Closed-Loop Mold Temperature Control for Aluminum Wheel Casting
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Solution Overview
Problem
The casting process of aluminum wheels is challenging due to the variability in mold temperature, which affects the quality and stability of the hub products, as manual adjustments are subjective and cannot be made in real-time during the casting process.
Innovation Solution
A closed-loop control method and system for mold temperature in the wheel casting process, using thermocouples to acquire data on mold position temperatures and cooling pipeline signals, which are processed to calculate and adjust temperature control parameters, enabling precise control of the casting process through a PLC system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual evaluation and adjustment of casting process are used, then operational simplicity is maintained, but manufacturing precision and quality consistency deteriorate due to subjectivity and lack of real-time control
Solution Approach 1:
The patent implements a closed-loop control system where thermocouples continuously monitor mold temperature, the host computer analyzes temperature data and compares it with preset standards, and automatically generates control signals to adjust cooling pipelines. This feedback mechanism eliminates manual subjectivity while maintaining operational simplicity through automation.
Solution Approach 2:
The patent replaces manual mechanical evaluation and adjustment with an automated computer-based control system. The host computer processes temperature data and controls cooling pipelines through PLC, substituting human operators with automated systems that provide consistent, objective control without sacrificing ease of operation.
2Manufacturing precision
If real-time temperature monitoring and control systems are implemented, then manufacturing precision and quality stability improve, but device complexity increases due to additional sensors and control mechanisms
Solution Approach 1:
The host computer serves multiple functions: acquiring temperature data from thermocouples, analyzing temperature trends, comparing with preset standards, generating control signals, and storing process data. The PLC also handles both monitoring and control functions. This multi-functionality reduces the need for separate dedicated devices, thereby limiting complexity increase.
Solution Approach 2:
The patent introduces a PLC (programmable logic controller) as an intermediary between the host computer and the cooling pipeline system. The PLC receives control signals from the host computer and executes the actual control of cooling pipelines, simplifying the direct control architecture and reducing overall system complexity while maintaining precise control capabilities.
3Measurement precision
If multiple thermocouples are placed at various mold positions to monitor temperature distribution, then measurement precision and temperature uniformity control improve, but device complexity and cost increase
Solution Approach 1:
The patent divides the mold into multiple monitoring zones with thermocouples placed at critical positions including flange position, spoke middle position, riser position, spoke-to-felloe transition position, outer rim position, and inner rim position. This segmentation allows targeted monitoring of temperature distribution without requiring exhaustive coverage, balancing measurement precision with device complexity.
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 stabilizes the low-pressure casting process, improves the quality and yield of aluminum wheels by allowing real-time adjustments to mold temperature, reducing fluctuations and enhancing the precision of the casting process.
Implementation Method 1
The plurality of position temperatures are acquired by thermocouples
Data Source
AI summary
The invention relates to the field of aluminum wheel casting molds, and more particularly relates to a closed-loop control method and system for a mold temperature in a wheel casting process. The control method includes: step 1, acquiring data, that is, acquiring a plurality of mold position temperatures, and cooling pipeline opening and closing signals in a target wheel casting process according to a fixed frequency; step 2, storing, based on acquired mold opening and closing signals of casting equipment, the acquired data in a database in the form of a unique ID according to a single wheel casting process; step 3, calculating new process parameters based on the acquired plurality of position temperatures and time; and step 4, integrating the calculated process parameters, and issuing the process parameters to a PLC of a casting equipment to perform new casting. According to the invention, the temperature control parameters are calculated based on the acquired temperature data and time process to form the temperature control process of the casting process, which solves the technical problem of significant fluctuations in the quality of the low-pressure casting process of aluminum wheels and improves casting stability and yield.