Permanent Mold Casting MPC for Stable Temperature Control
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Solution Overview
Problem
Existing temperature control methods for casting processes, such as feedforward and feedback control, result in significant temperature fluctuations and inaccuracies, particularly in permanent mold casting, leading to defects in castings.
Innovation Solution
Implementing model predictive control (MPC) to adjust input variables like coolant flow rate and heating rate based on predicted temperature trajectories, minimizing temperature differences from a preset profile by optimizing a cost function that considers temperature deviations, input variable changes, and system constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If feedforward control is used to preset input variables before casting cycles, then the control system is simple to operate, but temperature fluctuations between individual casting cycles increase significantly
Solution Approach 1:
The patent implements feedback control by measuring actual temperatures during casting cycles and using these measurements to adjust input variables for subsequent cycles. Temperature sensors monitor the casting process, and the control system modifies coolant flow rates or heating power based on detected temperature deviations, thereby reducing temperature fluctuations between cycles while maintaining operational simplicity.
Solution Approach 2:
The patent applies preliminary action by calculating and presetting optimized input variable values before each casting cycle based on predictions from a digital twin model. The control system pre-determines optimal coolant flow rates or heating power settings that will maintain target temperature profiles, allowing proactive temperature management rather than reactive adjustments.
2Device complexity
If simple feedback control with thermocouples is used, then the control system is easy to implement, but the reaction time is slow and significant temperature peaks occur
Solution Approach 1:
The patent uses a digital twin model to predict future temperature trajectories and calculate optimal input variable adjustments before temperature deviations occur. This predictive approach allows the control system to act in advance, preventing temperature peaks rather than reacting to them, thereby achieving fast effective response without requiring complex real-time sensing infrastructure.
Solution Approach 2:
The patent introduces a digital twin model as an intermediary between the physical casting system and the control system. This virtual model simulates temperature evolution and predicts future states, enabling the control system to make informed decisions about input variable adjustments without needing complex arrays of physical sensors, thus maintaining simple device implementation while achieving fast predictive response.
3Manufacturing precision
If model predictive control is implemented to proactively adjust input variables, then temperature control accuracy improves, but the computational complexity and system complexity increase
Solution Approach 1:
The patent creates a digital twin (a virtual copy) of the physical casting system that replicates its thermal behavior. This digital model is used to predict temperature evolution and optimize control decisions without requiring complex physical modifications to the actual casting equipment. The copy handles the computational complexity while the physical system remains relatively simple.
Solution Approach 2:
The patent applies preliminary action by using the digital twin to pre-calculate optimal input variable values before each casting cycle or at strategic intervals. This predictive optimization achieves high temperature control accuracy by proactively determining control settings, reducing the need for complex real-time computational systems during the actual casting process.
Data Source
AI summary
A method for controlling, in particular for temperature control, a casting process, in particular a gravity die casting process, including control of at least one input variable indicative of at least one input variable of the casting process, in particular as a function of at least one output variable indicative of at least one temperature of the casting process, in particular for a temperature of a casting mould. A temperature difference between the temperature of the casting process and a preset temperature profile is minimized. The control of the at least one input variable is based on a model predictive control. The present invention also relates to a control system for a casting process, in particular for a permanent mold casting process, a device including at least one processor and at least one memory as well as a computer program including program instructions.