CN115283659B - Fixed point casting system based on artificial intelligence - Google Patents
Fixed point casting system based on artificial intelligence Download PDFInfo
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- CN115283659B CN115283659B CN202210942853.1A CN202210942853A CN115283659B CN 115283659 B CN115283659 B CN 115283659B CN 202210942853 A CN202210942853 A CN 202210942853A CN 115283659 B CN115283659 B CN 115283659B
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- 238000005266 casting Methods 0.000 title claims abstract description 131
- 238000013473 artificial intelligence Methods 0.000 title description 4
- 239000007788 liquid Substances 0.000 claims abstract description 49
- 238000012544 monitoring process Methods 0.000 claims abstract description 31
- 238000012937 correction Methods 0.000 claims abstract description 29
- 238000000034 method Methods 0.000 claims abstract description 19
- 238000005516 engineering process Methods 0.000 claims abstract description 10
- 230000033001 locomotion Effects 0.000 claims abstract description 7
- 238000011156 evaluation Methods 0.000 claims description 29
- 238000012806 monitoring device Methods 0.000 claims description 19
- 238000012545 processing Methods 0.000 claims description 10
- 238000004458 analytical method Methods 0.000 claims description 7
- 238000004140 cleaning Methods 0.000 claims description 3
- 238000003708 edge detection Methods 0.000 claims description 3
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- 238000012935 Averaging Methods 0.000 claims 1
- 239000002184 metal Substances 0.000 abstract description 7
- 230000009471 action Effects 0.000 abstract description 5
- 230000006399 behavior Effects 0.000 description 24
- 238000011161 development Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 238000005058 metal casting Methods 0.000 description 3
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- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
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- 238000013461 design Methods 0.000 description 1
- 230000029087 digestion Effects 0.000 description 1
- 230000004807 localization Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D46/00—Controlling, supervising, not restricted to casting covered by a single main group, e.g. for safety reasons
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D35/00—Equipment for conveying molten metal into beds or moulds
- B22D35/04—Equipment for conveying molten metal into beds or moulds into moulds, e.g. base plates, runners
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Casting Support Devices, Ladles, And Melt Control Thereby (AREA)
Abstract
The application discloses fixed point casting system based on machine vision includes: the system comprises an image acquisition module, a safety monitoring module and a control module; the image acquisition module is used for acquiring image information at the gate to obtain gate position information, position correction parameters and gate liquid level information; the safety monitoring module is used for collecting behavior video information and working environment temperature information of staff and sending out a braking signal; the control module is used for controlling the movement of the casting platform based on the gate position information and the position correction parameter, controlling the dumping angle and the dumping time of the furnace body based on the position correction parameter and the gate liquid level information, and performing emergency braking based on the braking signal. The method solves the problems of mechanization and automation of fixed-point casting of the molten metal of the casting enterprise through the image recognition technology, evaluates the safety of the actions of staff through the action capturing technology, and can perform emergency braking at any time when potential safety hazards occur, so that the life safety of the staff and the equipment safety are ensured.
Description
Technical Field
The application relates to the field of metal casting, in particular to a fixed-point casting system based on artificial intelligence.
Background
Metal casting is one of the main methods for obtaining mechanical product blanks, is an important basic process for the mechanical industry, and occupies an important position in national economy. In recent years, the achievement achieved by the casting industry in China is seen, the technical level of matched products such as large castings, key basic parts and the like is greatly broken through, and the industrial development foundation is tamped; depending on the national important construction engineering, large-scale autonomous operation of important technical equipment is developed; the independent development and the introduction of digestion and absorption are combined, and large-scale and high-end key castings are provided for national pillar industries such as energy, electric power, steel, ships, rail transit, machine tools, aerospace, automobiles and the like by increasing the technical transformation investment; the method has the advantages of fully playing the combined advantages of production, study and research, advocating the creation of an industry strategy alliance, overcoming key technical difficulties, improving the independent research and development capability and further improving the localization level of the automatic production line of the casting enterprises, and is the development direction of the casting enterprises.
However, the metal melting and casting links of metal casting enterprises, especially small and medium-sized casting enterprises still need manual operation casting blanks, the production efficiency is low, and the potential safety hazards exist.
Disclosure of Invention
Based on above industrial application, this application provides a fixed point casting system based on machine vision, adopts artificial intelligence technique to upgrade the manual casting operation of inefficiency into automatic operation, confirms the position of casting gate and casting gate liquid level height through image recognition technique, simultaneously through the security of video monitoring personnel's action, when the potential safety hazard appears, can carry out emergency braking in order to guarantee personnel and equipment's safety.
To achieve the above object, the present application provides the following solutions:
a machine vision-based fixed point casting system comprising: the system comprises an image acquisition module, a safety monitoring module and a control module;
the image acquisition module is connected with the control module and is used for acquiring image information at the casting nozzle to obtain position information, position correction parameters and liquid level information of the casting nozzle;
the safety monitoring module is connected with the control module and is used for collecting behavior video information and working environment temperature information of staff and sending out a braking signal;
the control module is used for controlling the movement of the casting platform based on the position information of the casting nozzle and the position correction parameter, is also used for controlling the pouring angle and the pouring time of the furnace body based on the position correction parameter and the liquid level information of the casting nozzle, and is also used for carrying out emergency braking based on the braking signal.
Preferably, the image at the casting nozzle comprises: blank mold image and sprue gate level image.
Preferably, the image acquisition module includes: a sprue gate positioning device, a sprue gate liquid level monitoring device and a first processor;
the casting nozzle positioning device is connected with the first processor and is used for acquiring blank mould images;
the casting nozzle liquid level monitoring device is connected with the first processor and is used for collecting a casting nozzle liquid level image;
the first processor is connected with the control module and is used for receiving and processing the blank mold image and the casting nozzle liquid level image to obtain the casting nozzle position information, the position correction parameters and the casting nozzle liquid level information.
Preferably, the working method of the image acquisition module comprises the following steps:
acquiring the blank mold image, and determining the position of the casting nozzle through an image recognition technology to obtain the position information of the casting nozzle and the position correction parameter;
and acquiring the liquid level image of the casting nozzle, and monitoring the liquid level information of the casting nozzle in real time through an image recognition technology.
Preferably, the safety monitoring module includes: the system comprises a personnel behavior monitoring device, a temperature monitoring device and a second processor;
the personnel behavior monitoring device is connected with the second processing and is used for collecting behavior video information of the staff;
the temperature monitoring device is connected with the second processing device and is used for monitoring the temperature of the working environment to obtain temperature information;
the second processor is connected with the control module and is used for carrying out personnel behavior safety analysis and evaluation based on the behavior video information to obtain a behavior safety evaluation result, the second processor is also used for receiving and processing the temperature information to obtain a temperature evaluation result, and the second processor is also used for sending out the braking signal based on the behavior safety evaluation result and the temperature evaluation result.
Preferably, the working method of the safety monitoring module comprises the following steps:
collecting behavior video information of the staff, and carrying out security assessment analysis in real time by a motion capturing method to obtain a behavior security assessment result;
acquiring the temperature information, and evaluating in real time to obtain a temperature evaluation result;
and sending out the braking signal based on the behavior safety evaluation result and the temperature evaluation result.
Preferably, the control module includes: an emergency braking device, a casting table control device and a furnace body control device;
the emergency braking device is respectively connected with the safety monitoring module, the furnace body control device and the casting table control device and is used for carrying out emergency braking based on the braking signal;
the casting platform control device is also connected with the image acquisition module and is used for controlling the casting platform to move to a designated position based on the casting port position information and the position correction parameter;
the furnace body control device is also connected with the image acquisition module and is used for controlling the pouring angle and the pouring time of the furnace body based on the position correction parameters and the casting nozzle liquid level information.
Preferably, the working method of the control module comprises the following steps:
controlling the casting platform to move to a designated position based on the casting nozzle position information and the position correction parameter;
controlling the pouring angle and the pouring time of the furnace body based on the position correction parameters and the liquid level information of the casting nozzle;
emergency braking is performed when a braking signal is received.
The beneficial effects of this application are:
according to the method, the artificial intelligent technology is adopted to upgrade and reform the manual casting operation with low efficiency into automatic operation, the problem of mechanization and automation of fixed-point casting of molten metal in a casting enterprise is solved through the image recognition technology, meanwhile, the safety of the actions of workers is evaluated through the action capturing technology, emergency braking can be carried out at any time when potential safety hazards occur, and the life safety and equipment safety of the workers are guaranteed.
Drawings
For a clearer description of the technical solutions of the present application, the drawings that are required to be used in the embodiments are briefly described below, it being evident that the drawings in the following description are only some embodiments of the present application, and that other drawings can be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic diagram of a machine vision-based fixed-point casting system;
FIG. 2 is a schematic view of a positioning device for a casting nozzle according to an embodiment of the present application;
fig. 3 is a schematic structural diagram of a casting table control device and a furnace body control device according to an embodiment of the present application.
Reference numerals illustrate:
1. the first layer is linked with three cameras; 2. the second layer is linked with three cameras; 3. a casting nozzle; 4. blank mold; 5. fine tuning the base; 6. a hydraulic lifting rod; 7. a hydraulic lifting platform; 8. a furnace body.
Detailed Description
The following description of the embodiments of the present application will be made clearly and fully with reference to the accompanying drawings, in which it is evident that the embodiments described are only some, but not all, of the embodiments of the present application. All other embodiments, which can be made by one of ordinary skill in the art without undue burden from the present disclosure, are within the scope of the present disclosure.
In order that the above-recited objects, features and advantages of the present application will become more readily apparent, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings.
Example 1
In a first embodiment, a machine vision-based fixed-point casting system, as shown in fig. 1, includes: the system comprises an image acquisition module, a safety monitoring module and a control module.
The image acquisition module comprises: a sprue gate positioning device, a sprue gate liquid level monitoring device and a first processor; the casting nozzle positioning device is connected with the first processor, and as shown in fig. 2, the casting nozzle positioning device adopts a double-layer three-camera linkage positioning device, and comprises: the first-layer linkage three cameras 1 and the second-layer linkage three cameras 2 are respectively 4K high-definition self-cleaning cameras, and the upper and lower planes are slightly inclined differently and are used for acquiring images of the blank mold 4 and transmitting the blank mold images to the first processor; the casting nozzle liquid level monitoring device is connected with the first processor by using a 4K high-definition self-cleaning camera with an infrared function, is used for monitoring the liquid level of the casting nozzle 3, obtaining a casting nozzle liquid level image, transmitting the casting nozzle liquid level image to the first processor, and can also collect the liquid level infrared image of the casting nozzle 3 for assisting the monitoring work of the visible light camera; the first processor is connected with the control module and is used for receiving and processing the blank mould image and the casting nozzle liquid level image to obtain casting nozzle position information and casting nozzle liquid level information.
The working method of the image acquisition module comprises the following steps: three cameras of the same layer in the double-layer three-camera linkage positioning device form double purposes, the horizontal positions are rotated in a certain dislocation mode, images of the blank mold 4 are respectively collected, the collected images of the blank mold are subjected to center position taking through an edge detection algorithm, the obtained center positions are averaged to obtain an accurate blank mold image, and the accurate blank mold image is subjected to image recognition to determine the position of a casting nozzle, so that position information of the casting nozzle and position correction parameters are obtained; and (3) collecting a liquid level image of the casting nozzle, and monitoring the liquid level height of the casting nozzle in real time through an image recognition technology to obtain liquid level information of the casting nozzle.
The safety monitoring module includes: the system comprises a personnel behavior monitoring device, a temperature monitoring device and a second processor; the personnel behavior monitoring device is connected with the second processing and is used for collecting behavior video information of the staff; the temperature monitoring device is connected with the second processing device and can adopt an infrared temperature monitor, and the temperature monitoring device is used for monitoring the temperature of the working environment to obtain temperature information; the second processor is connected with the control module and is used for carrying out personnel behavior safety analysis and evaluation based on behavior video information to obtain a behavior safety evaluation result, the second processor is also used for receiving and processing temperature information to obtain a temperature evaluation result, the second processor is also used for sending out a braking signal based on the behavior safety evaluation result and the temperature evaluation result, the braking signal comprises a furnace body braking control signal and a casting table braking control signal, and in order to ensure personnel life safety, the furnace body braking is the highest control priority.
The working method of the safety monitoring module comprises the following steps: collecting behavior video information of the staff, and carrying out security assessment analysis in real time by a motion capturing method to obtain a behavior security assessment result; acquiring the temperature information, and evaluating in real time to obtain a temperature evaluation result; and sending out a braking signal based on the behavior safety evaluation result and the temperature evaluation result, wherein the braking signal comprises a furnace body braking control signal and a casting table braking control signal.
The control module comprises: an emergency braking device, a casting table control device and a furnace body control device; the casting table control device and the furnace body control device are respectively connected with the safety monitoring module, the furnace body control device and the casting table control device as shown in fig. 3, the emergency braking device is used for automatically performing emergency braking based on a braking signal, firstly, the furnace body 8 is directly controlled to stop dumping and quickly restore to an initial position based on the furnace body braking control signal, then, the casting table is directly controlled to restore to a home position based on the casting table braking control signal, and the emergency braking device can also perform emergency braking manually by a staff; the casting platform control device is also connected with the image acquisition module, and comprises a fine adjustment base 5 for controlling the casting platform to move to a designated position based on the position information of the casting nozzle and fine adjustment based on the position correction parameters; the furnace body control device comprises: the hydraulic lifting rod 6 and the hydraulic lifting table 7 are connected with the image acquisition module, and the furnace body control device is used for controlling the pouring angle and the pouring time of the furnace body 8 based on the casting nozzle liquid level information and the position correction parameters.
The working method of the control module comprises the following steps: controlling the casting table to move to a designated position based on the position information of the casting nozzle, and performing Y-axis direction fine adjustment on the casting nozzle based on the position correction parameters; controlling the pouring angle of the furnace body 8 based on the position correction parameters, namely controlling the positions of the pouring gate in the X-axis and Z-axis directions so as to ensure that molten metal solution can be accurately poured into the pouring gate, and controlling the pouring time based on the liquid level information of the pouring gate so as to ensure that molten metal solution cannot overflow; when a braking signal is received, the furnace body 8 is directly controlled to stop dumping and quickly restore to an initial position based on the furnace body braking control signal, and then the casting table is directly controlled to restore to a home position based on the casting table braking control signal.
Example two
In a second embodiment, a working procedure of the fixed-point casting system based on machine vision is described in detail;
three cameras of the same layer in the double-layer three-camera linkage positioning device are formed in pairs to be binocular, tiny differential inclination is carried out between two layers of planes, the horizontal positions are rotated in a certain dislocation mode, blank mold images are respectively collected, the collected blank mold images are subjected to center position taking through an edge detection algorithm, the obtained center positions are averaged to obtain an accurate blank mold image, and the accurate blank mold images are subjected to image recognition to determine the position of a casting nozzle, so that casting nozzle position information and position correction parameters are obtained; and (3) collecting a liquid level image of the casting nozzle, and monitoring the liquid level height of the casting nozzle in real time through an image recognition technology to obtain liquid level information of the casting nozzle. Controlling the casting table to move to a designated position based on the position information of the casting nozzle, and performing Y-axis direction fine adjustment on the casting nozzle based on the position correction parameters; the pouring angle of the furnace body 8 is controlled based on the position correction parameters, namely, the positions of the pouring gate in the X-axis and Z-axis directions are controlled so as to ensure that molten metal solution can be accurately poured into the pouring gate, and meanwhile, the pouring time is controlled based on the liquid level information of the pouring gate so as to ensure that molten metal solution cannot overflow.
In order to ensure the life safety of the staff and the equipment safety, the safety monitoring module is further arranged, the behavior video information of the staff is collected in real time, and safety evaluation analysis is performed in real time through a motion capturing method to obtain a behavior safety evaluation result; and acquiring the temperature information, and evaluating in real time to obtain a temperature evaluation result. When the safety evaluation result or the temperature evaluation result is dangerous, a braking signal is sent, firstly, the furnace body 8 is directly controlled to stop dumping and quickly restore to an initial position based on the furnace body braking control signal, and then the casting table is directly controlled to restore to a home position based on the casting table braking control signal; when dangerous behaviors of personnel which cannot be identified by the safety monitoring module occur, emergency braking can be performed manually by a safety officer.
The foregoing embodiments are merely illustrative of the preferred modes of the present application, and are not intended to limit the scope of the present application, and various modifications and improvements made by those skilled in the art to the technical solutions of the present application should fall within the scope of protection defined by the claims of the present application without departing from the spirit of the design of the present application.
Claims (5)
1. A machine vision-based fixed point casting system, comprising: the system comprises an image acquisition module, a safety monitoring module and a control module;
the image acquisition module is connected with the control module and is used for acquiring image information at the casting nozzle to obtain position information, position correction parameters and liquid level information of the casting nozzle;
the safety monitoring module is connected with the control module and is used for collecting behavior video information and working environment temperature information of staff and sending out a braking signal;
the control module is used for controlling the movement of the casting table based on the position information of the casting nozzle and the position correction parameter, is also used for controlling the pouring angle and the pouring time of the furnace body based on the position correction parameter and the liquid level information of the casting nozzle, and is also used for carrying out emergency braking based on the braking signal;
the image of the casting nozzle comprises: blank mold image and casting nozzle liquid level image;
the image acquisition module comprises: a sprue gate positioning device, a sprue gate liquid level monitoring device and a first processor;
the casting nozzle positioning device is connected with the first processor and is used for acquiring blank mould images;
the casting nozzle liquid level monitoring device is connected with the first processor and is used for collecting a casting nozzle liquid level image;
the first processor is connected with the control module and is used for receiving and processing the blank mold image and the casting nozzle liquid level image to obtain the casting nozzle position information, the position correction parameters and the casting nozzle liquid level information;
the casting nozzle positioning device adopts a double-layer three-camera linkage positioning device, and comprises: the method comprises the steps of a first-layer linkage three-camera and a second-layer linkage three-camera, wherein three cameras of the same layer in the double-layer three-camera linkage positioning device are formed in a double-layer manner, the horizontal positions of the three cameras are rotated in a certain dislocation manner, the upper and lower planes are slightly inclined in a differential manner and are used for respectively collecting images of blank molds, transmitting the images of the blank molds to a first processor, taking a center position of the collected images of the blank molds through an edge detection algorithm, averaging the obtained center positions to obtain an accurate blank mold image, and carrying out image recognition on the accurate blank mold image to determine the position of a pouring nozzle so as to obtain pouring nozzle position information and position correction parameters;
the device for monitoring the liquid level of the casting nozzle is characterized in that the device for monitoring the liquid level of the casting nozzle is a 4K high-definition self-cleaning camera with an infrared function and is used for monitoring the liquid level of the casting nozzle to obtain a liquid level image of the casting nozzle, the liquid level image of the casting nozzle is transmitted to the first processor, and the collected liquid level image of the casting nozzle is used for monitoring the liquid level of the casting nozzle in real time through an image recognition technology to obtain liquid level information of the casting nozzle.
2. The machine vision-based spot casting system of claim 1, wherein the safety monitoring module comprises: the system comprises a personnel behavior monitoring device, a temperature monitoring device and a second processor;
the personnel behavior monitoring device is connected with the second processor and is used for collecting behavior video information of the staff;
the temperature monitoring device is connected with the second processor and is used for monitoring the temperature of the working environment to obtain temperature information;
the second processor is connected with the control module and is used for carrying out personnel behavior safety analysis and evaluation based on the behavior video information to obtain a behavior safety evaluation result, the second processor is also used for receiving and processing the temperature information to obtain a temperature evaluation result, and the second processor is also used for sending out the braking signal based on the behavior safety evaluation result and the temperature evaluation result.
3. The machine vision-based fixed point casting system of claim 2, wherein the safety monitoring module operating method comprises:
collecting behavior video information of the staff, and carrying out security assessment analysis in real time by a motion capturing method to obtain a behavior security assessment result;
acquiring the temperature information, and evaluating in real time to obtain a temperature evaluation result;
and sending out the braking signal based on the behavior safety evaluation result and the temperature evaluation result.
4. The machine vision-based spot casting system of claim 1, wherein the control module comprises: an emergency braking device, a casting table control device and a furnace body control device;
the emergency braking device is respectively connected with the safety monitoring module, the furnace body control device and the casting table control device and is used for carrying out emergency braking based on the braking signal;
the casting platform control device is also connected with the image acquisition module and is used for controlling the casting platform to move to a designated position based on the casting port position information and the position correction parameter;
the furnace body control device is also connected with the image acquisition module and is used for controlling the pouring angle and the pouring time of the furnace body based on the position correction parameters and the casting nozzle liquid level information.
5. The machine vision-based fixed point casting system of claim 4, wherein the control module operating method comprises:
controlling the casting platform to move to a designated position based on the casting nozzle position information and the position correction parameter;
controlling the pouring angle and the pouring time of the furnace body based on the position correction parameters and the liquid level information of the casting nozzle;
emergency braking is performed when a braking signal is received.
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CH667406A5 (en) * | 1984-09-15 | 1988-10-14 | Woehr Gmbh Und Co Kg Geb | Automatic casting of liquid metal |
US4744407A (en) * | 1986-10-20 | 1988-05-17 | Inductotherm Corp. | Apparatus and method for controlling the pour of molten metal into molds |
JP3361369B2 (en) * | 1993-10-18 | 2003-01-07 | 藤和機工株式会社 | Automatic pouring method and apparatus |
JP3079018B2 (en) * | 1995-04-19 | 2000-08-21 | 藤和機工株式会社 | Automatic pouring method and device |
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JP5116722B2 (en) * | 2009-04-28 | 2013-01-09 | 新東工業株式会社 | Ladle tilting automatic pouring method, ladle tilt control system, and storage medium storing ladle tilt control program |
TW201208788A (en) * | 2010-08-26 | 2012-03-01 | Sintokogio Ltd | Pouring equipment and method of pouring using the pouring equipment |
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CN108705071B (en) * | 2018-05-28 | 2021-05-18 | 宁波中科毕普拉斯新材料科技有限公司 | Alloy liquid pouring method capable of automatically controlling flow speed |
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