Integrated flow meter for aluminum casting

Abstract

The invention discloses an integrated flow meter for aluminum casting. The molten metal scrubbing system includes a pump that draws molten metal from the reservoir. The heated channel receives the molten metal from the pump and carries a flow of the molten metal. A conduit extends from the heated channel and is exposed outside of the heated channel. The conduit carries flow. The temperature sensor senses a temperature of the molten metal in the conduit. An outlet at an end of the duct directs flow from the duct into the casting mold. The flow meter is placed along the conduit, wherein the conduit extends through the flow meter. The flow meter senses a flow rate of the flow of the molten metal in the conduit. The control module adjusts operation of the pump based at least on the flow rate sensed by the flow meter and the temperature sensed by the temperature sensor.

Description

[0001] The information provided in this section is for the purpose of presenting the general background of this disclosure. The work of the currently named inventors, to the extent described in this section, and in all aspects of that description which at the time of filing may not be regarded as prior art, is neither expressly nor implicitly considered prior art to this disclosure. Technical Field

[0002] This disclosure relates primarily to systems and methods for measuring the flow rate of conductive fluids passing through pipes in a foundry system using a flow meter integrated with the foundry system. Background Technology

[0003] Many systems that carry conductive fluids (such as molten aluminum or alkali metals) through pipes require accurate measurement of the conductive fluid flow. For example, a washing system that transports molten metal to a casting mold can monitor the flow of the molten metal in the mold using the filling time. However, time-based measurements can be relatively inaccurate and do not allow for flow rate adjustments during the casting process.

[0004] While some flow meters are capable of measuring the flow rate of conductive fluids, these flow meters typically use probes that extend at least partially into the pipe carrying the conductive fluid. Other typical examples include electrodes that contact the conduit, with measurements involving the voltage induced in the conductive fluid between the electrodes. Therefore, these examples involve direct contact between the flow meter and the conductive fluid and / or the pipe carrying the conductive fluid, and require the flow meter to withstand the high temperatures of the conductive fluid. Summary of the Invention

[0005] One aspect of this disclosure provides a molten metal washing system. The molten metal washing system includes a pump configured to draw molten metal from a storage tank. A heated channel is configured to receive molten metal from the pump and carry the flow of molten metal. A conduit extends from the heated channel and is exposed to the outside of the heated channel. The conduit is configured to carry the flow of molten metal. A temperature sensor is configured to sense the temperature of the molten metal in the conduit. An outlet is located at the end of the conduit and configured to direct the flow of molten metal from the conduit into a casting mold. A flow meter is placed along the conduit. The conduit extends through the flow meter. The flow meter is configured to sense the flow rate of the molten metal in the conduit. A control module in communication with the pump is configured to adjust the operation of the pump based at least on the flow rate sensed by the flow meter and the temperature sensed by the temperature sensor, so as to adjust the flow of molten metal into the casting mold.

[0006] Various aspects of this disclosure may include one or more of the following optional features. In some embodiments, the flow meter includes a non-contact flow meter. In other embodiments, the conduit includes a non-magnetic material. In some examples, the flow meter includes a contact-based flow meter. In other examples, the conduit includes a non-magnetic metallic material.

[0007] In some aspects, the conduit is a component of the heated channel. A portion of the conduit extends from one end of the heated channel to be exposed to the outside of the heated channel. In some embodiments, the conduit is a component of a flow meter. A gasket placed at the outlet end of the conduit is configured to interface with the heated channel.

[0008] In some examples, the inner diameter of the pipe differs from the inner diameter of the heated channel. In some aspects, the control module is configured to adjust the operation of the pump to achieve a target flow rate of molten metal in the pipe. Optionally, the molten metal includes molten aluminum, and the casting mold is for vehicle parts.

[0009] Another aspect of this disclosure provides a computer-implemented method that, when executed on data processing hardware, causes the data processing hardware to perform operations. The operations include operating a pump of a molten metal washing system to draw molten metal from a storage tank. A heated channel receives molten metal from the pump and carries the flow of molten metal. A conduit extends from the heated channel and is exposed to the outside of the heated channel. The conduit carries the flow of molten metal to an outlet at one end of the conduit. The outlet directs the flow of molten metal from the conduit into a casting mold. The operations include receiving first sensor data from a temperature sensor. The first sensor data represents the temperature of the molten metal in the conduit. The operations include receiving second sensor data from a flow meter placed along the conduit. The conduit extends through the flow meter. The second sensor data represents the flow rate of the molten metal flow in the conduit. In response to processing the first and second sensor data, the operations include adjusting the operation of the pump based at least on the flow rate of the molten metal flow in the conduit and the temperature of the molten metal in the conduit, in order to adjust the flow of molten metal into the casting mold. This aspect of the disclosure may include one or more of the following optional features.

[0010] In some implementations, the flow meter includes a non-contact flow meter. In some examples, the flow meter includes a contact-based flow meter. In some aspects, the conduit is a component of the heated channel. A portion of the conduit extends from the end of the heated channel to expose it to the outside. Optionally, the operation of the pump is adjusted based on a target flow rate of molten metal flowing in the conduit.

[0011] Another aspect of this disclosure provides a system. The system includes memory hardware storing instructions, which, when executed on data processing hardware in communication with the memory hardware, causes the data processing hardware to perform operations. The operations include operating a pump of a molten metal washing system to draw molten metal from a storage tank. A heated channel receives molten metal from the pump and carries the flow of molten metal. A conduit extends from the heated channel and is exposed to the outside of the heated channel. The conduit carries the flow of molten metal to an outlet at one end of the conduit. The outlet directs the flow of molten metal from the conduit into a casting mold. The operations include receiving first sensor data from a temperature sensor. The first sensor data represents the temperature of the molten metal in the conduit. The operations include receiving second sensor data from a flow meter placed along the conduit. The conduit extends through the flow meter. The second sensor data represents the flow rate of the molten metal flow in the conduit. In response to processing the first and second sensor data, the operations include adjusting the operation of the pump based at least on the flow rate of the molten metal flow in the conduit and the temperature of the molten metal in the conduit, to adjust the flow of molten metal into the casting mold. This aspect of the disclosure may include one or more of the following optional features.

[0012] In some implementations, the flow meter includes a non-contact flow meter. In some examples, the flow meter includes a contact-based flow meter. In some aspects, the conduit is a component of the heated channel. A portion of the conduit extends from the end of the heated channel to expose it to the outside. Optionally, the operation of the pump is adjusted based on a target flow rate of molten metal flowing in the conduit.

[0013] The present invention also discloses the following technical solutions:

[0014] Option 1. A molten metal washing system, the molten metal washing system comprising:

[0015] A pump configured to extract molten metal from a storage tank;

[0016] A heated channel, the heated channel being configured to receive the molten metal from the pump and to carry the flow of the molten metal;

[0017] A conduit extending from the heated channel and exposed outside the heated channel, the conduit being configured to carry the flow of the molten metal;

[0018] A temperature sensor configured to sense the temperature of the molten metal in the pipe;

[0019] An outlet, located at the end of the pipe, is configured to guide the flow of the molten metal from the pipe into a casting mold;

[0020] A flow meter, placed along the pipe through which the flow meter extends, the flow meter configured to sense the flow rate of the molten metal in the pipe; and

[0021] A control module, which communicates with the pump, is configured to adjust the operation of the pump based at least on the flow rate sensed by the flow meter and the temperature sensed by the temperature sensor, in order to adjust the flow of the molten metal in the casting mold.

[0022] Option 2. The molten metal washing system according to Option 1, wherein the flow meter includes a non-contact flow meter.

[0023] Option 3. The molten metal washing system according to Option 2, wherein the pipe comprises a non-magnetic material.

[0024] Option 4. The molten metal washing system according to Option 1, wherein the flow meter includes a contact-based flow meter.

[0025] Option 5. The molten metal washing system according to Option 4, wherein the pipe comprises a non-magnetic metal material.

[0026] Option 6. The molten metal washing system according to Option 1, wherein the pipe is a component of the heated channel, and a portion of the pipe extends from the end of the heated channel to be exposed to the outside of the heated channel.

[0027] Option 7. The molten metal washing system according to Option 1, wherein the pipe is a component of the flow meter, and a gasket placed at the end of the pipe opposite to the outlet is configured to interface with the heated channel.

[0028] Option 8. The molten metal washing system according to Option 1, wherein the inner diameter of the pipe is different from the inner diameter of the heated channel.

[0029] Option 9. The molten metal washing system according to Option 1, wherein the control module is configured to adjust the operation of the pump in order to achieve the target flow rate of the molten metal in the pipeline.

[0030] Option 10. The molten metal washing system according to Option 1, wherein the molten metal comprises molten aluminum, and the casting mold is used for vehicle parts.

[0031] Option 11. A computer-implemented method, when executed on data processing hardware, causes the data processing hardware to perform operations, the operations including:

[0032] A pump that operates a molten metal washing system to draw molten metal from a storage tank; a heated channel that receives the molten metal from the pump and carries the flow of the molten metal; a pipe extending from the heated channel and exposed outside the heated channel, the pipe carrying the flow of the molten metal to an outlet at the end of the pipe, the outlet guiding the flow of the molten metal from the pipe into a casting mold;

[0033] Receive first sensor data from a temperature sensor, the first sensor data representing the temperature of the molten metal in the pipe;

[0034] The system receives data from a second sensor, which is positioned along the pipe through which the flow meter extends, and the second sensor data represents the flow rate of the molten metal in the pipe; and

[0035] In response to processing the first sensor data and the second sensor data, the operation of the pump is adjusted based at least on the flow rate of the molten metal in the pipe and the temperature of the molten metal in the pipe, so as to adjust the flow of the molten metal in the casting mold.

[0036] Option 12. The method according to Option 11, wherein the flow meter includes a non-contact flow meter.

[0037] Option 13. The method according to Option 11, wherein the flow meter includes a contact-based flow meter.

[0038] Option 14. The method according to Option 11, wherein the pipe is a component of the heated channel, and a portion of the pipe extends from an end of the heated channel to be exposed to the outside of the heated channel.

[0039] Option 15. The method according to Option 11, wherein adjusting the operation of the pump is based on the target flow rate of the molten metal in the pipeline.

[0040] Option 16. A system comprising:

[0041] Memory hardware storing instructions, which, when executed on data processing hardware in communication with the memory hardware, cause the data processing hardware to perform operations, the operations including:

[0042] A pump that operates a molten metal washing system to draw molten metal from a storage tank; a heated channel that receives the molten metal from the pump and carries the flow of the molten metal; a pipe extending from the heated channel and exposed outside the heated channel, the pipe carrying the flow of the molten metal to an outlet at the end of the pipe, the outlet guiding the flow of the molten metal from the pipe into a casting mold;

[0043] Receive first sensor data from a temperature sensor, the first sensor data representing the temperature of the molten metal in the pipe;

[0044] The system receives data from a second sensor, which is positioned along the pipe through which the flow meter extends, and the second sensor data represents the flow rate of the molten metal in the pipe; and

[0045] In response to processing the first sensor data and the second sensor data, the operation of the pump is adjusted based at least on the flow rate of the molten metal in the pipe and the temperature of the molten metal in the pipe, so as to adjust the flow of the molten metal in the casting mold.

[0046] Option 17. The system according to Option 16, wherein the flow meter includes a non-contact flow meter.

[0047] Option 18. The system according to Option 16, wherein the flow meter includes a contact-based flow meter.

[0048] Option 19. The system according to Option 16, wherein the conduit is a component of the heated channel, and a portion of the conduit extends from an end of the heated channel to be exposed to the outside of the heated channel.

[0049] Option 20. The system according to Option 16, wherein adjusting the operation of the pump is based on the target flow rate of the molten metal in the pipeline.

[0050] Details of one or more embodiments of this disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will become apparent from the description and drawings, as well as from the claims. Attached Figure Description

[0051] The accompanying drawings described herein are for illustrative purposes only for the selected configurations and are not intended to limit the scope of this disclosure.

[0052] Figure 1 It is a perspective view of a vehicle with parts formed through a casting process.

[0053] Figure 2 This is an exploded view of a washing system with an integrated flow meter.

[0054] Figure 3 yes Figure 2 A magnified view of region 3 in the middle.

[0055] Figure 4 This is a schematic diagram of the flow meter and pump in the washing system during the pump drying process.

[0056] Figure 5 This is a flowchart of an example method for adjusting the operation of a washing system pump during a casting process based on the flow rate sensed by an integrated flow meter.

[0057] The corresponding reference numerals throughout the accompanying drawings indicate the corresponding components. Detailed Implementation

[0058] Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be comprehensive and will fully convey the scope of the disclosure to those skilled in the art. Specific details, such as examples of specific parts, apparatus, and methods, are set forth to provide a full understanding of the configurations of this disclosure. It will be apparent to those skilled in the art that specific details are not required, example configurations may be included in a large number of different forms, and the specific details and example configurations should not be construed as limiting the scope of the disclosure.

[0059] The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “described” may be intended to include the plural forms as well, unless the context explicitly indicates otherwise. The terms “comprising,” “including,” “containing,” and “having” are inclusive and therefore describe the presence of features, steps, operations, elements, and / or parts, but do not exclude the presence or addition of one or more other features, steps, operations, elements, parts, and / or combinations thereof. The method steps, processes, and operations described herein should not be construed as necessarily requiring them to be performed in the specific order discussed or shown, unless specifically identified as such. Additional or alternative steps may be employed.

[0060] When an element or layer is referred to as being "on," "joined to," "connected to," "attached to," or "linked to" another element or layer, it may be directly on, directly joined to, directly connected to, directly attached to, or directly linked to the other element or layer, or there may be an intervening element or layer present. Conversely, when an element is referred to as being "directly on," "directly joined to," "directly connected to," directly attached to, or directly linked to another element or layer, there may be no intervening element or layer present. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., contrast between "between" and "directly between," contrast between "adjacent" and "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the related enumerated items.

[0061] The terms “first,” “second,” “third,” etc., may be used herein to describe various elements, parts, regions, layers, and / or sections. These elements, parts, regions, layers, and / or sections should not be limited by these terms. These terms may be used only to distinguish one element, part, region, layer, or section from another. Terms such as “first,” “second,” and other numerical terms do not imply order or sequence unless explicitly indicated by the context. Therefore, the first element, part, region, layer, or section discussed below may be referred to as the second element, part, region, layer, or section without departing from the teachings of the example configuration.

[0062] In this application, including the definitions below, the term "module" may be replaced by the term "circuit". The term "module" may refer to, be a part of, or include the following: application-specific integrated circuit (ASIC); digital, analog, or mixed-signal analog / digital discrete circuit; digital, analog, or mixed-signal analog / digital integrated circuit; combinational logic circuit; field-programmable gate array (FPGA); processor (shared, dedicated, or group) for executing code; memory (shared, dedicated, or group) for storing code executed by the processor; other suitable hardware components that provide the described functionality; or some or all of the above, such as in a system-on-a-chip.

[0063] The term "code," as used above, can include software, firmware, and / or microcode, and can refer to a program, routine, function, class, and / or object. The term "shared processor" includes a single processor that executes some or all of the code from multiple modules. The term "group processor" includes processors that, in conjunction with additional processors, execute some or all of the code from one or more modules. The term "shared memory" includes a single memory that stores some or all of the code from multiple modules. The term "memory group" includes memory that, in conjunction with additional memory, stores some or all of the code from one or more modules. The term "memory" can be a subset of the term "computer-readable medium." The term "computer-readable medium" does not include transient electrical and electromagnetic signals propagating through the medium, and therefore can be considered tangible and non-transient memory. Non-limiting examples of non-transient memory include tangible computer-readable media, which include non-volatile memory, magnetic storage, and optical storage.

[0064] The apparatus and methods described in this application can be implemented, in whole or in part, by one or more computer programs executed by one or more processors. The computer program includes processor-executable instructions stored on at least one non-transitory tangible computer-readable medium. The computer program may also include and / or depend on stored data.

[0065] A software application (i.e., a software resource) can refer to computer software that enables a computing device to perform tasks. In some examples, a software application may be called an "application," "app," or "program." Example applications include, but are not limited to, system diagnostic applications, system management applications, system maintenance applications, word processing applications, spreadsheet applications, messaging applications, streaming media applications, social networking applications, and game applications.

[0066] Non-transient memory can be a physical device used to store programs (e.g., sequences of instructions) or data (e.g., program state information) on a temporary or permanent basis for use by a computing device. Non-transient memory can be volatile and / or non-volatile addressable semiconductor memory. Examples of non-volatile memory include, but are not limited to, flash memory and read-only memory (ROM) / programmable read-only memory (PROM) / erasable programmable read-only memory (EPROM) / electronically erasable programmable read-only memory (EEPROM) (e.g., typically used in firmware, such as bootloaders). Examples of volatile memory include, but are not limited to, random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), phase-change memory (PCM), and magnetic disks or magnetic tapes.

[0067] These computer programs (also referred to as programs, software, software applications, or code) include machine instructions for a programmable processor and can be implemented in high-level procedural and / or object-oriented programming languages ​​and / or in assembly / machine language. As used herein, the terms “machine-readable medium” and “computer-readable medium” refer to any computer program product, non-transitory computer-readable medium, device, and / or apparatus (e.g., disk, optical disk, memory, programmable logic device (PLD)) used to provide machine instructions and / or data to a programmable processor, including machine-readable media that receive machine instructions as machine-readable signals. The term “machine-readable signal” refers to any signal used to provide machine instructions and / or data to a programmable processor.

[0068] Various implementations of the systems and techniques described herein can be implemented in digital electronic and / or optical circuits, integrated circuits, specially designed ASICs (Application-Specific Integrated Circuits), computer hardware, firmware, software, and / or combinations thereof. These various implementations can be implemented in one or more computer programs executable and / or interpretable on a programmable system, the programmable system including at least one programmable processor (which may be special-purpose or general-purpose), the programmable processor being configured to receive data and instructions from a storage system, at least one input device, and at least one output device, and to transmit data and instructions to the storage system, at least one input device, and at least one output device.

[0069] The processes and logical flows described in this specification can be executed by one or more programmable processors (also known as data processing hardware), which execute one or more computer programs to perform functions by manipulating input data and producing output. The processes and logical flows can also be executed by special-purpose logic circuits, such as FPGAs (Field-Programmable Gate Arrays) or ASICs (Application-Specific Integrated Circuits). Processors suitable for executing computer programs include (by way of example) both general-purpose and special-purpose microprocessors, and any one or more processors of any kind of digital computer. Typically, the processor receives instructions and data from read-only memory or random access memory, or both. The basic elements of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Typically, a computer will also include one or more mass storage devices for storing data, such as magnetic disks, magneto-optical disks, or optical disks, or operatively coupled to receive data from or transfer data to one or more mass storage devices, or both. However, a computer does not need to have such devices. Computer-readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media, and memory devices, including (by way of example) semiconductor memory devices such as EPROM, EEPROM, and flash memory devices; magnetic disks, such as internal hard disks or removable disks; magneto-optical disks; and CD ROMs and DVD-ROMs. Processors and memory can be supplemented by or incorporated into special-purpose logic circuitry.

[0070] To provide interaction with a user, one or more aspects of this disclosure can be implemented on a computer having a display device (e.g., a CRT (cathode ray tube), LCD (liquid crystal display) monitor, or touchscreen for displaying information to the user) and (optionally) a keyboard and pointing device (e.g., a mouse or trackball, through which the user can provide input to the computer). Other types of devices can also be used to provide interaction with the user; for example, feedback provided to the user can be feedback from any form of sensor, such as visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including sound, speech, or tactile input. Furthermore, the computer can interact with the user by sending data to and receiving data from the device used by the user; for example, by sending a webpage to a web browser on the user's client device in response to a request received from a web browser.

[0071] Referring now to the accompanying drawings and the configuration shown in the drawings, vehicle 10 includes one or more parts formed via a metal casting process. Figure 1For example, vehicle 10 includes an engine block 12 formed of cast aluminum. That is, the engine block 12 (or one or more other parts of vehicle 10) is formed by casting molten aluminum 14 using a casting technique. Figure 4 It is formed by distributing it into a mold or package. Aspects of the casting process can utilize a casting transport or washing system 100 ( Figure 2 Real-time flow rate measurement of molten aluminum 14 transported to the mold. As further described below, the washing system 100 includes a flow meter 200, which is integrated with or placed in line with components and / or piping of the washing system 100 to reliably determine the flow rate F of molten aluminum 14 from the washing system 100. 14 And adjust the flow rate F through the washing system 100 based on the reading from the flow meter 200. 14 In some examples, the flow meter 200 can determine the flow rate F without the flow meter 200 being directly engaged with the molten aluminum 14 and / or without interrupting or separating the washing system 100 in a manner that would cause a leak. 14 Although described herein, the flow rate F of molten aluminum 14 through the washing system 100 is determined. 14 It should be understood that the flow meter 200 can be configured to determine the flow rate of any suitable molten metal through various casting transport systems and / or other conductive fluids (such as alkali metals or electrochemical solutions) through the pipes of various systems.

[0072] like Figure 2 As illustrated, the casting conveying or washing system 100 includes a reservoir or pool 102 for molten metal (e.g., molten aluminum 14) and a pump 104 configured to draw molten aluminum 14 from the reservoir 102. During operation, the pump 104 conveys the flow of molten aluminum 14 from the reservoir 102 to a fill port 106 at a first end 110 of a channel or channel track 108. The flow of molten aluminum 14 moves along a channel or passageway of the channel 108 from the first end 110 to a second end 112 of the channel 108 opposite to the first end 110. The channel 108 can be heated to maintain or regulate the temperature of the molten aluminum 14, and thus maintain or regulate the viscosity and flow rate F of the molten aluminum 14. 14 .

[0073] In the illustrated example, a filling port 106 is positioned at the first end 110 of channel 108 and fluidly coupled to channel 108, with a gasket and interface plate 114 positioned between the filling port 106 and channel 108 to provide a sealed connection between the filling port 106 and channel 108. In some examples, the filling port 106 may be integrated with the heated channel 108. When the pump 104 is operated to deliver molten aluminum 14 to the filling port 106, the filling port 106 ensures that the channel or passageway of channel 108 is completely filled. As discussed further below, this ensures accurate flow rate measurement at flow meter 200.

[0074] A conduit or pipe 116 extends from the second end 112 of the channel 108 and is exposed to the outside of the heated channel 108. The conduit 116 may be an extension of a channel or passageway of the channel 108, such that the conduit 116 may be continuous from the first end 110 of the channel 108 through the second end 112 of the channel 108 toward an outlet 120 at the end 118 of the conduit 116 (remote from the second end 112 of the channel 108). Thus, the conduit 116 is configured to carry the flow of molten aluminum 14 toward the outlet 120, wherein the outlet 120 is configured to guide the flow of molten aluminum 14 from the end 118 of the conduit 116 and into a casting mold or package that receives the molten aluminum 14. A gasket or interface plate 122 may be placed between the end 118 of the conduit 116 and the outlet 120, and provides a sealing connection for mounting the end 118 of the conduit 116 at the outlet 120.

[0075] like Figure 3 As illustrated, conduit 116 may include a split tube fluidly connected to a channel or passageway of channel 108 at a second end 112 of channel 108. That is, end 124 of conduit 116, opposite end 118 located at outlet 120, is fluidly connected to channel 108. A gasket or interface plate 126 may be placed between end 124 of conduit 116 and second end 112 of channel 108 to allow for the installation of conduit 116 to channel 108 with a sealed fluid connection. The conduit 116, separated from channel 108, may be a component of flow meter 200.

[0076] A flow meter 200 is placed along pipe 116 between the second end 112 of channel 108 and outlet 120, and is configured to sense the flow rate F of molten aluminum 14 flowing through pipe 116. 14Using an exposed conduit 116 integrated with channel 108, flow meter 200 can be fixedly positioned at conduit 116, for example, clamped to conduit 116 from the opposite side to substantially surround conduit 116 and / or slidably positioned along conduit 116 such that conduit 116 extends through flow meter 200. Conduit 116, attached to a second end 112 of channel 108, can be a component of flow meter 200. Therefore, flow meter 200 and conduit 116 can be removable from scrubbing system 100, for example, for easier maintenance, for moving flow meter 200 between different systems, for replacement with flow meters having different flow rate sensitivities, and for similar purposes.

[0077] In addition, the washing system 100 and / or flow meter 200 include a configuration for sensing the temperature T of the molten aluminum 14 in the channel 108 and / or pipe 116. 14 Temperature sensor 128. Temperature sensor 128 will represent temperature T. 14 The sensor data is transmitted to the control module 130 of the washing system 100, and the flow meter 200 will display the flow rate F. 14 Sensor data is transmitted to the control module 130 of the washing system 100, for example via a wired or wireless communication link (e.g., via Wi-Fi). TM The flow meter 200 and temperature sensor 128 can send analog signals representing the temperature and flow status of the molten aluminum 14. As discussed further below, the control module 130 communicates with the pump 104 and is based at least on the flow rate F sensed by the flow meter 200. 14 and the temperature T sensed by temperature sensor 128 14 The operation of the control pump 104 is used to adjust the flow of molten aluminum 14 into the casting mold.

[0078] In other words, the flow meter 200 and / or the washing system 100 may include or communicate with a control module 130, which includes data processing hardware 132 and memory hardware 134 communicating with the data processing hardware 132. The memory hardware 134 stores instructions that, when executed on the data processing hardware 132, cause the data processing hardware 132 to perform operations. For example, the control module 130 stores instructions for using the flow rate F sensed by the flow meter 200. 14 Instructions to operate pump 104 of washing system 100, such as those discussed further below. Figure 5 Method 500.

[0079] In some examples, the flow meter 200 is a contact-based flow meter, wherein the flow meter 200 includes a probe that extends at least partially into the pipe 116 to determine the flow rate F of the molten aluminum 14. 14This is because the molten aluminum 14 flows through and interacts with the probe. In these examples, the pipe 116 can be a component of the flow meter 200. Optionally, the flow meter 200 is a contact-based flow meter, wherein the flow meter 200 operates to generate a magnetic field that passes through the pipe 116 and interacts at least partially with the molten aluminum 14. As a conductive fluid, the magnetic field induces eddy currents in the molten aluminum 14. The reaction magnetic field generated by the eddy currents can generate an electric charge between opposite sides of the pipe 116, which can be sensed by electrodes of the flow meter 200 contacting opposite sides of the pipe 116. The strength of the reaction magnetic field can be related to the flow rate F of the molten aluminum 14. 14 This is correlated and can be detected based on the charge sensed by the flow meter 200. Therefore, the contact-based flow meter 200 can utilize a conduit 116 formed of a non-magnetic metallic material, such as a tungsten-based alloy (e.g., ANVILOY). TM Alternatively, pipe 116 can be coated with a compatible material, such as stainless steel pipe coated with tungsten.

[0080] Alternatively, the flow meter 200 may be a non-contact or contactless flow meter that does not directly engage with the molten aluminum 14 and / or the conduit 116. For example, the flow meter 200 may operate to generate a magnetic field that passes through the conduit 116 and induces eddy currents in the conductive molten aluminum 14. The non-contact flow meter 200 may be configured to sense the force of the reaction magnetic field experienced at the flow meter. By way of example, the non-contact flow meter 200 may include a magnetic element coupled to a load cell, and the load cell may be configured to sense the reaction magnetic field interacting with the magnetic field. The force of the magnetic field can be calibrated for the flow rate of the molten aluminum 14 through the conduit 116. Sensing the force of the magnetic field generated by the molten aluminum 14 can provide less noise than sensing voltage in an industrial environment such as a foundry environment. In these examples, the flow meter 200 may utilize the conduit 116, which is formed of a non-magnetic material, such as a non-magnetic metal or a non-metallic ceramic material.

[0081] In some examples, the inner diameter of the pipe 116 at flow meter 200 may differ from the inner diameter of the heated channel 108 in order to adjust the flow rate F of the molten material 14. 14 This is to better match the sensitivity or sensing range of the flow meter 200. For example, if the desired flow rate of the molten material 14 through channel 108 is faster than the desired flow rate through the flow meter 200, then channel 116 can widen at the flow meter 200 to increase the flow rate F of the molten material 14 through the flow meter 200. 14 Slowing down. Similarly, if the desired flow of molten material 14 through channel 108 is slower than the desired flow through flow meter 200, then pipe 116 may narrow or bend at flow meter 200 to increase the flow rate F of molten material 14 through flow meter 200.14 Although this may cause turbulence in the flow of molten material 14, resulting in pressure changes in the washing system 100, and / or the accumulation of corundum in the pipe 116, the accuracy of the flow meter 200 can be improved.

[0082] Because the density and viscosity of molten aluminum 14 are based on temperature changes, the control module 130 can be calibrated to determine the flow rate F of molten aluminum 14 based on sensor data captured by the flow meter 200 and the temperature sensor 128 during the calibration process. 14 For example, the control module 130 can be calibrated at various temperatures of the molten aluminum 14 and based on the diameter of the pipe 116, the desired flow rate of the molten aluminum 14 from the reservoir 102 (e.g., based on voltage or power settings of the pump 104), the fill rate calculated from the volume of the casting mold, the type of molten metal or conductive fluid, and the like. The control module 130 can store predetermined calibration curves to achieve the desired flow rate as the temperature T of the molten aluminum 14 increases during subsequent use of the washing system 100 after the calibration process. 14 The changing flow rate F 14 Precise measurement.

[0083] In other words, during the calibration process, molten aluminum 14 is passed through different temperatures T 14 The integrated washing system 100 is sent as a function of time to a known volume and generates a temperature-dependent calibration curve for determining the flow rate F based on the signal output by the flow meter 200. 14 The quality of the die casting can be tracked as a function of time to determine the flow rate during the calibration process. Calibration profiles can be determined at various molten aluminum temperatures and using pump 104 operating at different rates. The calibration process can be performed paired for each flowmeter 200 and washing system 100, either periodically at the washing system 100 to maintain tolerance standards, and / or after the reconstruction of the washing system 100.

[0084] refer to Figure 4 The interface between the flow meter 200 and the heated channel 108 can be a replaceable gasket, meaning the flow meter 200 can be removed or replaced from the washing system 100, for example, for use during the drying process of the pump 104. During the drying process, molten aluminum 14 is drawn from the storage tank 102 by the pump 104 and sent back to the storage tank 102 in the closed loop via pipe 116. This can occur at the washing system 100, or, as illustrated, the flow meter 200 can be used as an offline unit to measure the flow rate F of the molten aluminum 14 produced by the pump 104. 14 During the drying process, a voltage within a certain range can be applied to pump 104 to change the flow rate F. 14And the flow rate F measured by flow meter 200 14 It can be compared with the expected value to determine whether pump 104 falls within or deviates from the predetermined operating specifications.

[0085] Figure 5 Provides a method for using flow rate F 14 A flowchart illustrating an exemplary arrangement of the operation of the washing system 100, with a flow rate F. 14 The flow is sensed by flow meter 200, for example, after drying of pump 104 and after calibration by control module 130. Method 500 can be executed by control module 130, for example, at data processing hardware 132 based on operations stored in memory storage hardware 134. At operation 502, method 500 includes operating pump 104 of molten metal washing system 100 to draw molten metal 14 (e.g., molten aluminum or other suitable molten metal and / or conductive fluid) from reservoir 102. Heated channel 108 receives molten metal 14 from pump 104 and carries the flow of molten metal 14. Pipe 116 extending from end 112 of heated channel 108 away from pump 104 carries the flow of molten metal 14 to outlet 120 at end 118 of pipe 116 away from heated channel 108. Outlet 120 directs the flow of molten metal 14 from pipe 116 into casting mold. At operation 504, method 500 includes receiving first sensor data from temperature sensor 128, wherein the first sensor data represents the temperature T of the molten metal 14 in pipe 116. 14 At operation 506, method 500 includes receiving second sensor data from a flow meter 200 positioned between end 112 and outlet 120 of the heated channel 108. The conduit 116 extends through the flow meter 200 (or optionally within, through, below, or above the flow meter 200). The second sensor data represents the flow rate F of the molten metal 14 flowing in the conduit 116. 14 In response to processing the first sensor data and the second sensor data, method 500 includes, at operation 508, processing at least the flow rate F of the molten metal 14 in the conduit 116. 14 The temperature T of the molten metal 14 in pipe 116 14 The operation of pump 104 is adjusted to regulate the flow of molten metal 14 into the casting mold. For example, pump 104 can be adjusted to achieve a target flow rate F of molten metal 14 into the casting mold. 14 The operation of pump 104 can be based on the real-time sensing flow rate F of molten metal 14. 14 and real-time sensed temperature T 14 To adjust continuously or occasionally in order to adjust the flow rate F 14Maintain position at or near the target. Additionally, the target flow rate F... 14 Adjustments can be made during the operation of pump 104, for example, based on a casting procedure performed by washing system 100. Control module 130 can be programmed with a predetermined calibration curve (which takes into account density changes in the molten metal 14 based on temperature) to adjust the flow.

[0086] Numerous embodiments have been described. However, it should be understood that various modifications can be made without departing from the spirit and scope of this disclosure. Accordingly, other embodiments are within the scope of the following claims.

[0087] The foregoing description has been provided for illustrative purposes only and is not intended to be exhaustive or limiting of this disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but rather, where applicable, individual elements or features of a particular configuration are interchangeable and can be used in selected configurations, although not specifically illustrated or described. Identical items can be modified in many ways. Such modifications are not considered to depart from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A molten metal washing system, the molten metal washing system comprising: A pump configured to extract molten metal from a storage tank; A heated channel, the heated channel being configured to receive the molten metal from the pump and to carry the flow of the molten metal; A conduit extending from the heated channel and exposed outside the heated channel, the conduit being configured to carry the flow of the molten metal; A temperature sensor configured to sense the temperature of the molten metal in the pipe; An outlet, located at the end of the pipe, is configured to guide the flow of the molten metal from the pipe into a casting mold; A flow meter, placed along the pipe through which the pipe extends, the flow meter being configured to sense the flow rate of the molten metal in the pipe; as well as A control module, which communicates with the pump, is configured to adjust the operation of the pump based at least on the flow rate sensed by the flow meter and the temperature sensed by the temperature sensor, in order to adjust the flow of the molten metal in the casting mold.

2. The molten metal washing system according to claim 1, wherein, The flow meter includes a non-contact flow meter.

3. The molten metal washing system according to claim 2, wherein, The pipes are made of non-magnetic materials.

4. The molten metal washing system according to claim 1, wherein, The flow meters include contact-based flow meters.

5. The molten metal washing system according to claim 4, wherein, The pipe is made of non-magnetic metallic material.

6. The molten metal washing system according to claim 1, wherein, The pipe is a component of the heated channel, and a portion of the pipe extends from the end of the heated channel to be exposed to the outside of the heated channel.

7. The molten metal washing system according to claim 1, wherein, The pipe is a component of the flow meter, and the gasket placed at the end of the pipe opposite to the outlet is configured to interface with the heated channel.

8. The molten metal washing system according to claim 1, wherein, The inner diameter of the pipe is different from the inner diameter of the heated channel.

9. A computer-implemented method, when executed on data processing hardware, causes the data processing hardware to perform operations, the operations including: The pumps of the molten metal washing system are operated to extract molten metal from the storage tank; The heated channel receives the molten metal from the pump and carries the flow of the molten metal. A pipe extending from the heated channel and exposed outside the heated channel carries the flow of the molten metal to an outlet at the end of the pipe, the outlet guiding the flow of the molten metal from the pipe into the casting mold; Receive first sensor data from a temperature sensor, the first sensor data representing the temperature of the molten metal in the pipe; The flow meter is placed along the pipe through which the flow meter is received, and the second sensor data represents the flow rate of the molten metal in the pipe. and In response to processing the first sensor data and the second sensor data, the operation of the pump is adjusted based at least on the flow rate of the molten metal in the pipe and the temperature of the molten metal in the pipe, so as to adjust the flow of the molten metal in the casting mold.

10. A system comprising: Memory hardware storing instructions, which, when executed on data processing hardware in communication with the memory hardware, cause the data processing hardware to perform operations, the operations including: A pump that operates a molten metal washing system to draw molten metal from a storage tank; a heated channel that receives the molten metal from the pump and carries the flow of the molten metal; a pipe extending from the heated channel and exposed outside the heated channel, the pipe carrying the flow of the molten metal to an outlet at the end of the pipe, the outlet guiding the flow of the molten metal from the pipe into a casting mold; Receive first sensor data from a temperature sensor, the first sensor data representing the temperature of the molten metal in the pipe; The system receives data from a second sensor, which is positioned along the pipe through which the flow meter extends, and the second sensor data represents the flow rate of the molten metal in the pipe. In response to processing the first sensor data and the second sensor data, the operation of the pump is adjusted based at least on the flow rate of the molten metal in the pipe and the temperature of the molten metal in the pipe, so as to adjust the flow of the molten metal in the casting mold.

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