Self-adaptive die-casting control method and system based on multi-parameter real-time feedback

Abstract

The embodiment of the invention discloses a self-adaptive die-casting control method and system based on multi-parameter real-time feedback. According to the technical scheme provided by the embodiment of the invention, by introducing a multi-parameter real-time feedback mechanism such as the number of die-casting cycles, the real-time temperature of the designated area and the actual film layer thickness, the actual film layer thickness is compared with the target distribution index to calculate the film layer thickness deviation value; the nozzle opening duration is calculated based on the film layer thickness deviation value, carbon deposition correction is conducted based on the real-time temperature and the die-casting cycle number to calculate the atomization air pressure, and therefore spraying parameters can be dynamically adjusted according to the actual film layer states of different areas of a die in the release agent spraying operation; partitioned precise control over the thickness of a release agent film layer in the die-casting cycle operation process is achieved, the consistency and stability of release agent spraying are improved, the reliability of demolding operation is effectively guaranteed, and the requirement for precise control over technological parameters of high-precision die castings is met.

Description

Technical Field

[0001] This application relates to the field of die casting technology, and in particular to an adaptive die casting control method and system based on real-time feedback of multiple parameters. Background Technology

[0002] Currently, in the die-casting production process of alloy molds, after the die-cast part solidifies in the mold cavity, it needs to be separated from the mold surface through a demolding operation. The demolding process requires a release agent spraying step to form an isolation coating on the mold cavity surface, thereby preventing the die-cast part from directly contacting the mold and causing sticking. The thinness of the film also helps control the uniformity of the temperature field on the mold surface, ensuring a smooth demolding operation. During the release agent spraying operation, the die-casting control system typically performs the spraying operation on the mold cavity surface according to fixed parameters. When there is a deviation between the measured temperature of the mold and the target temperature, the spraying amount is adjusted according to preset rules to maintain the thermal balance of the mold.

[0003] However, the final effect of mold release agent spraying depends on the actual distribution of the mold release agent film thickness on the mold surface. Simply adjusting the spraying amount by temperature parameters is insufficient to accurately control the uniformity of the mold release agent film thickness distribution. Due to the complex structure of the mold cavity, even with the same spraying parameters, the actual film thickness in different areas will still fluctuate significantly. When the film thickness distribution is uneven in some areas, problems such as mold sticking and thermal fatigue can easily occur, affecting the stability and reliability of the demolding operation. Summary of the Invention

[0004] This application provides an adaptive die-casting control method and system based on real-time feedback of multiple parameters. It enables the release agent spraying operation to dynamically adjust the spraying parameters according to the actual film layer state of different areas of the mold, and realizes precise control of the release agent film layer thickness in different zones during the die-casting cycle. This solves the technical problems of existing methods that only adjust the spraying amount by temperature parameters, which make it difficult to accurately control the uniform distribution of film layer thickness, and easily cause mold sticking and thermal fatigue.

[0005] In a first aspect, embodiments of this application provide an adaptive die-casting control method based on real-time feedback of multiple parameters, comprising: After the mold release agent is sprayed into the mold cavity, the current die casting cycle number and the real-time temperature of each specified area are collected in real time. The actual film thickness of each specified area is also collected. The actual film thickness is compared with the preset target film thickness distribution index, and the film thickness deviation value of each specified area is calculated. The opening time of the release agent nozzle in the specified area corresponding to the next release agent spraying operation cycle is calculated based on the film thickness deviation value. The opening time is positively correlated with the film thickness deviation value. Based on the real-time temperature and the number of die casting cycles, the carbon deposition correction of the specified area is performed to obtain the atomization pressure of the release agent nozzle in the specified area. Based on the opening duration and atomizing air pressure, the release agent nozzles in the corresponding designated areas are controlled to perform the release agent spraying operation for the next release agent spraying cycle.

[0006] Furthermore, the actual film thickness of each designated area is collected, including: Based on capacitive film thickness sensors embedded in designated areas of the mold cavity, the capacitance change of each designated area before and after the release agent spraying operation is obtained in real time. By querying the pre-stored capacitance and film thickness calibration curve based on the capacitance change, the actual film thickness of the corresponding specified area can be obtained.

[0007] Furthermore, based on the film thickness deviation value, the opening duration of the release agent nozzle in the specified area corresponding to the next release agent spraying operation cycle is calculated, including: Obtain the nozzle coverage area, atomization efficiency coefficient, nozzle flow coefficient, and release agent density of the release agent nozzle in the corresponding specified area; Based on the film thickness deviation, nozzle coverage area, atomization efficiency coefficient, nozzle flow coefficient, and release agent density, calculate the opening time of the release agent nozzle in the specified area corresponding to the next release agent spraying cycle.

[0008] Furthermore, based on real-time temperature and the number of die-casting cycles, carbon deposit correction is performed in the corresponding designated area to obtain the atomizing gas pressure of the release agent nozzle in the corresponding designated area, including: Obtain the reference air pressure, reference temperature, temperature compensation coefficient, and carbon deposit compensation coefficient of the release agent nozzle in the corresponding specified area; Based on real-time temperature, number of die-casting cycles, reference temperature, temperature compensation coefficient, and carbon deposit compensation coefficient, carbon deposit correction calculation is performed on the reference air pressure to obtain the atomization air pressure of the release agent nozzle in the corresponding specified area.

[0009] Furthermore, the method also includes: Based on the film thickness deviation value of each specified area, the moving speed of the release agent nozzle in the specified area corresponding to the next release agent spraying operation cycle is calculated. The moving speed is negatively correlated with the film thickness deviation value.

[0010] Furthermore, based on the film thickness deviation values ​​of each designated area, the moving speed of the release agent nozzle in the designated area corresponding to the next release agent spraying cycle is calculated, including: Obtain the cavity compensation coefficient and the reference speed of the release agent nozzle for the specified area; Based on the film thickness deviation, the deep cavity compensation coefficient, and the reference speed, calculate the moving speed of the release agent nozzle in the specified area corresponding to the next release agent spraying cycle.

[0011] Furthermore, after controlling the release agent nozzles in the corresponding designated areas to perform the release agent spraying operation for the next release agent spraying cycle, the process also includes: Record the operational effect data for the corresponding mold release agent spraying cycle; The film thickness deviation, real-time temperature, number of die-casting cycles, opening time, atomization pressure and corresponding operation effect data are stored in the operation database. The target film thickness distribution index is dynamically optimized and updated periodically based on the operation database.

[0012] In a second aspect, embodiments of this application provide an adaptive die-casting control system based on multi-parameter real-time feedback, comprising: The data acquisition module is used to collect the current number of die casting cycles and the real-time temperature of each specified area of ​​the mold after the release agent spraying operation is performed in the mold cavity. It also collects the actual film thickness of each specified area, compares the actual film thickness with the preset target film thickness distribution index, and calculates the film thickness deviation value of each specified area. The calculation module is used to calculate the opening time of the release agent nozzle in the specified area corresponding to the next release agent spraying operation cycle based on the film thickness deviation value. The opening time is positively correlated with the film thickness deviation value. Based on the real-time temperature and the number of die casting cycles, the module corrects the carbon deposit in the specified area and obtains the atomization pressure of the release agent nozzle in the specified area. The control module is used to control the release agent nozzles in the corresponding designated area to perform the release agent spraying operation in the next release agent spraying cycle according to the opening duration and atomization pressure.

[0013] In a third aspect, embodiments of this application provide an electronic device, including: Memory and one or more processors; The memory is used to store one or more programs; When the one or more programs are executed by the one or more processors, the one or more processors implement the adaptive die-casting control method based on multi-parameter real-time feedback as described in the first aspect.

[0014] In a fourth aspect, embodiments of this application provide a storage medium containing computer-executable instructions, which, when executed by a computer processor, are used to perform the adaptive die-casting control method based on multi-parameter real-time feedback as described in the first aspect.

[0015] This embodiment of the application collects the current die-casting cycle number and the real-time temperature of each designated area of ​​the mold in real time after the mold release agent spraying operation is performed in the mold cavity. It also collects the actual film thickness of each designated area and compares the actual film thickness with the preset target film thickness distribution index to calculate the film thickness deviation value of each designated area. Based on the film thickness deviation value, it calculates the opening time of the mold release agent nozzle in the designated area corresponding to the next mold release agent spraying operation cycle. The opening time is positively correlated with the film thickness deviation value. Based on the real-time temperature and the number of die-casting cycles, it performs carbon deposition correction in the corresponding designated area to obtain the atomization pressure of the mold release agent nozzle in the corresponding designated area. According to the opening time and atomization pressure, it controls the mold release agent nozzle in the corresponding designated area to perform the mold release agent spraying operation in the next mold release agent spraying operation cycle. By employing the aforementioned technical means, and introducing a real-time feedback mechanism for multiple parameters such as the number of die-casting cycles, the real-time temperature of a specified area, and the actual film thickness, the actual film thickness is compared with the target distribution index to calculate the film thickness deviation. Based on the film thickness deviation, the nozzle opening time is calculated, and carbon deposition correction is performed based on the real-time temperature and the number of die-casting cycles to calculate the atomization pressure. This allows the release agent spraying operation to dynamically adjust the spraying parameters according to the actual film state of different areas of the mold, achieving precise zonal control of the release agent film thickness during the die-casting cycle operation. This improves the consistency and stability of the release agent spraying, effectively ensures the reliability of the demolding operation, and meets the requirements of high-precision die-casting parts for refined control of process parameters. Attached Figure Description

[0016] Figure 1 This is a flowchart of an adaptive die-casting control method based on real-time feedback of multiple parameters provided in Embodiment 1 of this application; Figure 2 This is a flowchart illustrating the calculation of the activation duration in Embodiment 1 of this application; Figure 3 This is a flowchart illustrating the calculation of atomizing pressure in Embodiment 1 of this application; Figure 4 This is a flowchart illustrating the calculation of the moving speed in Embodiment 1 of this application; Figure 5 This is a schematic diagram of the structure of an adaptive die-casting control system based on real-time feedback of multiple parameters provided in Embodiment 2 of this application; Figure 6 This is a schematic diagram of the structure of an electronic device provided in Embodiment 3 of this application. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this application clearer, specific embodiments of this application will be described in further detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are merely for explaining this application and not for limiting it. It should also be noted that, for ease of description, only the parts relevant to this application are shown in the drawings, not all of them. Before discussing exemplary embodiments in more detail, it should be mentioned that some exemplary embodiments are described as processes or methods depicted as flowcharts. Although the flowcharts describe operations (or steps) as sequential processes, many of these operations can be performed in parallel, concurrently, or simultaneously. Furthermore, the order of the operations can be rearranged. The process can be terminated when its operation is completed, but may also have additional steps not included in the drawings. The process can correspond to a method, function, procedure, subroutine, subprogram, etc.

[0018] Example 1: Figure 1 A flowchart of an adaptive die-casting control method based on real-time multi-parameter feedback, provided in Embodiment 1 of this application, is given. This adaptive die-casting control method based on real-time multi-parameter feedback can be executed by an adaptive die-casting control device based on real-time multi-parameter feedback. This device can be implemented through software and / or hardware. The device can consist of two or more physical entities, or it can consist of a single physical entity. Generally, this adaptive die-casting control device can be a die-casting control system, controller, or other processing equipment.

[0019] The following description uses a die-casting control system as the main body for implementing an adaptive die-casting control method based on multi-parameter real-time feedback. (Refer to...) Figure 1 The adaptive die-casting control method based on real-time feedback of multiple parameters specifically includes: S110. After the mold release agent is sprayed into the mold cavity, the current die casting cycle number and the real-time temperature of each designated area are collected in real time. The actual film thickness of each designated area is also collected. The actual film thickness is compared with the preset target film thickness distribution index, and the film thickness deviation value of each designated area is calculated.

[0020] In this application, during a single die-casting cycle, after the mold cavity is coated with a release agent, relevant process parameters are collected in real time by a sensing system deployed inside and around the mold. These parameters include the cumulative number of die-casting cycles, the real-time temperature of designated areas (such as the deep cavity, slide block, core pulling area, and key areas near the gate), and the actual film thickness in each designated area. The number of die-casting cycles refers to the number of times the mold completely produces a die-cast part, from mold closing, injection, pressure holding, cooling, mold opening to ejection. Real-time temperature is collected by temperature sensors embedded in the designated areas. The actual film thickness is collected by a capacitive film thickness sensor.

[0021] Specifically, the actual film thickness of each specified area is collected, including: Based on capacitive film thickness sensors embedded in designated areas of the mold cavity, the capacitance change of each designated area before and after the release agent spraying operation is obtained in real time. By querying the pre-stored capacitance and film thickness calibration curve based on the capacitance change, the actual film thickness of the corresponding specified area can be obtained.

[0022] This application uses capacitive film thickness sensors embedded in designated areas of the mold cavity to perform real-time detection when collecting the actual film thickness in various specified regions. The capacitive film thickness sensors employ a high-temperature resistant encapsulation structure, with their sensing end face flush with the mold cavity surface. When a release agent is sprayed onto this sensing end face, the release agent film acts as a dielectric, filling the space between the sensor electrodes and the mold substrate. Due to the significant difference between the dielectric constant of the release agent and that of air, the capacitance value between the sensor electrodes changes accordingly. Based on this characteristic, by real-time acquisition of the capacitance value of the sensing end face before and after the release agent spraying operation (when covered), and comparing it with the reference capacitance value before spraying without the release agent, the capacitance change introduced by the release agent film layer can be obtained. The capacitance follows the formula C=εS / d, where ε is the dielectric constant, S is the electrode area, and d is the electrode spacing (related to the film thickness). Therefore, there is a definite functional relationship between the capacitance change and the thickness of the release agent film. By pre-measuring the mapping relationship between different capacitance changes and the thickness of the release agent film, a corresponding capacitance-film thickness calibration curve can be constructed. Subsequently, the real-time collected capacitance change is used as an input parameter for querying to obtain the current actual film thickness value for the corresponding specified area.

[0023] By using a capacitive film thickness sensor, the thickness of the release agent film layer can be directly measured, avoiding the errors caused by estimating the film thickness through indirect parameters such as temperature, thereby improving the accuracy and real-time performance of film thickness sensing.

[0024] Optionally, the thickness of the release agent film can also be measured using an optical interferometric thickness sensor, calculating the film thickness by analyzing the optical path difference of the reflected light from the upper and lower surfaces of the release agent film. Alternatively, an ultrasonic thickness sensor can be used to invert the film thickness by measuring the propagation time and reflection characteristics of ultrasonic waves in the release agent film. This application does not impose fixed limitations on the method of measuring the thickness of the release agent film, and will not elaborate further here.

[0025] Furthermore, after collecting the aforementioned multi-source data, the actual film thickness in each designated area is compared with the preset target film thickness distribution index region by region to calculate the film thickness deviation value for each designated area. The target film thickness distribution index is the optimal film thickness benchmark value for each area, pre-calibrated through die-casting process experiments or numerical simulation analysis based on the mold's structural characteristics, demolding difficulty, and process requirements. This index can also be dynamically generated and continuously optimized based on historical production data, through cluster analysis of film thickness data from successful demolding cases using a machine learning model. By subtracting the preset film thickness benchmark value for each area from the actual film thickness collected in real time for that area point by point, the film thickness deviation value for that area can be obtained. This deviation value quantifies the difference between the current spraying effect and the ideal state, providing direct feedback for subsequent parameter adjustments.

[0026] S120. Calculate the opening time of the release agent nozzle in the specified area corresponding to the next release agent spraying operation cycle based on the film thickness deviation value. The opening time is positively correlated with the film thickness deviation value. Based on the real-time temperature and the number of die casting cycles, perform carbon deposition correction in the specified area to obtain the atomization pressure of the release agent nozzle in the specified area.

[0027] Furthermore, based on the calculated film thickness deviation values ​​for each designated area, the opening duration of the release agent nozzle for each designated area is calculated for the next release agent spraying cycle. This opening duration is positively correlated with the film thickness deviation value of the corresponding area; that is, the larger the deviation, the longer the opening duration, thus increasing the amount of release agent deposited. Simultaneously, based on the collected real-time temperature of each designated area and the current cumulative die-casting cycle count of the mold, the atomization pressure of the release agent nozzle for each area is independently corrected. The real-time temperature is used to compensate for fluctuations in the release agent atomization characteristics with temperature changes, while the die-casting cycle count is used to correct for the decrease in release agent adhesion efficiency caused by carbon accumulation on the mold surface. The optimal atomization pressure for each designated area is determined through temperature compensation and carbon accumulation correction. Thus, by integrating multiple parameters such as film thickness deviation, temperature, and cycle count for calculation, and separately solving for the opening duration and atomization pressure, refined calculation of spraying parameters is achieved, enabling the spraying parameters for each area to adaptively match its current actual needs and mold condition.

[0028] Specifically, refer to Figure 2Based on the film thickness deviation value, the opening time of the release agent nozzle in the specified area corresponding to the next release agent spraying operation cycle is calculated, including: S1201. Obtain the nozzle coverage area, atomization efficiency coefficient, nozzle flow coefficient, and release agent density of the release agent nozzle in the corresponding specified area; S1202. Based on the film thickness deviation, nozzle coverage area, atomization efficiency coefficient, nozzle flow coefficient, and release agent density, calculate the opening time of the release agent nozzle in the specified area corresponding to the next release agent spraying operation cycle.

[0029] When calculating the opening time of the release agent nozzle in a designated area corresponding to the next release agent spraying cycle based on the film thickness deviation value, this application first obtains the inherent parameters of the nozzle and its spraying area associated with the designated area. Specifically, these parameters include the effective area covered by the release agent nozzle corresponding to the area, the atomization efficiency coefficient of the nozzle, the nozzle flow rate coefficient, and the physical density of the release agent used. The nozzle coverage area determines the effective range of release agent that can be applied in a single spray; the atomization efficiency coefficient characterizes the proportion of atomized release agent droplets actually adhering to the mold surface; the nozzle flow rate coefficient reflects the volumetric flow rate of the release agent passing through the nozzle under unit air pressure; and the release agent density is a necessary parameter for converting the volumetric flow rate into the mass flow rate.

[0030] After obtaining the above parameters, and combining them with the previously calculated film thickness deviation value for the specified region, the opening time is calculated using a preset opening time calculation formula. The opening time calculation formula is expressed as: in, The nozzle opening duration corresponding to the i-th specified area. This represents the film thickness deviation value for the i-th specified region. Density of the release agent Let i be the nozzle coverage area corresponding to the i-th specified region. This is the atomization efficiency coefficient. This represents the nozzle flow coefficient.

[0031] The product of the film thickness deviation, the nozzle coverage area, and the release agent density represents the required amount of release agent to be added. The product of the atomization efficiency coefficient and the nozzle flow rate coefficient indicates the actual amount of release agent that can be deposited in the area per unit time. Dividing the required amount of release agent to be added by the deposition rate per unit time yields the nozzle opening time required to achieve the target film thickness.

[0032] By introducing process parameters such as nozzle coverage area and atomization efficiency coefficient, the film thickness deviation value is accurately converted into an executable start-up time control command, thereby realizing the quantitative and precise control of the release agent spraying amount and avoiding the uncertainty caused by relying on experience or rough adjustment.

[0033] In addition, this application can also employ an image processing-based indirect film thickness estimation method. This involves using a high-speed camera to capture the optical features of the mold surface after spraying, combining this with a pre-trained deep learning model to invert the film thickness distribution, and then inferring the required opening time. This application does not impose fixed restrictions on the specific method for calculating the nozzle opening time, and will not elaborate further here.

[0034] On the other hand, refer to Figure 3 Based on real-time temperature and the number of die-casting cycles, carbon deposit correction is performed in the corresponding designated area to obtain the atomizing gas pressure of the release agent nozzle in the corresponding designated area, including: S1203. Obtain the reference air pressure, reference temperature, temperature compensation coefficient, and carbon deposit compensation coefficient of the release agent nozzle in the corresponding specified area. S1204. Based on real-time temperature, number of die-casting cycles, reference temperature, temperature compensation coefficient, and carbon deposit compensation coefficient, the reference air pressure is calculated to correct for carbon deposit, thereby obtaining the atomization air pressure of the release agent nozzle in the corresponding specified area.

[0035] This application, when determining the atomization pressure by correcting carbon buildup in a designated area based on real-time temperature and the number of die-casting cycles, first obtains the reference pressure, reference temperature, temperature compensation coefficient, and carbon buildup compensation coefficient of the release agent nozzle associated with that designated area. The reference pressure is the optimal atomization pressure value calibrated through process testing under standard operating conditions; the reference temperature is the median of the ideal mold temperature range where the release agent atomization characteristics are best; the temperature compensation coefficient quantifies the impact of temperature deviation from the reference temperature on the atomization effect; and the carbon buildup compensation coefficient characterizes the additional pressure compensation required to maintain the same release agent adhesion efficiency after carbon buildup on the mold surface due to increased die-casting cycles. After obtaining these parameters, the atomization pressure is calculated using a preset correction model, combined with the current temperature of the designated area and the current cumulative number of die-casting cycles obtained in real-time. The calculation formula for the correction model is expressed as follows: in, The atomizing pressure corresponding to the i-th specified area. As the reference pressure, The real-time temperature of the i-th specified region. For reference temperature, This is the temperature compensation coefficient. Let β be the carbon deposition compensation coefficient, and β > 1. This represents the current number of die-casting cycles in the mold. The critical number of cycles at which carbon buildup begins to affect adhesion rate.

[0036] This correction model uses the deviation between real-time temperature and reference temperature as input for the temperature compensation term. It adjusts the reference gas pressure through a temperature compensation coefficient to compensate for the impact of temperature changes on the atomized particle size, evaporation rate, and adhesion performance of the release agent. Simultaneously, it compares the current number of die-casting cycles with the critical number at which carbon buildup begins to significantly affect adhesion. When the number of cycles exceeds the critical value, the carbon buildup compensation coefficient gradually increases the gas pressure compensation amount, thereby offsetting the attenuation effect of the carbon buildup layer on the adhesion efficiency of the release agent droplets. By applying the temperature compensation component and the carbon buildup compensation component together to the reference gas pressure, an atomized gas pressure value adapted to the actual temperature of the current region and the aging state of the mold can be obtained. This allows the atomized gas pressure to be dynamically adjusted according to changes in the mold's thermal state and service life, ensuring that the release agent is always deposited on the mold surface with optimal atomization morphology and kinetic energy.

[0037] By introducing temperature compensation and carbon deposit compensation correction mechanisms, the atomized air pressure can adaptively respond to mold thermal fluctuations and long-term aging, effectively maintaining the stability of the release agent adhesion efficiency and avoiding the problem of deterioration of the spraying effect caused by temperature deviation and carbon deposit accumulation.

[0038] S130. According to the opening duration and atomizing air pressure, control the release agent nozzles in the corresponding designated areas to perform the release agent spraying operation of the next release agent spraying operation cycle.

[0039] Finally, based on the calculated opening duration and atomization pressure for each designated area, the release agent nozzles in the corresponding areas are controlled to perform the next release agent spraying cycle. During execution, each nozzle sprays the release agent for its own determined duration according to independent control commands, and atomizes it with its own corrected air pressure, ensuring that the release agent can cover the corresponding area with a precise amount and appropriate atomization state. Through the above-mentioned independent control of zones, each designated area on the entire mold cavity surface can obtain an actual film layer that approximates the target film thickness distribution, thereby achieving precise control of the release agent film thickness.

[0040] Based on the above scheme, by introducing real-time feedback of multiple parameters such as the number of die-casting cycles, zone temperature, and zone film thickness, and dynamically calculating the opening time based on the film thickness deviation value, and correcting the atomization pressure based on temperature and cycle number, precise adaptive control of the release agent spraying process by zone is achieved. This avoids problems such as uneven film thickness distribution, easy sticking and thermal fatigue caused by adjusting the spraying amount solely based on temperature parameters, thereby improving the stability and reliability of the demolding operation.

[0041] Optionally, the adaptive die-casting control method based on multi-parameter real-time feedback in this application further includes: Based on the film thickness deviation value of each specified area, the moving speed of the release agent nozzle in the specified area corresponding to the next release agent spraying operation cycle is calculated. The moving speed is negatively correlated with the film thickness deviation value.

[0042] This application configures a lower moving speed in areas with larger film thickness deviation values, and a higher moving speed in areas with smaller deviation values ​​or those that have met the target value. By acquiring the film thickness deviation value of each designated area, the film thickness deviation value reflects the degree of deviation between the actual film thickness and the target film thickness at each position on the mold cavity surface. Based on this film thickness deviation value, the control system adjusts the nozzle's moving speed in real time according to the film thickness deviation value of the area to which the release agent nozzle belongs as the release agent nozzle moves along the preset path.

[0043] Specifically, when the release agent nozzle enters an area with a large film thickness deviation, the control system reduces its moving speed, allowing the nozzle to remain in that area for a longer time, thereby increasing the actual deposition amount of release agent. Conversely, when the nozzle enters an area with a small or negative deviation, the control system increases its moving speed to reduce unnecessary overspray. This moving speed adjustment process, in conjunction with the aforementioned opening duration and atomizing air pressure adjustments, works together to improve the release agent deposition effect in each area. This achieves joint control of the spraying process, enabling differentiated distribution of the release agent according to the actual needs of each area, further improving the uniformity and control accuracy of the film thickness distribution.

[0044] Among them, reference Figure 4 Based on the film thickness deviation values ​​of each specified area, calculate the moving speed of the release agent nozzle in the specified area corresponding to the next release agent spraying cycle, including: S1401. Obtain the cavity compensation coefficient and the reference speed of the release agent nozzle for the corresponding specified area; S1402. Based on the film thickness deviation value, the deep cavity compensation coefficient, and the reference speed, calculate the moving speed of the release agent nozzle in the specified area corresponding to the next release agent spraying operation cycle.

[0045] This application introduces a cavity compensation coefficient to correct the impact of regional geometric differences on the spraying effect, thereby calculating an accurate moving speed of the release agent nozzle. By obtaining the cavity compensation coefficient for each specified region and the reference speed of the release agent nozzle, where the cavity compensation coefficient can be a pre-calibrated process parameter based on the region's depression depth, sidewall tilt angle, and droplet flight distance, used to quantify the degree of attenuation of release agent droplet deposition efficiency by deep cavities or depressions; and the reference speed is the ideal moving speed in a standard planar region with zero film thickness deviation. After obtaining the above parameters, combined with the previously calculated film thickness deviation value for the specified region, the moving speed is solved using a preset speed model. The speed model formula is expressed as: in, The moving speed of the release agent nozzle corresponding to the specified area. As the reference speed, This represents the film thickness deviation value for the i-th specified region. This is the speed adjustment coefficient, used to control the sensitivity of film thickness deviation to the moving speed. It is determined through process testing and calibration. This is the deep cavity compensation coefficient for the i-th specified region, with a value ranging from 0 to 1. is the depth level index for the i-th specified region, used to quantify the relative depth of that region.

[0046] This velocity model formula uses the film thickness deviation as the primary adjustment basis, establishing a negative correlation between the moving speed and the film thickness deviation; that is, the larger the deviation, the lower the speed. This extends the nozzle's residence time in that area and increases the amount of release agent deposited. Simultaneously, a deep cavity compensation coefficient is introduced for secondary speed correction. For areas where droplets are difficult to deposit effectively, such as deep cavities and depressions, the moving speed is further reduced to compensate for deposition efficiency losses caused by geometric factors. Thus, by combining film thickness deviation feedback with regional geometric feature compensation, the moving speed can simultaneously respond to the actual film thickness requirements and spraying difficulty of each area, achieving precise control of the spraying residence time.

[0047] As the nozzle moves along the preset trajectory, the speed value is loaded into the nozzle motion controller in real time, enabling the nozzle to run at different speeds when passing through different areas. This ensures that areas with larger film thickness deviations receive longer spraying times, while deep cavity areas receive additional speed compensation.

[0048] In addition, after controlling the release agent nozzles in the corresponding designated areas to perform the release agent spraying operation for the next release agent spraying cycle, the following is also included: Record the operational effect data for the corresponding mold release agent spraying cycle; The film thickness deviation, real-time temperature, number of die-casting cycles, opening time, atomization pressure and corresponding operation effect data are stored in the operation database. The target film thickness distribution index is dynamically optimized and updated periodically based on the operation database.

[0049] After the release agent spraying operation is completed in each die-casting cycle, this application first records the operation effect data of that cycle. This data may include, but is not limited to, process indicators that can directly or indirectly reflect the effect of the release agent spraying, such as demolding success rate, measured ejection resistance, casting surface quality inspection results, and number of sticking alarms. Subsequently, the key process parameters involved in the operation cycle are associated and stored with the corresponding effect data. The key process parameters include the film thickness deviation values ​​of each specified area calculated in the previous step, the real-time collected area temperature, the current die-casting cycle number of the mold, and the actual opening time and atomization pressure control command values ​​executed in this operation cycle. The above data is uniformly stored in the operation database to form historical data covering multiple die-casting cycles.

[0050] Based on this, the die-casting control system periodically calls upon the accumulated data in the operation database to dynamically optimize and update the preset target film thickness distribution index. Specifically, the die-casting control system uses statistical analysis to uncover the optimal film thickness distribution pattern under different operating conditions, and can also use machine learning models to perform cluster analysis and fitting of film thickness data from successful demolding cases, thereby generating a corrected target distribution index that is more adapted to the current mold state and product requirements. The updated target film thickness distribution index will serve as the benchmark for calculating film thickness deviation in subsequent die-casting cycles, enabling the control system's reference standard to adaptively adjust as the production process evolves.

[0051] Optionally, the die-casting control system of this application can also construct a film thickness distribution prediction model based on a long short-term memory neural network. This model takes the film thickness deviation values, temperature field distribution, number of die-casting cycles, and corresponding spraying parameters from multiple historical die-casting cycles as inputs, and learns the evolution law of film thickness distribution through time series analysis. Before the release agent spraying operation of the current die-casting cycle is executed, the initial state parameters of the cycle (such as the current temperature and cumulative number of cycles) and the film thickness evolution trend of the previous cycle are input into the prediction model. The model outputs the predicted film thickness distribution value expected to be achieved after this spraying. The control system compares the predicted film thickness distribution with the target distribution. If the prediction deviation exceeds the allowable range, the start time, atomizing air pressure, and moving speed of this spraying are corrected in advance, so that the actual spraying operation can pre-compensate for the upcoming film thickness deviation, thereby further improving the timeliness and accuracy of control.

[0052] Furthermore, the die-casting control system can dynamically reconfigure the nozzle array based on the spatial distribution characteristics of film thickness deviation. By identifying the actual film thickness deviation area, multiple adjacent nozzles originally belonging to different fixed areas are temporarily grouped into a collaborative execution unit to jointly compensate for the continuous deviation area. Within the reconfigured group, the opening duration and atomizing pressure of each nozzle are differentiated according to its distance and angle relative to the center of the deviation area. The nozzles corresponding to the central area execute a longer opening duration and higher pressure, while the pressure is moderately reduced in the edge areas, forming a gradient spraying effect. This eliminates the limitations of fixed area division, achieving adaptive matching between the nozzle array and the spatial distribution of film thickness deviation, further improving the compensation capability for complex film thickness deviation patterns.

[0053] As described above, after the mold release agent spraying operation is performed in the mold cavity, the current die casting cycle number and the real-time temperature of each designated area of ​​the mold are collected in real time, and the actual film thickness of each designated area is collected. The actual film thickness is compared with the preset target film thickness distribution index to calculate the film thickness deviation value of each designated area. Based on the film thickness deviation value, the opening time of the mold release agent nozzle in the designated area corresponding to the next mold release agent spraying operation cycle is calculated. The opening time is positively correlated with the film thickness deviation value. Based on the real-time temperature and the die casting cycle number, the carbon deposition correction of the corresponding designated area is performed to obtain the atomization pressure of the mold release agent nozzle in the corresponding designated area. According to the opening time and atomization pressure, the mold release agent nozzle in the corresponding designated area is controlled to perform the mold release agent spraying operation of the next mold release agent spraying operation cycle. By employing the aforementioned technical means, and introducing a real-time feedback mechanism for multiple parameters such as the number of die-casting cycles, the real-time temperature of a specified area, and the actual film thickness, the actual film thickness is compared with the target distribution index to calculate the film thickness deviation. Based on the film thickness deviation, the nozzle opening time is calculated, and carbon deposition correction is performed based on the real-time temperature and the number of die-casting cycles to calculate the atomization pressure. This allows the release agent spraying operation to dynamically adjust the spraying parameters according to the actual film state of different areas of the mold, achieving precise zonal control of the release agent film thickness during the die-casting cycle operation. This improves the consistency and stability of the release agent spraying, effectively ensures the reliability of the demolding operation, and meets the requirements of high-precision die-casting parts for refined control of process parameters.

[0054] Example 2: Based on the above embodiments, Figure 5 This is a schematic diagram of an adaptive die-casting control system based on real-time feedback of multiple parameters, provided in Embodiment 2 of this application. (Reference) Figure 5 The adaptive die-casting control system based on real-time feedback of multiple parameters provided in this embodiment specifically includes: The acquisition module 21 is used to collect the current die-casting cycle number of the mold and the real-time temperature of each designated area after the mold release agent spraying operation is performed in the mold cavity, and to collect the actual film thickness of each designated area, compare the actual film thickness with the preset target film thickness distribution index, and calculate the film thickness deviation value of each designated area. Calculation module 22 is used to calculate the opening time of the release agent nozzle in the specified area corresponding to the next release agent spraying operation cycle based on the film thickness deviation value. The opening time is positively correlated with the film thickness deviation value. Based on the real-time temperature and the number of die casting cycles, the carbon deposition correction is performed in the specified area to obtain the atomization pressure of the release agent nozzle in the specified area. Control module 23 is used to control the release agent nozzles in the corresponding designated area to perform the release agent spraying operation of the next release agent spraying operation cycle according to the opening duration and atomization pressure.

[0055] Specifically, the actual film thickness of each specified area is collected, including: Based on capacitive film thickness sensors embedded in designated areas of the mold cavity, the capacitance change of each designated area before and after the release agent spraying operation is obtained in real time. By querying the pre-stored capacitance and film thickness calibration curve based on the capacitance change, the actual film thickness of the corresponding specified area can be obtained.

[0056] Specifically, based on the film thickness deviation value, the opening duration of the release agent nozzle in the specified area corresponding to the next release agent spraying operation cycle is calculated, including: Obtain the nozzle coverage area, atomization efficiency coefficient, nozzle flow coefficient, and release agent density of the release agent nozzle in the corresponding specified area; Based on the film thickness deviation, nozzle coverage area, atomization efficiency coefficient, nozzle flow coefficient, and release agent density, calculate the opening time of the release agent nozzle in the specified area corresponding to the next release agent spraying cycle.

[0057] Specifically, based on real-time temperature and the number of die-casting cycles, carbon deposit correction is performed in the corresponding designated area to obtain the atomizing gas pressure of the release agent nozzle in the corresponding designated area, including: Obtain the reference air pressure, reference temperature, temperature compensation coefficient, and carbon deposit compensation coefficient of the release agent nozzle in the corresponding specified area; Based on real-time temperature, number of die-casting cycles, reference temperature, temperature compensation coefficient, and carbon deposit compensation coefficient, carbon deposit correction calculation is performed on the reference air pressure to obtain the atomization air pressure of the release agent nozzle in the corresponding specified area.

[0058] Specifically, the methods also include: Based on the film thickness deviation value of each specified area, the moving speed of the release agent nozzle in the specified area corresponding to the next release agent spraying operation cycle is calculated. The moving speed is negatively correlated with the film thickness deviation value.

[0059] Specifically, based on the film thickness deviation values ​​of each designated area, the moving speed of the release agent nozzle in the designated area corresponding to the next release agent spraying cycle is calculated, including: Obtain the cavity compensation coefficient and the reference speed of the release agent nozzle for the specified area; Based on the film thickness deviation, the deep cavity compensation coefficient, and the reference speed, calculate the moving speed of the release agent nozzle in the specified area corresponding to the next release agent spraying cycle.

[0060] Specifically, after controlling the release agent nozzles in the corresponding designated area to perform the release agent spraying operation for the next release agent spraying cycle, the process also includes: Record the operational effect data for the corresponding mold release agent spraying cycle; The film thickness deviation, real-time temperature, number of die-casting cycles, opening time, atomization pressure and corresponding operation effect data are stored in the operation database. The target film thickness distribution index is dynamically optimized and updated periodically based on the operation database.

[0061] As described above, after the mold release agent spraying operation is performed in the mold cavity, the current die casting cycle number and the real-time temperature of each designated area of ​​the mold are collected in real time, and the actual film thickness of each designated area is collected. The actual film thickness is compared with the preset target film thickness distribution index to calculate the film thickness deviation value of each designated area. Based on the film thickness deviation value, the opening time of the mold release agent nozzle in the designated area corresponding to the next mold release agent spraying operation cycle is calculated. The opening time is positively correlated with the film thickness deviation value. Based on the real-time temperature and the die casting cycle number, the carbon deposition correction of the corresponding designated area is performed to obtain the atomization pressure of the mold release agent nozzle in the corresponding designated area. According to the opening time and atomization pressure, the mold release agent nozzle in the corresponding designated area is controlled to perform the mold release agent spraying operation of the next mold release agent spraying operation cycle. By employing the aforementioned technical means, and introducing a real-time feedback mechanism for multiple parameters such as the number of die-casting cycles, the real-time temperature of a specified area, and the actual film thickness, the actual film thickness is compared with the target distribution index to calculate the film thickness deviation. Based on the film thickness deviation, the nozzle opening time is calculated, and carbon deposition correction is performed based on the real-time temperature and the number of die-casting cycles to calculate the atomization pressure. This allows the release agent spraying operation to dynamically adjust the spraying parameters according to the actual film state of different areas of the mold, achieving precise zonal control of the release agent film thickness during the die-casting cycle operation. This improves the consistency and stability of the release agent spraying, effectively ensures the reliability of the demolding operation, and meets the requirements of high-precision die-casting parts for refined control of process parameters.

[0062] The adaptive die-casting control system based on real-time feedback of multiple parameters provided in Embodiment 2 of this application can be used to execute the adaptive die-casting control method based on real-time feedback of multiple parameters provided in Embodiment 1 above, and has the corresponding functions and beneficial effects.

[0063] Example 3: This application provides an electronic device in embodiment three, referring to... Figure 6 The electronic device includes a processor 31, a memory 32, a communication module 33, an input device 34, and an output device 35. The electronic device may have one or more processors and one or more memories. The processor, memory, communication module, input device, and output device of the electronic device can be connected via a bus or other means.

[0064] Memory, as a computer-readable storage medium, can be used to store software programs, computer-executable programs, and modules, such as the program instructions / modules corresponding to the adaptive die-casting control method based on multi-parameter real-time feedback described in any embodiment of this application (e.g., the acquisition module, calculation module, and control module in the adaptive die-casting control system based on multi-parameter real-time feedback). Memory may primarily include a program storage area and a data storage area. The program storage area may store the operating system and at least one application program required for a function; the data storage area may store data created based on the use of the device, etc. Furthermore, memory may include high-speed random access memory and non-volatile memory, such as at least one disk storage device, flash memory device, or other non-volatile solid-state storage device. In some instances, memory may further include memory remotely located relative to the processor, and these remote memories can be connected to the device via a network. Examples of such networks include, but are not limited to, the Internet, corporate intranets, local area networks, mobile communication networks, and combinations thereof.

[0065] The communication module is used for data transmission.

[0066] The processor executes various functional applications and data processing of the device by running software programs, instructions, and modules stored in memory, thereby realizing the above-mentioned adaptive die-casting control method based on multi-parameter real-time feedback.

[0067] Input devices can be used to receive input digital or character information, and to generate key signal inputs related to user settings and function control of the device. Output devices may include display devices such as displays.

[0068] The electronic device provided above can be used to execute the adaptive die-casting control method based on real-time feedback of multiple parameters provided in Embodiment 1 above, and has corresponding functions and beneficial effects.

[0069] Example 4: This application embodiment also provides a storage medium containing computer-executable instructions. When executed by a computer processor, these computer-executable instructions are used to execute an adaptive die-casting control method based on multi-parameter real-time feedback. This adaptive die-casting control method includes: after performing a release agent spraying operation in the mold cavity, real-time acquisition of the current die-casting cycle number and the real-time temperature of each designated area of ​​the mold, and acquisition of the actual film thickness of each designated area; comparison of the actual film thickness with a preset target film thickness distribution index; calculation of the film thickness deviation value for each designated area; calculation of the opening duration of the release agent nozzle in the designated area corresponding to the next release agent spraying operation cycle based on the film thickness deviation value, wherein the opening duration is positively correlated with the film thickness deviation value; carbon deposition correction of the corresponding designated area based on the real-time temperature and the number of die-casting cycles, obtaining the atomizing pressure of the release agent nozzle in the corresponding designated area; and control of the release agent nozzle in the corresponding designated area to perform the release agent spraying operation for the next release agent spraying operation cycle according to the opening duration and atomizing pressure. Storage medium – any type of memory device or storage device. The term “storage medium” is intended to include: mounting media, such as CD-ROM, floppy disk, or magnetic tape devices; computer system memory or random access memory, such as DRAM, DDR RAM, SRAM, EDO RAM, Rambus RAM, etc.; non-volatile memory, such as flash memory, magnetic media (e.g., hard disk or optical storage); registers or other similar types of memory elements, etc. Storage medium may also include other types of memory or combinations thereof. Furthermore, storage medium may reside in a first computer system in which the program is executed, or it may reside in a different second computer system connected to the first computer system via a network (such as the Internet). The second computer system can provide program instructions to the first computer for execution. The term “storage medium” can include two or more storage media residing in different locations (e.g., in different computer systems connected via a network). Storage medium may store program instructions (e.g., specifically implemented as a computer program) executable by one or more processors.

[0070] Of course, the computer-executable instructions provided in the embodiments of this application are not limited to the adaptive die-casting control method based on real-time feedback of multiple parameters as described above, but can also execute related operations in the adaptive die-casting control method based on real-time feedback of multiple parameters provided in any embodiment of this application.

[0071] The adaptive die-casting control system, storage medium, and electronic device based on real-time feedback of multiple parameters provided in the above embodiments can execute the adaptive die-casting control method based on real-time feedback of multiple parameters provided in any embodiment of this application. For technical details not described in detail in the above embodiments, please refer to the adaptive die-casting control method based on real-time feedback of multiple parameters provided in any embodiment of this application.

[0072] The above description is merely a preferred embodiment and the technical principles employed in this application. This application is not limited to the specific embodiments described herein, and various obvious changes, readjustments, and substitutions that can be made by those skilled in the art will not depart from the scope of protection of this application. Therefore, although this application has been described in detail through the above embodiments, this application is not limited to the above embodiments, and may include more other equivalent embodiments without departing from the concept of this application, the scope of which is determined by the scope of the claims.

Claims

1. A method of adaptive die casting control based on multi-parameter real-time feedback, characterized in that, The method comprises the following steps: After performing the release agent spraying operation in the mold cavity, the current die casting cycle number and the real-time temperature of each specified area of the current mold are collected in real time, and the actual film thickness of each specified area is collected. The actual film thickness is compared with the preset target film thickness distribution index, and the film thickness deviation value of each specified area is calculated; Based on the film thickness deviation value, the opening time of the release agent nozzle corresponding to the specified area in the next release agent spraying operation cycle is calculated, and the opening time is positively correlated with the film thickness deviation value; Based on the real-time temperature and the die casting cycle number, the carbon correction of the corresponding specified area is performed to obtain the atomizing gas pressure of the release agent nozzle corresponding to the specified area; According to the opening time and the atomizing gas pressure, the release agent nozzle corresponding to the specified area is controlled to perform the release agent spraying operation of the next release agent spraying operation cycle.

2. The adaptive die casting control method based on multi-parameter real-time feedback according to claim 1, characterized in that, The collection of the actual film thickness of each specified area comprises: Based on the capacitive film thickness sensor embedded in each specified area of the mold cavity, the capacitance change amount before and after the release agent spraying operation of each specified area is obtained in real time; Based on the capacitance change amount, the pre-stored capacitance and film thickness calibration curve is queried to obtain the actual film thickness of the corresponding specified area.

3. The adaptive die casting control method based on multi-parameter real-time feedback according to claim 1, characterized in that, The calculation of the opening time of the release agent nozzle corresponding to the specified area in the next release agent spraying operation cycle based on the film thickness deviation value comprises: The nozzle coverage area, atomization efficiency coefficient, nozzle flow coefficient and release agent density of the release agent nozzle corresponding to the specified area are obtained; Based on the film thickness deviation value, the nozzle coverage area, the atomization efficiency coefficient, the nozzle flow coefficient and the release agent density, the opening time of the release agent nozzle corresponding to the specified area in the next release agent spraying operation cycle is calculated.

4. The adaptive die casting control method based on multi-parameter real-time feedback according to claim 1, characterized in that, The carbon correction of the corresponding specified area based on the real-time temperature and the die casting cycle number to obtain the atomizing gas pressure of the release agent nozzle corresponding to the specified area comprises: The reference gas pressure, reference temperature, temperature compensation coefficient and carbon compensation coefficient of the release agent nozzle corresponding to the specified area are obtained; Based on the real-time temperature, the die casting cycle number, the reference temperature, the temperature compensation coefficient and the carbon compensation coefficient, the carbon correction calculation of the reference gas pressure is performed to obtain the atomizing gas pressure of the release agent nozzle corresponding to the specified area.

5. The adaptive die casting control method based on multi-parameter real-time feedback according to claim 1, characterized in that, The method further comprises: According to the film thickness deviation value of each specified area, the moving speed of the release agent nozzle corresponding to the specified area in the next release agent spraying operation cycle is calculated, and the moving speed is negatively correlated with the film thickness deviation value.

6. The adaptive die casting control method based on multi-parameter real-time feedback according to claim 5, characterized in that, The calculation of the moving speed of the release agent nozzle corresponding to the specified area in the next release agent spraying operation cycle according to the film thickness deviation value of each specified area comprises: The deep cavity compensation coefficient and the reference speed of the release agent nozzle corresponding to the specified area are obtained; Based on the film thickness deviation value, the deep cavity compensation coefficient, and the reference speed, the moving speed of the release agent nozzle in the designated area corresponding to the next release agent spraying operation cycle is calculated.

7. The adaptive die casting control method based on multi-parameter real-time feedback according to claim 1, characterized in that, After the release agent nozzle in the designated area corresponding to the control performs the release agent spraying operation for the next release agent spraying cycle, the method further includes: Record the operational effect data for the corresponding mold release agent spraying cycle; The film thickness deviation value, the real-time temperature, the number of die-casting cycles, the opening duration, the atomizing air pressure, and the corresponding work effect data are stored in the work database; The target film thickness distribution index is periodically optimized and updated based on the operation database.

8. An adaptive die casting control system based on multi-parameter real-time feedback, characterized by, include: The data acquisition module is used to collect the current number of die casting cycles and the real-time temperature of each designated area of ​​the mold after the release agent spraying operation is performed in the mold cavity, and to collect the actual film thickness of each designated area. The actual film thickness is compared with the preset target film thickness distribution index, and the film thickness deviation value of each designated area is calculated. The calculation module is used to calculate the opening time of the release agent nozzle in the specified area corresponding to the next release agent spraying operation cycle based on the film thickness deviation value. The opening time is positively correlated with the film thickness deviation value. Based on the real-time temperature and the number of die-casting cycles, the carbon deposit in the corresponding designated area is corrected to obtain the atomizing gas pressure of the release agent nozzle in the corresponding designated area; The control module is used to control the release agent nozzles in the corresponding designated area to perform the release agent spraying operation of the next release agent spraying operation cycle according to the opening duration and the atomizing air pressure.

9. An electronic device, comprising: include: Memory and one or more processors; The memory is used to store one or more programs; When the one or more programs are executed by the one or more processors, the one or more processors implement the adaptive die-casting control method based on real-time feedback of multiple parameters as described in any one of claims 1-7.

10. A storage medium containing computer-executable instructions, wherein: The computer-executable instructions, when executed by a computer processor, are used to perform the adaptive die-casting control method based on real-time feedback of multiple parameters as described in any one of claims 1-7.

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