Intelligent process management and control system for die-casting machine

Abstract

The utility model discloses an intelligent process management and control system for a die-casting machine. The intelligent process management and control system comprises a touch screen setting module, a PLC module, a touch screen display module, a verification module and a data storage module, the touch screen setting module is connected with the PLC module and is used for setting die-casting process parameters according to the input total weight of a casting, the mass after pouring gate removal, the net weight of a product, the thickness of a material cake, the air injection stroke, the diameter of a hammer head, the metal density, the speed of a flow gate, the area of the flow gate, the average wall thickness and casting pressure parameters; the PLC module is connected with the touch screen die setting block, and a die-casting process mathematical model and a process algorithm are arranged in the PLC module; the touch screen display module is connected with the PLC module and is used for displaying known data of an input casting and displaying an output result of the PLC module, so that an operator can fill injection parameters conveniently; the verification module is connected with the PLC module and is used for verifying an output result of the PLC module; and the data storage module is connected with the PLC module and is used for storing the die-casting process parameters and storing and calling different die-casting parameters according to die numbers.

Description

Technical Field

[0001] This utility model relates to the field of die casting machine technology, and in particular to an intelligent process control system for die casting machines. Background Technology

[0002] With the rapid development of technology, die-casting machines are increasingly widely used in industrial production. However, currently, die-casting process parameters are adjusted and set by skilled operators based on experience. Technicians check the quality of the die-cast parts and fine-tune the process parameters gradually according to the product requirements to ultimately produce qualified products. This process is time-consuming, labor-intensive, and material-intensive; changes in technicians can also lead to problems with saving process parameters. The development of intelligent process parameter systems can assist companies in quickly setting die-casting parameters that conform to the product's process, rapidly producing qualified products, and saving different die-casting parameters according to the mold number. Utility Model Content

[0003] To address the aforementioned issues, this application provides an intelligent process control system for die-casting machines, comprising: a touchscreen setting module, a PLC module, a touchscreen display module, a verification module, and a data storage module;

[0004] The touch screen setting module, connected to the PLC module, is used to set the die casting process parameters based on the input total weight of the casting, the mass after desprue, the net weight of the product, the thickness of the sprue, the air injection stroke, the hammer diameter, the metal density, the ingate speed, the ingate area, the average wall thickness, and the casting pressure parameters.

[0005] The PLC module is connected to the touch screen module and has a built-in mathematical model and process algorithm for die casting.

[0006] The touch screen display module is connected to the PLC module and is used to input known data of the casting and display the output results of the PLC module so that the operator can fill in the injection parameters.

[0007] The verification module, connected to the PLC module, is used to verify the output results of the PLC module.

[0008] The data storage module, connected to the PLC module, is used to store die-casting process parameters and to save and retrieve different die-casting parameters based on the mold number.

[0009] The touch screen setting module, connected to the PLC module, is used to set the die casting process parameters based on the input total weight of the casting, the mass after desprue, the net weight of the product, the thickness of the sprue, the air injection stroke, the hammer diameter, the metal density, the ingate speed, the ingate area, the average wall thickness, and the casting pressure parameters.

[0010] The PLC module is connected to the touch screen module and has a built-in mathematical model and process algorithm for die casting.

[0011] The touch screen display module is connected to the PLC module and is used to input known data of the casting and display the output results of the PLC module so that the operator can fill in the injection parameters.

[0012] The verification module, connected to the PLC module, is used to verify the output results of the PLC module.

[0013] The data storage module, connected to the PLC module, is used to store die-casting process parameters and to save and retrieve different die-casting parameters based on the mold number.

[0014] Optionally, the system also includes a user interface integrated into the touchscreen module for setting and displaying die-casting process parameters and operating instructions.

[0015] Optionally, the system also includes a fault diagnosis module connected to the PLC module for monitoring abnormalities during the die-casting process.

[0016] Optionally, the system also includes a remote update module connected to the PLC module, used to receive the latest die-casting process parameters and system upgrades via a network.

[0017] Optionally, the system also includes an energy consumption analysis module connected to the PLC module, used to calculate and optimize energy consumption during the die-casting process to improve energy efficiency.

[0018] Optionally, the system further includes a communication interface for enabling data exchange and communication between the modules.

[0019] Optionally, the system also includes a power module to provide a stable power supply to each module.

[0020] By adopting the above technical solution, it has at least the following beneficial effects compared with the prior art:

[0021] By adopting the system provided in this application, the die-casting machine realizes automated calculation and setting of die-casting process parameters, which improves production efficiency and product qualification rate, saves materials and costs, realizes precise control of process parameters, facilitates convenient saving and retrieval of parameters, enhances the reliability and stability of the system, simplifies the system upgrade and maintenance process, and optimizes energy consumption through energy consumption analysis, thereby improving energy utilization efficiency and reducing production costs. Attached Figure Description

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

[0023] Figure 1 This is a schematic diagram of the structure of an intelligent process control system for a die-casting machine provided in an exemplary embodiment of this application;

[0024] Figure 2 This is a schematic diagram of a casting condition calculation interface provided in an exemplary embodiment of this application;

[0025] Figure 3 This is a schematic diagram of a casting interface provided in an exemplary embodiment of this application;

[0026] Figure 4 This is a schematic diagram of the injection parameter setting interface provided in an exemplary embodiment of this application. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of this application clearer, the embodiments of this application will be described in further detail below with reference to the accompanying drawings.

[0028] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the present invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0029] This utility model provides an intelligent process control system for die-casting machines, including: a touch screen setting module, a PLC module, a touch screen display module, a verification module, and a data storage module. The following will describe in detail each component of the system and its specific implementation.

[0030] The following is combined Figures 1 to 4 The structure and connections of this system will be further elaborated in detail:

[0031] Touchscreen setting module: This module connects to the PLC module and is used to set die-casting process parameters based on the input casting parameters. These parameters include the total weight of the casting, the mass after desprue, the net weight of the product, the cake thickness, the air injection stroke, the hammer diameter, the metal density, the ingate speed, the ingate area, the average wall thickness, and the casting pressure. These parameters are key inputs in the die-casting process and directly affect product quality and production efficiency.

[0032] PLC Module: Connected to the touchscreen module, this module incorporates a mathematical model and algorithm for the die-casting process. Based on the parameters input from the setting module, it uses the built-in mathematical model and algorithm to calculate key die-casting process parameters such as slow speed, high speed, chamber filling position, metal arrival at the ingate position, filling end position, filling stroke, filling time, chamber filling rate, pressure boosting switching position, required pressure boosting and energy storage pressure, and pressure boosting ratio.

[0033] Touchscreen display module: Connected to the PLC module, it provides a user interface for displaying known data of the input casting and the output results of the PLC module. Operators can input injection parameters based on these results displayed on the touchscreen, thereby achieving precise control of the die-casting machine.

[0034] Verification Module: The verification module is connected to the PLC module and is used to verify the PLC module's output results. This step ensures the accuracy of the die-casting process parameters and avoids product quality problems caused by incorrect parameters.

[0035] Data storage module: Connected to the PLC module, the data storage module stores die-casting process parameters. This module can save and retrieve different die-casting parameters based on the mold number, enabling rapid parameter reuse and convenient management.

[0036] User Interface: The system also includes a user interface integrated into the touchscreen module for setting and displaying die-casting process parameters and operating instructions. This allows operators to intuitively understand the current process status and the next step, improving the convenience and accuracy of operation.

[0037] Fault diagnosis module: Connected to the PLC module, this module monitors abnormalities during the die-casting process. It can promptly detect and alert to potential problems, reducing production interruptions and product quality issues.

[0038] Remote Update Module: The system also includes a remote update module connected to the PLC module, which receives the latest die-casting process parameters and system upgrades via the network. This ensures continuous system updates and optimization to adapt to ever-changing production needs.

[0039] Energy Consumption Analysis Module: The system also includes an energy consumption analysis module, connected to the PLC module, used to calculate and optimize energy consumption during the die-casting process. This module helps improve energy efficiency and reduce production costs.

[0040] The system also includes a communication interface for data exchange and communication between modules. This interface ensures smooth information transmission and stable system operation.

[0041] The system also includes a power supply module to provide a stable power supply to all modules. This module ensures the reliability of the system under various operating conditions.

[0042] Through the above-described embodiments, the system provided in this application can achieve rapid setting and precise control of die-casting process parameters, improve production efficiency, reduce costs, and ensure consistent product quality. Furthermore, the system's modular design facilitates maintenance and upgrades, adapting to ever-changing production needs.

[0043] It should be noted that this application aims to protect the composition and connection relationships of the various components of the intelligent process control system for die-casting machines. The above-mentioned content regarding data acquisition methods, calculation methods, etc., is for the purpose of understanding the principles of this solution and the function of each component, and is not intended to limit the scope of protection.

[0044] The above description is merely a selection of preferred embodiments of this disclosure and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of the utility model involved in the embodiments of this disclosure is not limited to the specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the above-described inventive concept. For example, technical solutions formed by substituting the above features with (but not limited to) technical features with similar functions disclosed in the embodiments of this disclosure.

[0045] Other embodiments of this application will readily occur to those skilled in the art upon consideration of the specification and practice of the utility model disclosed herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not disclosed herein.

[0046] It should be understood that this application is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this application is limited only by the appended claims.

[0047] It should be understood that "multiple" as used in this article refers to two or more. "And / or" describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A alone, A and B simultaneously, or B alone. The character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0048] The above description is only a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. An intelligent process control system for die-casting machines, characterized in that, include: Touchscreen setting module, PLC module, touchscreen display module, verification module, and data storage module; The touch screen setting module, connected to the PLC module, is used to set the die casting process parameters based on the input total weight of the casting, the mass after desprue, the net weight of the product, the thickness of the sprue, the air injection stroke, the hammer diameter, the metal density, the ingate speed, the ingate area, the average wall thickness, and the casting pressure parameters. The PLC module is connected to the touch screen module and has a built-in mathematical model and process algorithm for die casting. The touch screen display module, connected to the PLC module, is used to display the known data of the input casting and the output results of the PLC module, so that the operator can fill in the injection parameters; The verification module, connected to the PLC module, is used to verify the output results of the PLC module. The data storage module, connected to the PLC module, is used to store die-casting process parameters and to save and retrieve different die-casting parameters based on the mold number.

2. The system according to claim 1, characterized in that, The system also includes a user interface integrated into the touchscreen module for setting and displaying die-casting process parameters and operating instructions.

3. The system according to claim 1, characterized in that, The system also includes a fault diagnosis module connected to the PLC module, used to monitor abnormalities during the die-casting process.

4. The system according to claim 1, characterized in that, The system also includes a remote update module connected to the PLC module, used to receive the latest die-casting process parameters and system upgrades via the network.

5. The system according to claim 1, characterized in that, The system also includes an energy consumption analysis module connected to the PLC module, used to calculate and optimize energy consumption during the die-casting process to improve energy efficiency.

6. The system according to claim 1, characterized in that, The system also includes a communication interface for data exchange and communication between the modules.

7. The system according to claim 1, characterized in that, The system also includes a power module to provide a stable power supply to each module.

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