local areas. It solves the problem of poor metallurgical quality of castings caused by flow rate or filling speed, thereby improving the metallurgical quality and production qualification rate of complex structural parts and reducing production costs.

[0026] Figure 1 A schematic flowchart of a metal melt flow control method according to an embodiment of the present invention is shown. Figure 1 The method includes: pre-setting at least one flow controller according to the location, control range, and triggering conditions of the target flow control area within the mold, and fixing the flow controller and its matching sensor inside the mold at a preset position; after completing the installation of the controller and sensor, performing a pouring operation on the mold equipped with the flow controller using preset process conditions; during the pouring process, generating and controlling the traveling wave magnetic field acting on the molten metal by adjusting the intensity, frequency, and energizing phase sequence of the three-phase excitation current applied to the flow controller in real time, thereby achieving the regulation of the molten metal flow rate during the pouring process.

[0027] In this embodiment of the invention, numerical simulation, physical simulation calculation, or empirical methods are used to preliminarily determine the location, control range, and triggering conditions of the target flow control area within the mold.

[0028] The following example illustrates the process of determining the location, control range, and triggering conditions of the target flow control region within the mold using numerical simulation. Optionally, the numerical simulation of this invention can use models such as ProCAST, MAGMA, or Flow-3D. Determine the location of the target flow control area within the mold: By inputting the physical properties of the molten metal and the pouring process parameters into a casting geometry model that does not contain any flow controllers; By observing the time and shape of the molten metal front reaching the farthest part of the cavity (such as thin walls, bosses, and deep parts of the cavity), if the temperature of the front drops too quickly and the flow stops, this is the primary control area. Observe the state at the confluence of two or more molten metal streams. If obvious cold spots or flashes appear at the confluence, it indicates that the temperature of the flow front is too low or the flow rate is mismatched. It is necessary to focus on controlling it to make it synchronized and merge smoothly. During the solidification simulation phase, areas that are far from the gate and solidify last are identified and marked as target areas for providing feeding pressure before solidification through control measures. By analyzing the static pressure cloud map at different locations within the cavity during the filling process, it can be found that the driving pressure will significantly decrease as the process increases. The area where the pressure is below a certain critical value is identified as the target control area.

[0029] Determine the target flow control range within the mold: After identifying the target area, the simulation results were analyzed to obtain the actual melt flow velocity and static pressure in that area. Based on the process objective, the difference between the current simulation result and the objective is calculated, and the difference is the control gap that the flow controller needs to make up. By further combining electromagnetic principles, the required magnetic field strength and current density are initially deduced. Based on the design formula of the traveling wave magnetic field generator, the core parameters such as the rated power, number of coil turns, and current capacity of the controller are determined.

[0030] Specifically, in this embodiment of the invention, the triggering conditions include time triggering, location triggering, or state triggering. Time-triggered: The flow controller is activated when the pouring time reaches a preset threshold; or, Position trigger: The flow controller is activated when the melt front reaches a specific location monitored by the sensor; or, Status trigger: The flow controller is activated when the melt temperature, flow rate or pressure detected by the sensor exceeds the preset range.

[0031] In this embodiment of the invention, the flow controller includes a traveling wave magnetic field generator 2. Figure 3 A partial schematic diagram of the traveling wave magnetic field in Embodiment 1 of the present invention is shown. Figure 3 In the process, the traveling wave magnetic field generator 2 is disposed on the outer wall side of the ceramic tube 9 through the heat insulation layer 10. Optionally, the assembly of the traveling wave magnetic field generator 2 includes: replacing the original sand gating channel in the target flow control area of ​​the mold with a prefabricated ceramic tube 9; axially arranging one or more traveling wave magnetic field generators 2 along the outer wall side of the ceramic tube 9; providing the heat insulation layer 10 between the traveling wave magnetic field generator 2 and the outer wall of the ceramic tube 9; and integrating the assembled ceramic tube 9, heat insulation layer 10 and traveling wave magnetic field generator 2 into the mold.

[0032] Optionally, the material selection of ceramic tube 9 covers all tubular products made of inorganic non-metallic materials through high-temperature sintering, including alumina, zirconium oxide, silicon carbide, quartz glass and other materials. In this embodiment of the invention, no specific limitation is made on the selection of the material of ceramic tube 9.

[0033] Optionally, the insulation layer 10 may be made of an ultra-thin high-temperature insulation material, specifically an ultra-thin aluminum silicate fiber felt. In this embodiment of the invention, no specific limitation is made on the selection of the material of the insulation layer 10.

[0034] In this embodiment of the invention, the types of sensors are also described. The sensors include at least a temperature sensor for monitoring melt temperature, a flow field sensor for monitoring melt surface velocity or pressure, and a positioning sensor for determining the arrival position of the melt front. It should be noted that the position and number of sensors in this embodiment are set according to the preset position, control range, and triggering conditions of the target flow control area within the mold, and no specific limitations are made on the number and position of the sensors.

[0035] To enhance the safety and applicability of the molten metal flow control method of the present invention, the method further includes a cooling step for the traveling wave magnetic field generator 2: integrating cooling channels around or inside the traveling wave magnetic field generator 2; and embedding a first temperature sensor in the insulation layer 10 to monitor the temperature of the insulation layer in real time. If the temperature of the first temperature sensor reaches the set cooling threshold, the cooling medium is introduced into the cooling channel to cool the traveling wave magnetic field generator 2.

[0036] Specifically, in this embodiment of the invention, the cooling system for the coil of the traveling wave magnetic field generator 2 includes cooling by using hollow wires and circulating cooling water through them, while other coils can be cooled by using thermally conductive materials to conduct heat outwards.

[0037] In this embodiment of the invention, the structure of the traveling wave magnetic field generator 2 is also described. The traveling wave magnetic field generator 2 includes: an electromagnetic coil wound from a conductive material, the electromagnetic coil being configured to generate a traveling wave magnetic field propagating in a specific direction when multiphase alternating current is applied; wherein, the winding of the electromagnetic coil is wound from at least one of hollow wire, enameled wire, and insulated bare wire; the coil material is preferably copper.

[0038] In this embodiment of the invention, no specific limitations are made on the selection of electromagnetic coils or the size of the coils. Any flow control that can satisfy the requirements of the intensity, frequency and energizing phase sequence of the three-phase excitation current of the flow controller of this invention is within the protection scope of this invention.

[0039] Optionally, the design shape of the traveling wave magnetic field generator 2 is based on the cross-sectional shape of the controlled aluminum alloy melt, preferably a conformal shape design. In this embodiment of the invention, no specific limitation is made on the shape of the traveling wave magnetic field generator 2.

[0040] Specifically, the control of the traveling wave magnetic field includes: dynamically adjusting the amplitude of the three-phase excitation current to change the magnetic induction intensity of the traveling wave magnetic field based on the deviation between the real-time flow rate and the target flow rate fed back by the sensor; dynamically adjusting the frequency of the excitation current to change the moving speed of the traveling wave magnetic field based on the current flow state of the molten metal and the target control requirements; and applying a positive thrust or a reverse braking force to the molten metal by changing the energizing sequence of the three-phase current to switch the direction of travel of the traveling wave magnetic field.

[0041] In this embodiment of the invention, the method further includes: recording the monitoring data of each sensor, the control parameters of the excitation current, and the quality data of the final casting during each pouring process; and training a flow control strategy model using a machine learning algorithm based on the recorded data to optimize the adjustment strategy of the excitation current intensity, frequency, and phase sequence in subsequent pouring processes.

[0042] In this embodiment of the invention, a specific embodiment is also provided to illustrate the metal melt flow control method of the present invention.

[0043] Example 1 Step S1, Numerical Simulation Figure 2 This shows an overall schematic diagram of the melt flow controller before triggering in Embodiment 1 of the present invention. Figure 2 In the numerical simulation, the filling speed of the middle runner of the molten metal 1 is significantly faster than that of other locations. Without control, its flow rate is 5 kg / s. With the help of external force in the initial stage of filling, its flow rate is controlled at 2.5 kg / s, which can meet the requirements of stable filling. After the casting is filled, the external force is removed to meet the requirements of the feeding pressure in the middle part.

[0044] Numerical simulations have shown that a downward pressure head Δp, with a value of 12 kPa, needs to be added at the middle runner.

[0045] Step S2: Fixed flow controller and its matching sensors In Example 1, the traveling wave magnetic field generator coil is made of hollow copper wire with an outer diameter of ø8 and an inner diameter of ø4, and the wire is wrapped with 0.5mm thick heat-resistant insulating cloth; each coil is 30mm wide and has 20 turns, for a total of 6 coils; refer to Figure 2 and Figure 3 A corundum tube with a length of 200mm and an inner diameter of 50mm is used to replace this part of the sand mold gating channel. The corundum tube has a wall thickness of 5mm and is wrapped with a 15mm heat insulation layer of 10-position ultra-thin aluminum silicate fiber felt. Following the Cramer wiring method, two thermocouples are arranged at equal angles on the top of the casting as position positioning signal sensors, respectively set at... Figure 2 The first signal sensor 3 at the left filling position and set Figure 2 The second signal sensor 4 at the right filling position is equipped with three thermocouples placed at the same horizontal height (one in the middle gating and two in the edge gating positions) as monitoring sensors. These monitoring sensors are positioning sensors to determine the arrival position of the melt front. Specifically, the monitoring sensors include the second monitoring sensor 6 in the middle gating, the first monitoring sensor 5 in the left edge gating, and the third monitoring sensor 7 in the right edge gating. The wiring of the traveling wave magnetic field generator 2, the first signal sensor 3, the second signal sensor 4, the first monitoring sensor 5, the second monitoring sensor 6, and the third monitoring sensor 7 are all connected to the controller 8 for communication.

[0046] Step S3: Perform the pouring operation The alloy was cast according to the parameters and triggering conditions set by the simulated traveling wave magnetic field generator 2, and the required test conditions were determined. During the casting process, the intensity, frequency, and energizing phase sequence of the three-phase excitation current applied to the flow controller were adjusted in real time to generate and control the traveling wave magnetic field acting on the molten metal, thereby regulating the flow rate of the molten metal during casting. Furthermore, data from monitoring sensors were collected to fine-tune and optimize the input parameters of the traveling wave magnetic field generator.

[0047] The relative height of the molten metal changes after the melt controller is triggered, as follows: Figure 4 As shown, Figure 4 This shows an overall schematic diagram of the melt flow controller after it is triggered in Embodiment 1 of the present invention. Figure 4 In the process, after configuring and installing the traveling wave magnetic field generator 2 to adjust the flow control and triggering conditions of the molten metal 1, the middle gating of the molten metal 1 is flush with the filling at other positions, which meets the casting requirements.

[0048] In Example 1, to improve the safety of the casting, the excitation current of the traveling wave magnetic field is cut off when the temperature of both thermocouples of the signal sensor is greater than 100°C.

[0049] This invention also provides a metal melt flow control system. Figure 5 A schematic diagram of the metal melt flow control system according to an embodiment of the present invention is shown. Figure 5 The system includes a flow control execution module, a pouring module, and a control module. The flow control execution module is configured to preset at least one flow controller based on the location, control range, and triggering conditions of the target flow control area within the mold, and to fix the flow controller and its associated sensor inside the mold at preset positions. The pouring module is configured to perform a pouring operation on the mold equipped with the flow controller using preset process conditions after the controller and sensor are installed. The control module is configured to, during the pouring process, generate and control a traveling wave magnetic field acting on the molten metal by real-time adjustment of the intensity, frequency, and energizing phase sequence of the three-phase excitation current applied to the flow controller, thereby regulating the flow rate of the molten metal during the pouring process.

[0050] This invention also provides a computer storage medium storing one or more instructions, which, when executed by one or more computers, cause the one or more computers to implement the molten metal flow control method of this invention.

[0051] The computer-readable storage medium stores a computer program that, when executed by a processor, implements the steps of the molten metal flow control method. Specifically, the computer-readable storage medium includes, but is not limited to, volatile memory and / or non-volatile memory. The volatile memory may include random access memory (RAM) and / or cache memory, etc. The non-volatile memory may include read-only memory (ROM), hard disk, flash memory, optical disk, magnetic disk, etc.

[0052] The present invention provides a method, system, and storage medium for controlling the flow rate of molten aluminum alloy in the casting of thin-walled complex structural parts. It adopts a non-contact control device, which does not contaminate the molten metal; the parameters can be programmed and controlled, and automation can be easily achieved; it solves the problem of uncontrollable local flow rate in complex structural parts, improves the stability of the casting filling process, enhances the local feeding effect of the molten aluminum alloy, and improves the metallurgical quality and production qualification rate of the casting.

[0053] This invention upgrades the control method from "passive flow channel design" to "active melt manipulation" by dynamically and quantitatively controlling the traveling wave magnetic field. By precisely controlling the intensity, frequency, and phase sequence of the excitation current, the melt is controlled to flow at a preset speed and direction, ensuring that the far end and thin-walled areas are fully filled and compensated. By adjusting the control parameters, the filling and compensation schemes can be quickly verified and optimized. Only a few physical tests are needed to lock in the optimal process window, greatly shortening the process cycle.

[0054] This invention ensures that the melt front maintains sufficient heat and kinetic energy to achieve seamless fusion by precisely controlling the shape, speed, and pressure of the melt flow front. It provides continuous and directional feeding pressure throughout the solidification process, "driving" shrinkage cavities from the inside of the casting to the pre-set riser or gating, thereby achieving densification of the casting. Through stable laminar flow guidance, it reduces the impact and tumbling of the melt on the molding sand, thereby reducing the tendency for inclusions and porosity to form.

[0055] This invention achieves one-time casting, avoiding all uncertainties, additional costs, and potential risks associated with post-processing. For casting parts that are structurally enclosed, deeply buried, or cannot be disassembled for inspection during service, the active control capabilities of this invention can directly target these "blind spots," ensuring high-quality molding structure from the source. This is revolutionary for core castings in key fields such as aerospace and energy.

[0056] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for controlling the flow rate of molten metal, characterized in that, The method includes: Based on the location, control range, and triggering conditions of the target flow control area within the mold, at least one flow controller is preset, and the flow controller and its associated sensor are fixed inside the mold at preset positions. After the controller and sensor are installed, the mold equipped with the flow controller is poured under preset process conditions. During the casting process, the intensity, frequency, and energizing phase sequence of the three-phase excitation current applied to the flow controller are adjusted in real time to generate and control the traveling wave magnetic field acting on the molten metal, thereby regulating the flow rate of the molten metal during the casting process.

2. The method for controlling the flow rate of molten metal according to claim 1, characterized in that, The triggering conditions include: The flow controller is activated when the pouring time reaches a preset threshold; or... The flow controller is activated when the melt front reaches a specific location monitored by the sensor; or... The flow controller is activated when the melt temperature, flow rate, or pressure detected by the sensor exceeds a preset range.

3. The method for controlling the flow rate of molten metal according to claim 1 or 2, characterized in that, The flow controller includes a traveling wave magnetic field generator, and the assembly of the traveling wave magnetic field generator includes: The original sand gating system in the target flow control area of ​​the mold was replaced with a prefabricated ceramic pipe. One or more traveling wave magnetic field generators are axially spaced along the outer wall of the ceramic tube. A heat insulation layer is provided between the traveling wave magnetic field generator and the outer wall of the ceramic tube; The assembled ceramic tube, insulation layer, and traveling wave magnetic field generator are integrated into the mold.

4. The method for controlling the flow rate of molten metal according to claim 1 or 2, characterized in that, The sensors include at least a temperature sensor for monitoring the melt temperature, a flow field sensor for monitoring the melt surface velocity or pressure, and a positioning sensor for determining the location of the melt front.

5. The method for controlling the flow rate of molten metal according to claim 3, characterized in that, The method also includes a cooling step for the traveling wave magnetic field generator: Cooling channels are integrated around or inside the traveling wave magnetic field generator; A first temperature sensor is embedded in the insulation layer to monitor the temperature of the insulation layer in real time. If the temperature of the first temperature sensor reaches the set cooling threshold, the cooling medium is introduced into the cooling channel to cool the traveling wave magnetic field generator.

6. The method for controlling the flow rate of molten metal according to claim 3, characterized in that, The traveling wave magnetic field generator includes: An electromagnetic coil made of conductive material is configured to generate a traveling wave magnetic field that propagates in a specific direction when a multiphase alternating current is applied. The winding of the electromagnetic coil is made of at least one of hollow wire, enameled wire, and insulated bare wire.

7. The method for controlling the flow rate of molten metal according to claim 1, characterized in that, The control of the traveling wave magnetic field includes: Based on the deviation between the real-time flow rate and the target flow rate fed back by the sensor, the amplitude of the three-phase excitation current is dynamically adjusted to change the magnetic induction intensity of the traveling wave magnetic field. Based on the current flow state of the molten metal and the target control requirements, the frequency of the excitation current is dynamically adjusted to change the moving speed of the traveling wave magnetic field. By changing the energizing sequence of the three-phase currents, the direction of travel of the traveling wave magnetic field is switched, thereby applying a positive thrust or a reverse braking force to the melt.

8. The method for controlling the flow rate of molten metal according to claim 1, characterized in that, The method further includes: Record the monitoring data of each sensor, the control parameters of the excitation current, and the quality data of the final casting during each pouring process; Based on the recorded data, a flow control strategy model is trained using machine learning algorithms to optimize the adjustment strategies for the excitation current intensity, frequency, and phase sequence in subsequent casting processes.

9. A metal melt flow control system, characterized in that, The system includes a flow control execution module, a pouring module, and a control module. The flow control execution module is configured to preset at least one flow controller according to the location, control range and triggering conditions of the target flow control area inside the mold, and fix the flow controller and its matching sensor in the mold at preset positions. The casting module is configured to perform a casting operation on the mold equipped with the flow controller using preset process conditions after the installation of the controller and sensor is completed. The control module is configured to generate and control the traveling wave magnetic field acting on the molten metal during the pouring process by adjusting the intensity, frequency and energizing phase sequence of the three-phase excitation current applied to the flow controller in real time.

10. A computer storage medium, characterized in that, The computer storage medium stores one or more instructions that, when executed by one or more computers, cause the one or more computers to perform the method of any one of claims 1-8.

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