INTEGRATED FLOW METER FOR ALUMINUM CASTINGS

Abstract

A molten metal pouring trough system includes a pump that draws molten metal from a reservoir. A heated channel receives the molten metal from the pump and carries a flow of the molten metal. A pipe extends from the heated channel and is exposed outside of it. This pipe carries the flow. A temperature sensor detects the temperature of the molten metal in the pipe. An outlet at one end of the pipe directs the flow from the pipe into a mold. A flow meter is positioned along the pipe, which extends through it. The flow meter measures the flow rate of the molten metal in the pipe. A control module adjusts the pump's operation based on at least the flow rate detected by the flow meter and the temperature detected by the temperature sensor.

Description

INTRODUCTION

[0001] The information provided in this section serves the purpose of presenting the context of the disclosure in general. Works of the inventors mentioned herein, insofar as they are described in this section, as well as aspects of the description that may not otherwise be considered prior art at the time of filing, are neither expressly nor implicitly admitted as prior art in relation to this disclosure.

[0002] The present disclosure relates in general to systems and methods for measuring the flow rate of a conductive fluid through a line of a foundry system using a flow meter integrated into the foundry system.

[0003] Many systems that carry conductive fluids, such as molten aluminum or alkali metals, through a conduit require accurate measurements of the conductive fluid flowing through the conduit. For example, a pouring trough system that delivers molten metal into a mold might use a fill time to monitor the flow rate of the molten metal to the mold. However, time-based measurements can be relatively inaccurate and do not allow for adjustment of the flow rate during the casting process.

[0004] Although some flow meters are capable of measuring the flow rate of a conductive fluid, these flow meters typically use a probe that extends at least partially into the conduit carrying the conductive fluid. Other typical examples involve electrodes in contact with the conduit, which measure the voltage induced in the conductive fluid between the electrodes. Thus, in these examples, there is direct contact between the flow meter and the conductive fluid and / or the conduit carrying the conductive fluid, and the flow meter must withstand the high temperatures of the conductive fluid. SUMMARY

[0005] One aspect of the revelation provides a molten metal pouring trough system. The molten metal pouring trough system includes a pump configured to draw molten metal from a reservoir. A heated trough is configured to receive the molten metal from the pump and carry a flow of the molten metal. A conduit extends from the heated trough and is exposed outside the heated trough. The conduit is configured to carry the flow of the molten metal. A temperature sensor is configured to detect the temperature of the molten metal in the conduit. An outlet is located at one end of the conduit and is configured to direct the flow of molten metal from the conduit into a mold. A flow meter is located along the conduit. The conduit extends through the flow meter.The flow meter is configured to detect the flow rate of the molten metal in the pipe. A control module, communicating with the pump, is configured to adjust the pump's operation to regulate the flow of molten metal into the mold, based at least on the flow rate detected by the flow meter and the temperature detected by the temperature sensor.

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

[0007] In some aspects, the pipe is part of the heated flow path. A portion of the pipe extends from one end of the heated flow path to be exposed outside of it. In some implementations, the pipe is part of the flow meter. A seal located at one end of the pipe opposite the outlet is configured to interface with the heated flow path.

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

[0009] Another aspect of the 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 pouring trough system to draw molten metal from a reservoir. A heated runner receives the molten metal from the pump and carries a flow of the molten metal. A conduit extends from the heated runner and is exposed outside the heated runner. 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 mold. The operations include receiving initial sensor data from a temperature sensor. The initial sensor data is representative of the temperature of the molten metal in the conduit.The processes involve receiving second sensor data from a flow meter located along the pipe. The pipe extends through the flow meter. The second sensor data is representative of the flow rate of the molten metal in the pipe. In response to processing the first and second sensor data, the processes involve adjusting the operation of the pump to control the flow of molten metal into the mold, based at least on the flow rate of the molten metal in the pipe and the temperature of the molten metal in the pipe. Aspects of the disclosure may include one or more of the following optional features.

[0010] In some embodiments, 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 pipe is part of the heated flow path. A portion of the pipe extends from one end of the heated flow path to be exposed outside the heated flow path. Optionally, the pump operation is adjusted based on a target flow rate of the molten metal in the pipe.

[0011] Yet another aspect of the revelation provides a system. The system includes memory hardware that stores instructions which, when executed on the data processing hardware in communication with the memory hardware, cause the data processing hardware to perform operations. The operations include operating a pump of a molten metal pouring trough system to draw molten metal from a reservoir. A heated trough receives the molten metal from the pump and carries a flow of the molten metal. A conduit extends from the heated trough and is exposed outside the heated trough. 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 mold. The operations include receiving initial sensor data from a temperature sensor.The first sensor data are representative of the temperature of the molten metal in the pipe. The operations include receiving second sensor data from a flow meter located along the pipe. The pipe extends through the flow meter. The second sensor data are representative of the flow rate of the molten metal in the pipe. In response to processing the first and second sensor data, the operations include adjusting the operation of the pump to set the flow rate of the molten metal into the mold, based at least on the flow rate of the molten metal in the pipe and the temperature of the molten metal in the pipe. Aspects of the disclosure may include one or more of the following optional features.

[0012] In some embodiments, 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 pipe is part of the heated flow path. A portion of the pipe extends from one end of the heated flow path to be exposed outside the heated flow path. Optionally, the pump operation is adjusted based on a target flow rate of the molten metal in the pipe.

[0013] The details of one or more embodiments of the disclosure are set forth in the accompanying drawings and in the description below. Further aspects, features, and advantages will become apparent from the description, the drawings, and the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The drawings described herein serve only to illustrate selected configurations and are not intended to limit the scope of this disclosure. Fig. Figure 1 is a perspective view of a vehicle that has a component manufactured using a casting process. Fig. Figure 2 is an exploded view of a pouring trough system that has an integrated flow meter. Fig. 3 is an enlarged view of area 3 in Fig. 2. Fig. Figure 4 is a schematic diagram showing the flow meter and pump of the trough system during a pump start-up process. Fig. Figure 5 is a flowchart of an exemplary procedure for adjusting the operation of the pump of the casting trough system during a casting process based on the flow rate detected by the integrated flow meter.

[0015] The corresponding reference symbols indicate the corresponding parts in all drawings. DETAILED DESCRIPTION

[0016] Exemplary configurations are now described in more detail with reference to the accompanying drawings. Exemplary configurations are provided to ensure that this disclosure is thorough and fully conveys its scope to those skilled in the art. Specific details, such as examples of particular components, devices, and processes, are presented to facilitate a comprehensive understanding of the configurations of this disclosure. It is obvious to those skilled in the art that specific details need not be used, that exemplary configurations can be implemented in many different forms, and that the specific details and exemplary configurations should not be interpreted as limiting the scope of the disclosure.

[0017] The terminology used herein serves only to describe certain exemplary configurations and is not to be understood as restrictive. The singular articles "a" and "the" used herein also include the plural forms unless the context clearly indicates otherwise. The terms "comprises," "comprehensive," "including / include," and "shows / show" are inclusive and therefore specify the presence of features, steps, processes, numbers, elements, and / or components, but do not exclude the presence or addition of one or more other features, numbers, steps, processes, elements, components, and / or groups thereof.The procedural steps, processes, and procedures described herein are not to be interpreted as necessarily requiring them to be carried out in the specific order explained or illustrated, unless they are expressly designated as the order of execution. Additional or alternative steps may be applied.

[0018] When an element or layer is described as being "on" or "interacting with" another element or layer, or as being "connected" or "coupled" or "attached" to the same, it may be directly on or interacting with, connected with, coupled to, or attached to the other element or layer, or there may be intervening elements or layers. However, when an element is described as being "directly on" or "directly interacting with" another element or layer, or as being "directly connected" or "directly coupled" or "attached" to the same, there must be no intervening elements or layers. Other words used to describe the relationship between elements should be interpreted similarly (e.g.,“Between” as opposed to “directly between”, “neighboring” or “adjacent” as opposed to “directly adjacent” or “directly bordering”, etc.). As used herein, the term “and / or” includes all combinations of one or more of the related listed items.

[0019] The terms first, second, third, etc., may be used here to describe different elements, components, regions, layers, and / or sections. These elements, components, regions, layers, and / or sections should not be restricted by these terms. These terms may only be used to distinguish one element, component, region, layer, or section from another. Terms such as "first," "second," and other numerical terms do not imply any sequence or order unless the context clearly indicates otherwise.Thus, one could refer to a first element, a first component, a first area, a first layer or a first section, as explained below, as a second element, second component, second area, second layer or second section, without deviating from the lessons of the exemplary configurations.

[0020] In this application, which includes the following definitions, the term "module" may be replaced by the term "circuit". The term "module" may refer to being part of, or comprising, an application-specific integrated circuit (ASIC), a digital, analog, or mixed analog / digital discrete circuit, a digital, analog, or mixed analog / digital integrated circuit, a combinational logic circuit, a field-programmable gate array (FPGA), a processor (shared, dedicated, or group) that executes code, a memory (shared, dedicated, or group) that stores code executed by a processor, other suitable hardware components that provide the described functionality, or a combination of some or all of the above components, such as in a system-on-a-chip.

[0021] The term "code," as used above, may include software, firmware, and / or microcode, and may refer to programs, routines, functions, classes, and / or objects. The term "shared processor" includes a single processor that executes code from multiple modules, either sectionally or as a whole. The term "group processor" includes a processor that, in combination with additional processors, executes code from one or more modules, either sectionally or as a whole. The term "shared memory" includes a single memory that stores code from multiple modules, either sectionally or as a whole. The term "group memory" includes memory that, in combination with additional memory, stores code from one or more modules, either sectionally or as a whole. The term "memory" may be a subset of the term "computer-readable medium."The term "computer-readable medium" excludes transitory electrical and electromagnetic signals propagating through a medium and can therefore be considered tangible, non-transient storage. Non-restrictive examples of non-transient storage include tangible, computer-readable media, including non-volatile memory, magnetic storage, and optical storage.

[0022] The devices and methods described in this application can be implemented in part or in their entirety by one or more computer programs executed by one or more processors. The computer programs comprise processor-executable instructions stored on at least one non-transient, concrete, computer-readable medium. The computer programs may also include or be based on stored data.

[0023] A software application (i.e., a software resource) can refer to computer software that causes a computer device to perform a task. In some examples, a software application may be called an "application," "app," or "program." Examples of applications include, but are not limited to, system diagnostic applications, system administration applications, system maintenance applications, word processing applications, spreadsheet applications, messaging applications, media streaming applications, social networking applications, and gaming applications.

[0024] Non-transient memory can be physical devices used for the temporary or permanent storage of programs (e.g., sequences of instructions) or data (e.g., program status information) for use by a computer 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 for firmware, such as boot programs).Examples of volatile storage 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 floppy disks or tapes.

[0025] These computer programs (also known as programs, software, software applications, or code) comprise machine instructions for a programmable processor and may be implemented in a procedural and / or object-oriented high-level language and / or in assembly / machine language. The terms "machine-readable medium" and "computer-readable medium" as used herein refer to any computer program product, non-transient computer-readable medium, device, and / or apparatus (e.g., magnetic disks, optical disks, memory, programmable logic devices (PLDs)) used to provide machine instructions and / or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term "machine-readable signal" refers to any signal used to provide machine instructions and / or data to a programmable processor.

[0026] Various implementations of the systems and techniques described herein may be realized 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 may include implementation in one or more computer programs that are executable and / or interpretable on a programmable system comprising at least one programmable processor, which can be used for special or general purposes and is coupled such that it receives data and instructions from and transmits data and instructions to a storage system, and at least one input device and at least one output device.

[0027] The processes and logic flows described in this description can be executed by one or more programmable processors, also known as data processing hardware, which run one or more computer programs to perform functions by responding to input data and producing outputs. The processes and logic flows can also be executed by specialized logic circuits, such as an FPGA (Field Programmable Gate Array) or an ASIC (Application Specific Integrated Circuit). Processors suitable for executing a computer program include, for example, both general-purpose and specialized microprocessors, as well as one or more processors in all types of digital computers. Generally, a processor receives instructions and data from read-only memory, random-access memory, or both.The essential elements of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Generally, a computer also includes one or more mass storage devices for storing data, such as magnetic, magneto-optical, or optical disks, or is operationally coupled to them to receive data from or transmit data to them, or both. However, a computer does not necessarily have to have such devices. Computer-readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media, and storage devices, such as semiconductor memory devices (e.g., EPROM, EEPROM, and flash memory devices), magnetic disks (e.g., internal hard disks or removable disks), magneto-optical disks, and CD-ROM and DVD-ROM disks.The processor and memory can be supplemented by special logic circuits or integrated into them.

[0028] To enable interaction with a user, one or more aspects of the revelation can be implemented on a computer that has a display device, such as a CRT (cathode ray tube), LCD (liquid crystal display) monitor, or touchscreen, for showing information to the user, and optionally a keyboard and pointing device, such as a mouse or trackball, with which the user can input information into the computer. Other types of devices can also be used to enable interaction with the user; for example, the user can receive any form of sensory feedback, such as visual, auditory, or tactile feedback, and user input can be received in any form, including acoustic, verbal, or tactile input.Additionally, a computer can interact with a user by sending and receiving documents to and from a device used by the user, for example, by sending web pages to a web browser on a user's client device in response to requests received from the web browser.

[0029] With reference to the figures and the illustrated configurations shown therein, a vehicle 10 comprises one or more components that are manufactured by a metallic casting process ( Fig. 1) The vehicle 10 includes, for example, an engine block 12 made of cast aluminum. That is, the engine block 12 (or one or more other components of the vehicle 10) is formed by casting molten aluminum 14 ( Fig. 4) using casting techniques into a mold or packaging. For certain aspects of the casting process, real-time flow measurements of the molten aluminium 14 being discharged into the mold from a casting discharge or trough system 100 can be used ( Fig. 2) As described below, the pouring trough system 100 includes a flow meter 200, which is integrated into the components and / or pipes of the pouring trough system 100 or arranged inline to measure the flow rate F 14 to reliably determine the amount of molten aluminium 14 from the casting trough system 100 and the flow rate F 14 The flow rate F can be set by adjusting the trough system 100 based on the readings of the flow meter 200. In some examples, the flow meter 200 can determine the flow rate F. 14Determine the flow rate F without the flow meter 200 coming into direct contact with the molten aluminum 14 and / or without interrupting or segmenting the casting trough system 100 in such a way as to cause leaks. Although this involves determining the flow rate F 14 As described in the section on the flow of molten aluminium 14 through the casting trough system 100, it should be understood that the flow meter 200 can be configured to determine the flow rates of any suitable molten metal through various casting discharge systems and / or other conductive fluids, such as alkali metals or charged chemical solutions, through lines of different systems.

[0030] As in Fig. As shown in Figure 2, the casting dispensing system or casting trough system 100 comprises a reservoir or bath 102 of molten metal, such as molten aluminum 14, and a pump 104 configured to draw the molten aluminum 14 from the reservoir 102. When operating, the pump 104 delivers a flow of molten aluminum 14 from the reservoir 102 to a filling port 106 at a first end 110 of a flow path or track 108. The flow of molten aluminum 14 travels along a channel or passage of the flow path 108 from the first end 110 to a second end 112 of the flow path 108 opposite the first end 110. The flow path 108 can be heated to maintain or regulate the temperature of the molten aluminum 14 and thus its viscosity and flow rate F. 14 to maintain or regulate the molten aluminium 14.

[0031] In the illustrated example, the filling port 106 is located at the first end 110 of the flow path 108 and is fluidically coupled to the flow path 108 by means of a seal or intermediate plate 114, which is positioned between the filling port 106 and the flow path 108, to provide a sealed connection between the filling port 106 and the flow path 108. In some examples, the filling port 106 may be integrated into the heated flow path 108. When the pump 104 is operated to deliver molten aluminum 14 to the filling port 106, the filling port 106 can ensure that the channel or passage of the flow path 108 is completely filled. As explained further below, this can ensure accurate flow measurements at the flow meter 200.

[0032] A conduit or pipe 116 extends from the second end 112 of the traverse 108 and is exposed outside the heated traverse 108. The conduit 116 may be an extension of the channel or passage of the traverse 108, such that the conduit 116 can extend from the first end 110 of the traverse 108 beyond the second end 112 of the traverse 108 and continue towards an outlet 120 at an end 118 of the conduit 116 that is remote from the second end 112 of the traverse 108. Thus, the conduit 116 is configured to carry the flow of molten aluminum 14 to the outlet 120, the outlet 120 being configured to direct the flow of molten aluminum 14 from the end 118 of the conduit 116 into the mold or packaging that receives the molten aluminum 14. A gasket or intermediate plate 122 can be arranged between the end 118 of the conduit 116 and the outlet 120, providing a sealed connection.

[0033] As in Fig. As shown in Figure 3, the line 116 can comprise a separate pipe that is fluidically coupled to the channel or passage of the flow path 108 at the second end 112 of the flow path 108. That is, one end 124 of the line 116, opposite the end 118 located at the outlet 120, is fluidically coupled to the flow path 108. A seal or interface plate 126 can be arranged between the end 124 of the line 116 and the second end 112 of the channel 108 to secure the line 116 to the flow path 108 with a sealed fluid connection. The line 116, separate from the flow path 108, can be part of the flow meter 200.

[0034] The flow meter 200 is arranged along the line 116 between the second end 112 of the traverse 108 and the outlet 120 and is configured to measure the flow rate F 14of the molten aluminum 14 flowing through the line 116. With the exposed line 116 integrated into the passage 108, the flow meter 200 can be fixedly attached to the line 116, for example by clamping it to the line 116 from opposite sides to essentially surround it, and / or slide along the line 116 so that the line 116 extends through the flow meter 200. With the exposed line 116 attached to the second end 112 of the passage 108, the line 116 can be part of the flow meter 200. The flow meter 200 and the pipe 116 can be removed from the trough system 100, for example for easier maintenance, to move the flow meter 200 between different systems, to replace it with flow meters that have different flow sensitivities, and the like.

[0035] Furthermore, the pouring trough system 100 and / or the flow meter 200 includes a temperature sensor 128, which is configured to measure the temperature T 14 of the molten aluminum 14 in the flow path 108 and / or the line 116. The temperature sensor 128 transmits sensor data that is relevant for the temperature T 14 are representative, and the flow meter 200 transmits sensor data that is relevant for the flow rate F 14The flow meter 200 and the temperature sensor 128 are representative of the temperature and flow conditions of the molten aluminum 14 and are connected to a control module 130 of the casting trough system 100, for example, via a wired or wireless communication link (e.g., via Wi-Fi™). The flow meter 200 and the temperature sensor 128 can transmit analog signals that are representative of the temperature and flow conditions of the molten aluminum 14. As explained below, the control module 130 is connected to the pump 104 and controls the operation of the pump 104 to ensure that the flow of the molten aluminum 14 into the mold is at least based on the flow rate F detected by the flow meter 200. 14 and the temperature T detected by temperature sensor 128 14 to adjust.

[0036] In other words, the flow meter 200 and / or the pouring trough system 100 can include or communicate with the control module 130, which includes data processing hardware 132 and storage hardware 134 in communication with the data processing hardware 132. The storage hardware 134 stores commands which, 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 operating the pump 104 of the pouring trough system 100 based on the flow rate F detected by the flow meter 200. 14 , such as according to procedure 500 of Fig. 5, which is explained further below.

[0037] In some examples, the flow meter 200 is a contact-based flow meter, in which the flow meter 200 includes a probe that extends at least partially into the line 116 to determine the flow rate F14 of the molten aluminum 14 as the molten aluminum 14 flows past and interacts with the probe. In these examples, the line 116 can be part of the flow meter 200. Optionally, the flow meter 200 is a contact-based flow meter, in which the flow meter 200 operates by generating a magnetic field that traverses the line 116 and interacts at least partially with the molten aluminum 14. Since the aluminum 14 is a conductive fluid, the magnetic field induces eddy currents in the molten aluminum 14.The reaction magnetic field produced by the eddy currents can generate an electric charge between opposite sides of the line 116, which can be detected by electrodes of the flow meter 200 that contact the opposite sides of the line 116. The strength of the reaction magnetic field can be related to the flow rate F. 14 of the molten aluminum 14 is correlated and detected based on the electrical charge measured by the flow meter 200. Thus, the contact-based flow meter 200 can utilize a conductor 116 formed from a non-magnetic metallic material, such as a tungsten-based alloy (e.g., ANVILOY™), or a conductor 116 coated with a compatible material, such as a tungsten-coated stainless steel conductor.

[0038] Optionally, the flow meter 200 can be a non-contact or contactless flow meter that does not come into direct contact with the molten aluminum 14 and / or the line 116. For example, the flow meter 200 can generate the magnetic field that traverses the line 116 and induces the eddy currents in the conductive molten aluminum 14. The non-contact flow meter 200 can be configured to detect the strength of the reactive magnetic field present at the flow meter. For example, the non-contact flow meter 200 can include a magnetic element coupled to a pressure sensor, and the pressure sensor can be configured to detect the reactive magnetic field in interaction with the magnetic field. The strength of the magnetic field can be calibrated to the flow rate of the molten aluminum 14 through the line 116.Measuring the strength of the magnetic field generated by the molten aluminum 14 can provide a less noisy signal than measuring the voltage in industrial environments such as foundries. In these examples, the flow meter 200 can utilize a line 116 formed from a non-magnetic material, such as a non-magnetic metal or a non-metallic ceramic material.

[0039] In some examples, the inner diameter of the line 116 at the flow meter 200 may differ from an inner diameter of the heated passage 108 in order to control the flow rate F 14to adjust the flow rate of the molten material 14 so that it better matches the sensitivity or sensing range of the flow meter 200. For example, if the expected flow rate of the molten material 14 through channel 108 is faster than a desired flow rate through the flow meter 200, the line 116 at the flow meter 200 can be widened to adjust the flow rate F 14 to slow down the flow of the molten material 14 through the flow meter 200. Similarly, if the expected flow of the molten material 14 through the channel 108 is slower than the desired flow through the flow meter 200, the line 116 at the flow meter 200 can be narrowed or constricted to reduce the flow rate F. 14to increase the flow rate of the molten material 14 through the flow meter 200. Although this may lead to turbulence in the flow of the molten material 14, to a pressure change in the casting trough system 100 and / or to a deposition of corundum in the pipe 116, the accuracy of the flow meter 200 can be increased.

[0040] Since the density and viscosity of the molten aluminum 14 change depending on the temperature, the control module 130 can be calibrated to adjust the flow rate F 14to determine the flow rate of the molten aluminum 14 based on sensor data acquired by the flow meter 200 and the temperature sensor 128 during a calibration session. For example, the control module 130 can be calibrated at different temperatures of the molten aluminum 14 and based on the diameter of the line 116, the expected flow rate of the molten aluminum 14 from the reservoir 102 (e.g., based on the voltage or power settings of the pump 104), based on a filling rate calculated from the volume of the mold, based on the type of molten metal or conductive fluid, and the like. The control module 130 can store the predetermined calibration curves to ensure precise measurement of the flow rate F. 14 with fluctuations in temperature T 14 to achieve the molten aluminium 14 during the subsequent use of the casting trough system 100 after the calibration process.

[0041] In other words, during the calibration process, molten aluminum 14 is heated to different temperatures F 14 Depending on the time, the fluid is sent through the integrated pouring trough system 100 into a known volume, and temperature-dependent calibration curves are used to determine the flow rate F. 14 Based on the signal output from the flow meter 200, the mass of the casting can be tracked over time to determine the flow rate during the calibration process. Calibration curves can be determined at various temperatures of the molten aluminum and at different operating speeds of the pump 104. The calibration process can be performed regularly on the casting trough system 100 for each pair of flow meter 200 and casting trough system 100 to maintain tolerance standards, and / or after a modification of the casting trough system 100.

[0042] With reference to Fig. 4. The interface between the flow meter 200 and the heated flow path 108 can be fitted with a replaceable seal, meaning that the flow meter 200 can be removed from or replaced within the casting trough system 100, for example, for use during a run-in process of the pump 104. During the run-in process, molten aluminum 14 is drawn from the reservoir 102 by the pump 104 and returned to the reservoir 102 in a closed loop via the line 116. This can take place within the casting trough system 100, or the flow meter 200 can be used, as shown, as a standalone unit to measure the flow rate F generated by the pump 104. 14 of molten aluminum 14 is used. During the start-up process, a series of voltages can be applied to the pump 104 to control the flow rate F. 14to vary, and the flow rates F measured by the flow meter 200 14 can be compared with expected values ​​to determine whether the pump 104 is within or outside a predetermined operating specification.

[0043] Fig. Figure 5 presents a flowchart of an exemplary sequence of processes for a procedure 500 for operating the casting trough system 100 based on the flow rate F recorded by the flow meter 200. 14, such as after the pump 104 is switched on and after the control module 130 has been calibrated. The procedure 500 can be executed by the control module 130, such as in the data processing hardware 132, based on operations stored in the memory hardware 134. In operation 502, the procedure 500 includes operating the pump 104 of the molten metal pouring trough system 100 to draw molten metal 14 (e.g., molten aluminum or another suitable molten metal and / or a conductive fluid) from the reservoir 102. The heated channel 108 receives the molten metal 14 from the pump 104 and carries the flow of the molten metal 14. The line 116, which extends from the end 112 of the heated channel 108 furthest from the pump 104, carries the flow of the molten metal 14 to the outlet 120 at the end 118 of the line 116 furthest from the heated channel 108.Outlet 120 directs the flow of molten metal 14 from line 116 into a mold. In process 504, procedure 500 comprises receiving initial sensor data from temperature sensor 128, wherein the initial sensor data for temperature T. 14 of the molten metal 14 in the line 116 are representative. In process 506, method 500 comprises receiving second sensor data from the flow meter 200, which is located between the end 112 of the heated runner 108 and the outlet 120. The line 116 extends through the flow meter 200 (or optionally inside, past, below, or above the flow meter 200). The second sensor data are for the flow rate F 14The flow rate of the molten metal 14 in the pipeline 116 is representative. In response to the processing of the first sensor data and the second sensor data, procedure 500 in operation 508 includes adjusting the operation of the pump 104 to reduce the flow rate of the molten metal 14 into the mold at least based on the flow rate F. 14 of the flow rate of the molten metal 14 in the line 116 and the temperature T 14 of the molten metal 14 in line 116. For example, the pump 104 can be set to achieve a target flow rate F 14 of the molten metal 14 to the mold. The operation of the pump 104 can be set to continuous or episodic to control the flow rate F. 14 based on the real-time recorded flow rate F 14 and the temperature T recorded in real time 14to maintain the flow rate of the molten metal 14 at or near the target value. Furthermore, the target flow rate F can be adjusted. 14 The flow rate can be adjusted during the operation of pump 104, for example, based on a casting program executed by the casting trough system 100. The control module 130 can be programmed with predefined calibration curves that take into account density changes in the molten metal 14 based on temperature in order to adjust the flow rate.

[0044] Several implementations have been described. It is understood, however, that various modifications can be made without deviating from the spirit and scope of the disclosure. Accordingly, other embodiments also fall within the scope of the following claims.

[0045] The foregoing description is provided for illustrative and descriptive purposes only. It makes no claim to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not restricted to that particular configuration but are optionally interchangeable and may be used in a selected configuration even if not specifically shown or described. They may also be modified in many ways. Such modifications are not to be considered a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

[1] Pouring trough system for molten metal, comprising: a pump configured to draw molten metal from a reservoir; a heated runner configured to receive the molten metal from the pump and to carry a flow of the molten metal; a conduit extending from the heated running path and exposed outside the heated running path, wherein the conduit is configured to carry the flow of the molten metal; a temperature sensor configured to detect the temperature of the molten metal in the pipe; an outlet located at one end of the conduit and configured to direct the flow of molten metal from the conduit into a mold; a flow meter arranged along the pipe, the pipe extending through the flow meter, and the flow meter configured to detect a flow rate of the molten metal flowing through the pipe; and a control module in communication with the pump, wherein the control module is configured to adjust the operation of the pump in order to adjust the flow of molten metal into the mold at least based on the flow rate detected by the flow meter and the temperature detected by the temperature sensor. [2] Pouring trough system for molten metal according to claim 1, wherein the flow meter comprises a non-contact flow meter. [3] Pouring trough system for molten metal according to claim 2, wherein the conduit comprises a non-magnetic material. [4] Pouring trough system for molten metal according to claim 1, wherein the flow meter is a contact-based flow meter. [5] Casting trough system for molten metal according to claim 4, wherein the conduit comprises a non-magnetic metallic material. [6] Casting trough system for molten metal according to claim 1, wherein the conduit is part of the heated trough, and part of the conduit extends from one end of the heated trough to be exposed outside the heated trough. [7] Casting trough system for molten metal according to claim 1, wherein the conduit is part of the flow meter, and a seal is arranged at one end of the conduit opposite the outlet, configured to form an interface with the heated trough. [8] Casting trough system for molten metal according to claim 1, wherein an inner diameter of the conduit differs from an inner diameter of the heated trough. [9] Pouring trough system for molten metal according to claim 1, wherein the control module is configured to adjust the operation of the pump to achieve a target flow rate of the flow of molten metal in the conduit. [10] Casting trough system for molten metal according to claim 1, wherein the molten metal comprises molten aluminium and the mold is intended for a vehicle component.

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