Die Casting Mold Temperature Control via Thermal Imaging
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Solution Overview
Problem
Conventional temperature control methods for casting processes, such as forward regulation and feedback control, often result in significant temperature fluctuations and maintenance challenges, leading to defects and inefficiencies in cast parts production.
Innovation Solution
A temperature control system utilizing a thermal imaging camera to measure mold temperature during the open state of the cast shape, allowing for real-time adjustment of input variables like coolant flow rates to minimize temperature differences and achieve a preset temperature profile, while reducing maintenance efforts by eliminating the need for multiple thermoelements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If thermocouples are used to measure mold temperature in feedback control, then temperature measurement capability is provided, but maintenance effort and system complexity increase significantly
Solution Approach 1:
The patent extracts the temperature measurement function from the mold interior to the exterior surface. The thermal imaging camera measures temperature on the mold's outer surface, which correlates with internal temperatures, eliminating the need to embed thermocouples within the mold structure. This extraction reduces maintenance effort while preserving measurement capability.
Solution Approach 2:
The patent uses a thermal imaging camera to create a visual copy/representation of the mold's temperature distribution. Instead of direct contact measurement with thermocouples, the system captures thermal radiation patterns that replicate temperature information, providing non-contact measurement that eliminates maintenance issues associated with embedded sensors.
2Reliability
If thermocouples are installed within the mold for continuous temperature monitoring, then real-time feedback control is enabled, but the system becomes more complex and requires constant maintenance
Solution Approach 1:
The patent introduces the mold's outer surface as an intermediary measurement point. Instead of directly measuring internal temperatures with thermocouples, the system measures temperatures on the accessible outer surface and uses these as proxies for internal temperature states. This intermediary approach simplifies the measurement system while maintaining control reliability.
Solution Approach 2:
The patent replaces the mechanical contact-based thermocouple system with an optical/thermal radiation-based measurement system. The thermal imaging camera detects infrared radiation from the mold surface, substituting mechanical sensor installation with non-contact optical measurement, thereby reducing system complexity and maintenance requirements.
3Reliability
If simple feedback control with thermocouples is used, then temperature regulation capability is provided, but response time is slow due to reaction delays
Solution Approach 1:
The patent implements preliminary measurement action by capturing thermal images at strategically timed moments during the casting cycle (e.g., when the mold is open). These preliminary measurements provide temperature data that can be used to predict and adjust for temperature changes during the closed mold phase, enabling proactive rather than reactive control and reducing overall response time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach provides reliable and accurate temperature control, minimizing temperature fluctuations and maintenance needs, and enabling quick adjustments to maintain a consistent temperature profile during casting cycles.
Implementation Method 1
the at least one output variable is detected during an open state of the mold using at least one thermal imaging camera
Data Source
Figure 1
AI summary
The present invention relates to a method for temperature control of a casting process, in particular a die casting process, comprising: determining at least one output variable indicatively for at least one temperature of a mold, wherein the at least one output variable is detected during an open state of the mold by means of at least one thermal imaging camera; controlling at least one input variable indicatively for at least one input variable of the casting process as a function of the output variable such that a temperature difference of at least one temperature of the mold to a preset temperature profile is minimized, wherein the at least one output variable is estimated during a closed state of the mold by means of a state estimator based at least on the output variable detected during the open state of the mold.The invention also relates to a control system for a casting process, in particular for a die casting process, a device and a computer program.