CN115401173A - Aluminum wheel casting forming technological process acquisition system and technological process characterization method - Google Patents
Aluminum wheel casting forming technological process acquisition system and technological process characterization method Download PDFInfo
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- CN115401173A CN115401173A CN202211361541.8A CN202211361541A CN115401173A CN 115401173 A CN115401173 A CN 115401173A CN 202211361541 A CN202211361541 A CN 202211361541A CN 115401173 A CN115401173 A CN 115401173A
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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
- B22D2/00—Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass
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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
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
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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
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/08—Controlling, supervising, e.g. for safety reasons
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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
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- 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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Abstract
The invention relates to the technical field of wheel casting, in particular to an aluminum wheel casting forming process acquisition system and a process characterization method, wherein the acquisition system comprises: the invention relates to a casting wheel mold, a communication acquisition module, a storage module, a processing module and an input/output module, which continuously acquire related data information of a plurality of key position temperatures of the mold, opening and closing signals of a cooling pipeline, casting hearth pressure, mold opening and closing signals of casting equipment, casting process and time in the wheel casting process according to fixed frequency, store the data of the same wheel production process and establish an aluminum wheel casting forming process diagram with time as the unified measurement for a single wheel. According to the invention, the technical problem that the low-pressure casting forming process of the aluminum wheel cannot be visually represented is solved, the low-pressure casting process of the aluminum wheel is digitally and accurately described, the quantitative basis of casting process adjustment is provided, the casting process optimization process is greatly simplified, and the casting process optimization efficiency is improved.
Description
Technical Field
The invention relates to the technical field of wheel casting, in particular to an aluminum wheel casting forming technological process acquisition system and a technological process characterization method.
Background
In the production of automobile parts, the casting of aluminum wheels is the most critical ring, the aluminum wheels are directly hooked with the safety of an automobile, and the aluminum wheels have various product models, more casting process parameters and more factors influencing the stability of the casting process, so that the factors are necessary to visually represent the influence of the factors on the casting process to adjust the process or treat waste materials in time.
Chinese patent publication No. CN109128131A discloses a detection alarm device for casting mould, including first temperature sensor, second temperature sensor, signal conditioning module, central processing unit, alarm module, timing module and display module, first temperature sensor is used for gathering the temperature signal in the mould, second temperature sensor is used for adopting the outer temperature signal of mould, first temperature sensor and second temperature sensor all are connected with central processing unit through signal conditioning module, alarm module, timing module and display module are equallyd divide and are do not connected with central processing unit. The device can detect the internal and external temperatures in the casting mold and give an alarm at regular time.
In the prior art, the temperature acquisition of the mold in the casting process is mostly timing acquisition, the casting time node is set to acquire the temperature of the casting process, then data analysis is carried out on the temperature condition acquired through the time node, and the acquisition process is not continuous enough. Under the condition that the direct correlation between the mold temperature and the casting process cannot be represented intuitively, the casting process adjustment can be carried out manually only by experience subjectively, and the conditions of long adjustment time and waste increase are easily caused.
Aiming at the problem that the casting and forming process of the aluminum wheel cannot be intuitively represented in the related art, an effective solution is not found at present.
Disclosure of Invention
Therefore, the invention provides an aluminum wheel casting forming process acquisition system and a process characterization method, which are used for solving the problem that the aluminum wheel casting forming process cannot be visually characterized in the prior art.
In order to achieve the above object, the present invention provides an aluminum wheel casting molding process collecting system, comprising:
a cast wheel mold, on which a temperature acquisition position is arranged;
the system comprises a communication acquisition module, a casting device PLC and a target wheel casting process, wherein the communication acquisition module is used for communicating with the casting device PLC through an industrial Ethernet, acquiring the temperatures of a plurality of positions of a casting wheel mold, a cooling pipeline opening and closing signal, a casting device opening and closing signal, a casting process and recording time in the target wheel casting process according to a fixed frequency, wherein the temperatures of the plurality of positions of the mold comprise the temperatures of a plurality of key hot or cold joint positions of a top mold, a bottom mold and a side mold;
the storage module is connected with the communication acquisition module and is used for storing the data acquired by the communication acquisition module; the storage module is used for storing the acquired data in a database with a unique ID according to the casting process of a single wheel based on the acquired mold opening and closing signals of the casting equipment so as to search all the casting process data of the single wheel;
the processing module is respectively connected with the communication acquisition module and the storage module and is used for processing the acquired data;
and the input and output module is connected with the processing module and is used for displaying the data information processed by the processing module.
Further, the cast wheel mold includes, in several positions: the device comprises a top die flange position, a top die spoke middle position, a bottom die riser position, a bottom die spoke and rim transition position, a side die outer rim position and a side die inner rim position, wherein each position is provided with a thermocouple for temperature acquisition.
Further, the processing module calculates temperature control parameters based on the acquired temperature data and the time process to form a temperature control process for accurately controlling the casting process.
Furthermore, the thermocouple that top mould flange position set up is first thermocouple, the thermocouple that top mould spoke intermediate position set up is the second thermocouple, the thermocouple that the rim position set up in the side forms is the third thermocouple, the thermocouple that the rim position set up in the side forms is the fourth thermocouple, the thermocouple that the die block rising head position set up is the fifth thermocouple, the thermocouple that die block spoke and rim transition position set up is the sixth thermocouple.
Further, the lower end face of a fourth thermocouple hole positioned at the outer rim of the side die is superposed with the horizontal line of the R-angle tail end point of the wheel well; the position of the inner edge of the side die is positioned at the inner edge of the side die, and the upper end surface of the third thermocouple hole is superposed with the horizontal line of the R-angle tail end point of the inner edge of the side die;
if the distance between the lower end face of the thermocouple and the processing reference surface is a non-integer value, rounding is adopted for rounding.
Furthermore, a demolding ejector rod hole is formed in the position of the top mold flange, and the first thermocouple is arranged in the demolding ejector rod hole;
the middle position of the top die spoke is located on the outer side of the T4 cooling channel, the middle position of two side walls of the material digging pit is located, and the distance between the center line of the second thermocouple hole and the center line of an air pipe of the T4 cooling channel is 15-20 mm.
Furthermore, the distance between the bottom of each thermocouple hole and the cavity surface of the mold is 3-7mm from the closest point of the arc end of the bottom of each thermocouple hole to the cavity surface, and all distances are the same on one set of mold; the bottom of each thermocouple hole is hemispherical, the diameter of each thermocouple hole is 4-6 mm, the top end of each thermocouple hole is a hollow cylinder, and the diameter of each thermocouple hole is the same as that of the bottom of each thermocouple hole.
The invention also provides a method for representing the casting forming process of the aluminum wheel, and the system for acquiring the casting forming process of the aluminum wheel comprises the following steps:
step 1, continuously acquiring relevant data information of a plurality of key position temperatures of a mold, a cooling pipeline opening and closing signal, casting hearth pressure, a casting equipment opening and closing signal, a casting process and time in the wheel casting process through an upper computer system according to fixed frequency;
step 2, based on the acquired mold opening and closing signals of the casting equipment, carrying out data slicing processing on continuously acquired data by taking a single wheel as a unit, and uniformly giving a unique ID to the data in the same wheel production process for storage;
step 3, carrying out data retrieval on the production process of a single wheel, sequencing the acquired temperature of the key position of each mould according to the acquisition time sequence, and then carrying out temperature data noise reduction based on the time sequence by using a moving window method;
step 4, establishing a multidimensional matrix based on the processed temperature and the corresponding acquisition time, and obtaining the temperature variation corresponding to the acquisition time through matrix transformation;
and 5, establishing an aluminum wheel casting forming process diagram with the same ID of the single wheel and the time as a unified measurement.
Further, the cooling pipeline switching signal, casting furnace pressure, casting equipment mould signal, the collection of casting process is applied host computer system and is established to be connected with casting equipment PLC through industrial ethernet and gather, and the data information content of gathering includes: the cooling pipeline opening and closing signal corresponds to a point position opening and closing Boolean value, the casting hearth pressure corresponds to a point position numerical value, the casting equipment opening and closing signal corresponds to a point position Boolean value, and the casting technology corresponds to a point position numerical value.
Further, in the step 5, the aluminum wheel casting forming process diagram comprises:
a curve for characterizing the temperature of the mold at key locations during the aluminum wheel casting process;
a bar graph image used for representing the opening and closing interval of the mold cooling pipeline in the aluminum wheel casting process;
the method is used for representing a furnace pressure process node line in the aluminum wheel casting process;
the curve and the temperature rise auxiliary marking line are used for representing the temperature variation of the mold in the aluminum wheel casting process;
labels for characterizing the operation of aluminum wheel casting process equipment.
Furthermore, the acquired time data information is the time of an upper computer system, and is convenient to correspond to the cooling pipeline opening and closing signal, the casting hearth pressure, the casting equipment mold opening and closing signal and the casting process acquired data.
After the mold with the thermocouple was mounted to the casting equipment, the thermocouple was connected to a temperature acquisition module of a Programmable Logic Controller (PLC) of the casting equipment via a thermocouple extension wire.
Furthermore, a communication acquisition module of the upper computer system is connected with the casting equipment PLC through the industrial Ethernet, and acquires the temperature value of the point position of the relevant PLC, the opening and closing Boolean value of the cooling pipeline, the pressure value of the casting hearth, the opening and closing Boolean value of the casting equipment and the casting process value according to the fixed frequency of 1-10 Hz.
Further, in the step 2, the stored casting process data of each wheel includes: collecting time, a thermocouple temperature value at the time, casting hearth pressure at the time, a Boolean value of opening and closing of a cooling channel at the time, a casting process and time.
In step 3, according to the stored temperature data, the noise reduction processing is carried out.
Furthermore, data retrieval is carried out on the temperature data in the production process of a single wheel, and the acquired temperature and the temperature of the key position of each mould are sequenced according to the time sequence;
further, carrying out temperature data noise reduction based on time series by using a moving window method;
and further, storing the temperature data subjected to noise reduction processing according to the unique ID and the acquisition time in the step 2.
In step 4, the transformation matrix process is as follows:
wherein t1 is a first detection time, x1 is temperature data of the first detection time, t2 is a second detection time, x2 is temperature data of the second detection time, n, tn is an nth detection time, and xn is temperature data of the nth detection time,
and finally obtaining a temperature variation matrix corresponding to the acquisition time by performing matrix transformation as follows:
further, the abscissa range of the aluminum wheel casting process diagram is the collection time range of the single wheel from the start of the casting mold closing to the start of the next casting mold closing.
The abscissa of the temperature curve used for representing the key positions of the die in the aluminum wheel casting process is the collection time, the ordinate of the temperature curve is the temperature, the temperature value used by the curve is the temperature value processed in the step 3, and 6 temperature curves are formed independently at each key position of the die.
Furthermore, the temperature curve is formed by connecting two adjacent points by a straight line through data points formed by the temperature values corresponding to each acquisition time. Each temperature curve has a legend.
The bar-shaped graph image used for representing the opening and closing interval of the cooling pipeline of the mold in the aluminum wheel casting process is characterized in that the abscissa is the acquisition time, each cooling pipeline forms a respective bar-shaped graph image, the opening time point and the closing time point of each cooling pipeline are taken, and a straight line is adopted to connect the two time points along the direction parallel to the abscissa to form the bar-shaped graph image of the opening and closing interval of each cooling pipeline.
Further, each bar graph image has a legend. Each legend location is near the corresponding bar graph image.
The horizontal coordinate of the furnace pressure change node line used for representing the aluminum wheel casting process is the acquisition time, 5 time points of completion of pressure pressurization, completion of casting pressure, completion of boosting pressure, completion of pressure maintaining pressure and pressure relief and mold opening of the casting furnace are taken, and a plurality of straight lines penetrating through the whole aluminum wheel casting forming process diagram are formed along the direction perpendicular to the horizontal coordinate;
further, each pressure change node line has a legend, and each legend location is adjacent to a corresponding pressure change node line.
The curve for representing the temperature variation of the mold in the aluminum wheel casting process is characterized in that the abscissa is the collection time, the ordinate is the temperature variation, the temperature variation value used by the curve is the temperature variation value processed in the step 4, and the key position of each mold independently forms one temperature variation curve with 6 temperature variation values.
Furthermore, the temperature variation curve is formed by connecting two adjacent points by a straight line with a data point formed by the temperature variation value corresponding to each acquisition time. Each temperature change curve has a legend.
The auxiliary marked line for representing the temperature rise of the die in the aluminum wheel casting process is formed by forming 1 straight line penetrating through the whole aluminum wheel casting forming process diagram in parallel with the abscissa at the position of which the ordinate is 0 on the basis of the temperature variation curve.
The temperature curve used for representing the key position of the mold in the aluminum wheel casting process, the bar-shaped graph image used for representing the opening and closing interval of the mold cooling pipeline in the aluminum wheel casting process, the hearth pressure change node line used for representing the aluminum wheel casting process, the curve used for representing the mold temperature change amount in the aluminum wheel casting process, the temperature rise auxiliary marking line and the label used for representing the action of the aluminum wheel casting process equipment are all preferably not covered by other figures and curves.
Further, based on the temperature curve representing the key position of the die in the aluminum wheel casting process, the temperature condition of the position in the whole casting process can be represented by a single curve value, and the temperature condition of the whole die can be represented by a plurality of curves along with the change of time;
further, based on the bar graph images representing the opening and closing sections of the mold cooling pipeline in the aluminum wheel casting process, the position relation between each cooling bar graph image and the casting hearth pressure maintaining pressure and the mold opening signal can represent the action condition of the cooling channel, and the influence effect of the cooling on the mold temperature can be represented by the correlation of the cooling bar graph image and the temperature curve near the cooling pipeline;
furthermore, based on the curves for representing the temperature variation of the mold in the aluminum wheel casting process and the temperature-rise auxiliary marked lines, the intersection points of the temperature variation curves and the temperature-rise auxiliary marked lines in the interval between the completion of pressurization of the casting hearth and the completion of pressurization of the casting hearth represent the time points when the aluminum liquid reaches the mold position, particularly the intersection points of the temperature variation curves of the inner edge position of the side mold and the temperature-rise auxiliary marked lines in the relation position of the mold variation curves and the temperature-rise auxiliary marked lines represent the actual time points of the completion of casting mold filling, and the comparison relation between the actual time points and the completion of casting pressure of the casting hearth can provide guidance for optimization of the pressure process.
Compared with the prior art, the method has the beneficial effects that the method collects the temperatures of a plurality of positions of the mold, the opening and closing signals of the cooling pipeline, the pressure of the casting hearth, the opening and closing signals of the casting equipment, the casting process and the time in the casting process of the target wheel according to the fixed frequency, wherein the temperatures of the plurality of positions of the mold comprise the temperatures of a plurality of key hot sections or cold section positions of a top mold, a bottom mold and a side mold; storing the collected data in a database with a unique ID according to the casting process of the single wheel based on the collected casting device mold opening and closing signals so as to search all the casting process data of the single wheel; based on the acquired temperature data, carrying out noise reduction processing on the acquired temperature data; establishing a multi-dimensional matrix based on the processed temperature and the corresponding acquisition time, and transforming the matrix to obtain the temperature variation in unit time; the method has the advantages that the aluminum wheel casting forming process diagram taking time as unified measurement is established based on the casting process data collected by the single wheel with the same ID and the processed data, the technical problem that the aluminum wheel low-pressure casting forming process cannot be directly represented is solved, the aluminum wheel low-pressure casting process can be digitally and accurately described, the quantitative basis of casting process adjustment is provided, the casting process optimization process is greatly simplified, and the casting process optimization efficiency is improved.
Drawings
FIG. 1 is a block diagram of an acquisition system for an aluminum wheel casting process according to an embodiment of the present invention;
FIG. 2 is a schematic structural view of a cast wheel mold according to an embodiment of the present invention;
FIG. 3 is a flow chart of a method for characterizing an aluminum wheel casting process in an embodiment of the present invention;
FIG. 4 is a graph of the noise reduction effect of the mold temperature data in an embodiment of the present invention;
FIG. 5 is a graph of the mold temperature variation calculation result and the mold temperature noise reduction data in an embodiment of the present invention;
fig. 6 is a process diagram of an aluminum wheel cast molding process in an embodiment of the invention.
Detailed Description
In order that the objects and advantages of the invention will be more clearly understood, the invention is further described below with reference to examples; it should be understood that the specific embodiments described herein are merely illustrative of the invention and do not delimit the invention.
Preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only for explaining the technical principles of the present invention, and do not limit the scope of the present invention.
It should be noted that in the description of the present invention, the terms of direction or positional relationship indicated by the terms "upper", "lower", "left", "right", "inner", "outer", etc. are based on the directions or positional relationships shown in the drawings, which are only for convenience of description, and do not indicate or imply that the device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present invention.
Furthermore, it should be noted that, in the description of the present invention, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
Referring to fig. 1-2, fig. 1 is a block diagram of an acquisition system for an aluminum wheel casting molding process according to an embodiment of the present invention, and fig. 2 is a schematic structural diagram of a casting wheel mold according to an embodiment of the present invention;
the invention provides an aluminum wheel casting forming process acquisition system, which comprises the following steps:
a cast wheel mold, on which a temperature acquisition position is arranged;
the communication acquisition module 106 is used for communicating with the casting equipment PLC through an industrial Ethernet, and acquiring a plurality of position temperatures of a casting wheel mold, a cooling pipeline opening and closing signal, a casting equipment opening and closing signal, a casting process and recording time in a target wheel casting process according to fixed frequency, wherein the plurality of position temperatures of the mold comprise temperatures of a plurality of key hot spots or cold spots of a top mold, a bottom mold and a side mold;
the storage module 104 is connected with the communication acquisition module and is used for storing the data acquired by the communication acquisition module; the storage module is used for storing the acquired data in a database with a unique ID according to the casting process of a single wheel based on the acquired mold opening and closing signals of the casting equipment so as to search all the casting process data of the single wheel;
the processing module 102 is connected with the communication acquisition module and the storage module respectively and used for processing the acquired data;
and the input and output module 108 is connected with the processing module and is used for displaying the data information processed by the processing module.
The memory module 104 may be used to store a program for operating a personal computer, for example, a software program of an application software and a module, such as an aluminum wheel casting process characterization system in the embodiment of the present invention, and the processing module 102 executes various functional applications and data processing by running the program stored in the memory module 104, so as to implement the method described above. The memory module 104 may include a high speed random access memory module and may also include a non-volatile memory module, such as one or more magnetic storage devices, flash memory, or other non-volatile solid state memory. In some examples, the memory module 104 may further include memory modules remotely located from the processing module 102, which may be connected to a personal computer via a network. Examples of such networks include, but are not limited to, the internet, intranets, local area networks, mobile communication networks, and combinations thereof.
The communication acquisition module 106 is used to receive or transmit data via a network. In one example, the communication collection module 106 includes a network adapter that can be coupled to other network devices via a base station to communicate. In one example, the communication collection module 106 may be an ethernet module.
The plurality of temperature collection positions of the target wheel casting mold comprise temperatures of a top mold, a bottom mold and a side mold in a plurality of key hot section or cold section positions. The temperature acquisition of a plurality of key position temperatures of the mould is realized by additionally arranging temperature thermocouples at corresponding positions and connecting the thermocouples to a PLC temperature communication acquisition module of the casting equipment for data acquisition. Fig. 2 is a schematic structural diagram of a casting wheel mold according to an embodiment of the present invention, in which a top mold 302, a bottom mold 304, and four side molds 306 form a complete aluminum wheel casting mold structure. The flange position 3021 and spoke mid-position 3022 positions of the top die 302 are mold hot spot positions during the casting process, and therefore a thermocouple is added to the top die flange position 3021 and the top die spoke mid-position 3022. The riser position of the bottom die 304 is a key position of a mold for determining the completion of casting, and the root position of the spoke is a cold joint position of the mold in the casting process, so a thermocouple is additionally arranged at the riser position 3041 of the bottom die and the transition position 3042 of the bottom die spoke and the rim. The inner rim position of the sideform 306 determines the filling mass and the outer rim position determines the rim mass, thus adding thermocouples at the inner rim position 3061 and the outer rim position 3062 of the sideform. It will be understood by those skilled in the art that the configuration shown in fig. 2 is merely illustrative and is not intended to limit the specific locations of the mold configuration or thermocouple placement described above. It can be understood by those skilled in the art that the cooling pipeline opening and closing signal, the casting furnace pressure, the casting equipment mold opening and closing signal, the casting process and the collection time may have different names in different factories, may have different points on different casting equipment PLCs, and do not limit the collected data.
Further, the lower end face of a fourth thermocouple hole at the outer rim of the side die is superposed with the horizontal line of the end point of the R corner 3072 of the wheel well; the position of the inner edge of the side die is positioned at the inner edge of the side die, and the upper end surface of the third thermocouple hole is superposed with the horizontal line of the end point of the R angle 3071 of the inner edge of the side die;
if the distance between the lower end face of the thermocouple and the processing reference surface is a non-integral value, rounding is adopted.
Furthermore, a demolding ejector rod hole is formed in the position of the top mold flange, and the first thermocouple is arranged in the demolding ejector rod hole;
the middle position of the top die spoke is located on the outer side of the T4 cooling channel, the middle position of two side walls of the material digging pit is located, and the distance between the center line of the second thermocouple hole and the center line of an air pipe of the T4 cooling channel is 15-20 mm.
Furthermore, the distance between the bottom of each thermocouple hole and the cavity surface of the mold is 3-7mm from the closest point of the arc end of the bottom of each thermocouple hole to the cavity surface, and all distances are the same on one set of mold; the bottom of each thermocouple hole is hemispherical, the diameter of each thermocouple hole is 4mm-6mm, the top end of each thermocouple hole is a hollow cylinder, and the diameter of each thermocouple hole is the same as that of each hole bottom.
Referring to fig. 3, fig. 3 is a flowchart of a method for characterizing a casting process of an aluminum wheel according to an embodiment of the present invention, where the method for characterizing a casting process of an aluminum wheel includes:
step 1, collecting the temperatures of a plurality of positions of a mold, opening and closing signals of a mold cooling pipeline, the pressure of a casting hearth, opening and closing signals of casting equipment, a casting process and casting time in the casting process of a target wheel according to a fixed frequency of 1 Hz. In one embodiment of this embodiment, the plurality of temperature collection locations of the target wheel casting mold include temperatures of a top mold, a bottom mold, and a side mold at a plurality of critical hot or cold junction locations. The temperature acquisition of a plurality of key position temperatures of the mould is realized by additionally arranging temperature thermocouples at corresponding positions and connecting the thermocouples to a PLC temperature communication acquisition module of the casting equipment for data acquisition.
And 2, storing the acquired data in a database by using a unique ID for searching conveniently according to the casting process of the single wheel based on the acquired mold opening and closing signals of the casting equipment. In one embodiment of this embodiment, the data collected by the target wheel casting process is retrieved with "collection casting machine number _ mold clamping signal time" as the unique ID of the individual wheel.
And 3, based on the acquired temperature data of the key position of the mold, carrying out noise reduction treatment on the acquired temperature data. In an embodiment of this embodiment, the temperature data of the critical positions of the mold, which are acquired in the casting process of the target wheel, are first acquired by retrieving the temperature data of a certain mold position of a single wheel, and are sorted according to the sequence of the acquisition time. And (3) carrying out temperature data noise reduction based on a time sequence by adopting a moving window method, wherein the width of the moving window is set to be 5, the center of the window is set to be 3, and the closing condition of the end points of the window interval is controlled to be not closed. The mold Temperature data noise reduction effect graph is shown in fig. 4, which is a mold Temperature data noise reduction effect graph in the embodiment of the present invention, wherein Temperature is a Temperature data graph of a top mold flange position in the whole process of casting a wheel by a certain mold, the collection frequency is 1hz, temperature rolling is a Temperature data graph subjected to noise reduction processing by a moving window method, and moving window processing and a matplotlib of a matplotlib package are performed by using a python language and a pandas. It can be understood by those skilled in the art that the above method for denoising temperature data is only an illustration, and the programming language and the functions used are only an illustration, which do not limit the above method for denoising data.
And 4, establishing a multi-dimensional matrix based on the processed temperature and the corresponding acquisition time, and transforming the matrix to obtain the temperature variation corresponding to the acquisition time. In an embodiment of this embodiment, after the mold temperature data collected in the target wheel casting process is subjected to noise reduction processing, a multidimensional matrix is formed corresponding to the collection time, and the matrix is subjected to the following elementary row transformation:
and finally obtaining a temperature variation matrix corresponding to the acquisition time by performing matrix transformation as follows:
FIG. 5 is a graph of the mold temperature variation calculation result and a graph of the mold temperature noise reduction data according to an embodiment of the present invention. Wherein, the temperature rolling is a temperature data curve 602 after the noise reduction processing by a moving window method, the temperature deviation is a mold temperature variation curve 604 after the matrix transformation, and the abscissa of the two curves can be unified by the acquisition time. And the intersection point 608 of the die temperature variation data curve and the die temperature heating auxiliary marked line is a characterization point of the aluminum liquid reaching the die temperature measurement position. It will be understood by those skilled in the art that the method of calculating the temperature change amount is merely illustrative and is not limited thereto.
And 5, establishing an aluminum wheel casting forming process diagram taking the acquisition time as a unified measurement single abscissa based on the casting process data acquired by the single wheel with the same ID and the processed data. In an embodiment of this embodiment, data acquired in a target wheel casting process is retrieved and processed to obtain data of a wheel casting process, and first, an acquisition time is established as a uniform measurement abscissa, and then a curve for representing a temperature of a key position of a mold in an aluminum wheel casting process, a bar graph image for representing an opening/closing interval of a mold cooling pipeline in the aluminum wheel casting process, a furnace pressure process node line for representing the aluminum wheel casting process, a curve and a temperature rise auxiliary mark line for representing a temperature variation of the mold in the aluminum wheel casting process, and a mark line for representing an operation of equipment in the aluminum wheel casting process are drawn.
Fig. 6 is a diagram of a process of an aluminum wheel casting process according to an embodiment of the present invention, in which a 0s position is a casting mold clamping signal 700, which represents that the mold clamping is completed and the wheel casting process is started; casting hearth pressure 710-713 respectively representing 5 stages of pressurization completion (710 of casting hearth pressurization), casting (711 of casting hearth casting pressure), boosting (712 of casting hearth boosting pressure), pressure maintaining (713 of casting hearth pressure maintaining pressure completion) and pressure relief mold opening (702 of mold opening signal) in the casting process;
the temperature curve 720 of the middle position of the spoke of the top die, the temperature curve 721 of the inner rim of the side die, the temperature curve 722 of the riser position of the bottom die, the temperature curve 723 of the transition position of the spoke of the bottom die and a rim, the temperature curve 724 of the outer rim of the side die and the temperature curve 725 of the flange position of the top die respectively represent the temperature change condition of each key position on the die along with time, the temperature condition of the position in the whole casting process can be represented by a single curve value, and the temperature change condition of the temperature field of the whole die along with time can be represented by a plurality of curves;
a top die shunting cone water cooling opening section bar-shaped graph image 730, a top die flange air cooling opening section bar-shaped graph image 731, a top die inclined plane water cooling opening section bar-shaped graph image 732, a top die spoke middle air cooling opening section bar-shaped graph image 733, a top die spoke root air cooling opening section bar-shaped graph image 734, a bottom die riser air cooling opening section bar-shaped graph image 735, a bottom die spoke root air cooling opening section bar-shaped graph image 736 and a side die water cooling opening section bar-shaped graph image 737 respectively represent the opening condition of each cooling pipeline on the die, an abscissa value corresponding to the left end of the cooling bar-shaped graph image is the opening time point of the cooling pipeline, an abscissa value corresponding to the right end of the cooling bar-shaped graph image is the closing time point of the cooling pipeline, the length of the cold region bar-shaped graph image represents the opening time of the cooling pipeline, text labels show the position and the cooling mode of the cooling pipeline, the position relation of the cooling pipeline with the pressure completion of the casting furnace and the die opening signal 702 can represent the cooling effect of the cooling on the die temperature, and the temperature curve near the cooling pipeline can represent the effect of the cooling on the die;
and (3) displaying temperature variation curves of all monitoring positions at the bottom in a casting forming process diagram of the aluminum wheel, wherein the marked line 750 is an auxiliary temperature rise marked line.
In the embodiment, a plurality of data of the target wheel casting process are acquired by the upper computer system according to fixed frequency, the casting process data acquired by a single wheel with the same ID and the processed data are established, an aluminum wheel casting forming process diagram with time as a unified measurement is used for representing the casting process, the technical problem that the aluminum wheel low-pressure casting forming process cannot be represented visually is solved, the digital accurate description of the aluminum wheel low-pressure casting process is realized, the quantitative basis of casting process adjustment is provided, the casting process optimization process is greatly simplified, and the casting process optimization efficiency is improved.
Through the above description of the embodiments, those skilled in the art can clearly understand that the method according to the above embodiments can be implemented by means of a software system, and certainly can also be implemented by means of hardware, but the former is a better implementation mode in many cases. With this understanding, the software system is stored in a storage medium and includes instructions for causing an electronic device to perform the method according to the embodiments of the present invention.
A processing module of an aluminum wheel casting forming process characterization system is provided with a top die spoke middle position temperature standard curve function f (t 0), a side die inner rim position temperature standard curve function f (t 1), a bottom die riser position temperature standard curve function f (t 2), a bottom die spoke and rim transition position temperature standard curve function f (t 3), a side die outer rim position temperature standard curve function f (t 4) and a top die flange position temperature standard curve function f (t 5), the processing module respectively compares a top die spoke middle position temperature curve 720, a side die inner rim position temperature curve 721, a bottom die riser position temperature curve 722, a bottom die spoke and rim transition position temperature curve 723, a side die outer rim position temperature curve 724 and a top die flange position temperature curve 725 with corresponding standard curve functions, judges whether temperature deviation exists in each temperature collection position, and judges the quality of a low-pressure casting process according to the deviation.
When the temperature curve 72i is compared with the standard curve function f (ti), i =0,1,2,3,4,5, the processing module selects any time tk corresponding to the temperature curve 72i and the standard curve function f (ti), the temperature value at the time tk in the temperature curve 72i is Pk, the temperature value at the time tk in the standard curve function f (ti) is Qk, the processing module calculates the absolute value D of the difference between Pk and Qk, D = |, the processing module is provided with a temperature difference evaluation value Dz at any time, the processing module compares D with the temperature difference evaluation value Dz,
when D is less than or equal to Dz, the processing module judges that the temperature of the temperature curve 72i at the tk moment is in a normal interval;
when D > Dz, the processing module determines that the temperature at time tk in the temperature curve 72i is in an abnormal interval.
The processing module compares the points at all times in the temperature curve 72i with the standard curve function f (ti) in the same way as the temperature comparison at any time tk.
When the time when the temperature is in the abnormal interval exists in the temperature curve 72i, the processing module integrates the time points in the abnormal interval, records the total abnormal temperature duration Ci of the temperature curve 72i, sets the total abnormal temperature duration evaluation parameter Cz in the processing module for the temperature curve 72i, compares the total abnormal temperature duration Ci of the temperature curve 72i with the total abnormal temperature duration evaluation parameter Cz,
when Ci is less than or equal to Cz, the processing module judges that the abnormal temperature of the temperature curve 72i is in a reasonable range;
when Ci is larger than Cz, the processing module judges that the abnormal temperature of the temperature curve 72i is in an unreasonable range, and the position corresponding to the temperature curve 72i possibly has risk, and performs important quality detection on the abnormal temperature.
When the temperature curve 72i does not have the time when the temperature is in the abnormal interval, the processing module directly judges that the abnormal temperature of the temperature curve 72i is in the reasonable range.
When the values represented by the values i in the temperature curve 72i are different, the temperature difference evaluation value Dz is different from the value of the abnormal temperature total time period evaluation parameter Cz.
When the processing module judges that the abnormal temperature of the temperature curve 72i is in a reasonable range, the processing module calculates the similar deviation value Ei of the temperature curve 72i and the standard curve function f (ti),
wherein T is the monitoring duration of the temperature curve 72i, a similar deviation value evaluation parameter Ez is arranged in the processing module, the processing module compares the similar deviation value Ei with the similar deviation value evaluation parameter Ez,
when Ei is less than or equal to Ez, the processing module judges that the similarity deviation value of the temperature curve 72i is in a reasonable range;
when Ei is larger than Ez, the processing module judges that the similar deviation value of the temperature curve 72i is in an unreasonable range, and the position corresponding to the temperature curve 72i possibly has risk, and performs important quality detection on the temperature curve.
Whether the temperature change condition of each monitoring point is in a reasonable range or not is obtained through the built-in standard curve function, the quality of a produced product can be judged in advance, the later-stage detection pressure is reduced, and the production flow is accelerated.
The processing module respectively compares the collected top mould spoke middle position temperature curve 720, the side mould inner rim position temperature curve 721, the bottom mould riser position temperature curve 722, the bottom mould spoke and rim transition position temperature curve 723, the side mould outer rim position temperature curve 724 and the top mould flange position temperature curve 725 with corresponding standard curve functions, integrates the total abnormal temperature duration and the similar deviation value of each curve, calculates the casting process score M of a single wheel after the integration is completed,
the ai is a calculation compensation parameter of the total abnormal temperature duration Ci on the casting process score, the bi is a calculation compensation parameter of the similar deviation value Ei on the casting process score, the ai and bi are different when the values represented by the i values are different, and the calculation compensation parameters have two functions, namely balancing the left and right dimensional quantities of an equation and adjusting the calculation result.
The processing module is internally provided with a first preset casting process scoring parameter M1 and a second preset casting process scoring parameter M2, the processing module respectively compares the casting process scoring M with the first preset casting process scoring parameter M1 and the second preset casting process scoring parameter M2,
when M is less than or equal to M1, the processing module judges that the quality of the corresponding wheel is first grade;
when M1 is larger than M and is less than or equal to M2, the processing module judges that the corresponding wheel mass is in a second level;
when M is larger than M2, the processing module judges that the corresponding wheel mass is three-level;
the key attention degree is different when the wheels with different grades are detected, the smaller the grade number is, the higher the quality in the casting process is, and the later quality detection can put less attention; the higher the number of stages, the lower the quality of the casting process, and the greater the effort required for later quality testing.
By calculating the grade of the casting process, the quality of the produced product can be judged in advance, the later detection pressure is reduced, and the production flow is accelerated.
So far, the technical solutions of the present invention have been described in connection with the preferred embodiments shown in the drawings, but it is apparent to those skilled in the art that the scope of the present invention is not limited to these specific embodiments. Equivalent changes or substitutions of related technical features can be made by those skilled in the art without departing from the principle of the invention, and the technical scheme after the changes or substitutions can fall into the protection scope of the invention.
Claims (10)
1. Aluminium wheel casting forming technology process acquisition system, its characterized in that includes:
a cast wheel mold, on which a temperature acquisition position is arranged;
the system comprises a communication acquisition module, a casting device PLC and a target wheel casting process, wherein the communication acquisition module is used for communicating with the casting device PLC through an industrial Ethernet, acquiring the temperatures of a plurality of positions of a casting wheel mold, a cooling pipeline opening and closing signal, a casting device opening and closing signal, a casting process and recording time in the target wheel casting process according to a fixed frequency, wherein the temperatures of the plurality of positions of the mold comprise the temperatures of a plurality of key hot or cold joint positions of a top mold, a bottom mold and a side mold;
the storage module is connected with the communication acquisition module and is used for storing the data acquired by the communication acquisition module; the storage module is used for storing the acquired data in a database with a unique ID according to the casting process of a single wheel based on the acquired mold opening and closing signals of the casting equipment so as to search all the casting process data of the single wheel;
the processing module is respectively connected with the communication acquisition module and the storage module and is used for processing the acquired data;
and the input and output module is connected with the processing module and is used for displaying the data information processed by the processing module.
2. The aluminum wheel casting forming process collecting system of claim 1, wherein the plurality of positions of the cast wheel mold comprise a top mold flange position, a top mold spoke middle position, a bottom mold riser position, a bottom mold spoke and rim transition position, a side mold outer rim position, and a side mold inner rim position, and a thermocouple is respectively arranged at each of the positions for temperature collection.
3. The system as claimed in claim 2, wherein the processing module calculates temperature control parameters based on the collected temperature data and time process to form a temperature control process for precise control of the casting process.
4. The aluminum wheel casting forming process collecting system of claim 3, wherein the thermocouple arranged at the top die flange position is a first thermocouple, the thermocouple arranged at the middle position of the top die spoke is a second thermocouple, the thermocouple arranged at the inner rim position of the side die is a third thermocouple, the thermocouple arranged at the outer rim position of the side die is a fourth thermocouple, the thermocouple arranged at the riser position of the bottom die is a fifth thermocouple, and the thermocouple arranged at the transition position of the bottom die spoke and the rim is a sixth thermocouple.
5. The aluminum wheel casting molding process collection system of claim 4, wherein the lower end face of the fourth thermocouple hole at the outer rim of the side mold coincides with the horizontal line of the R-angle end point of the wheel well; the position of the inner edge of the side die is positioned at the inner edge of the side die, and the upper end surface of the third thermocouple hole is superposed with the horizontal line of the R-angle tail end point of the inner edge of the side die;
if the distance between the lower end face of the thermocouple and the processing reference surface is a non-integer value, rounding is adopted for rounding.
6. The aluminum wheel casting forming process collecting system of claim 5, wherein the top die flange is provided with a knockout pin hole at a position, and the first thermocouple is arranged in the knockout pin hole;
the middle position of the top die spoke is located on the outer side of the T4 cooling channel, the middle position of two side walls of the material digging pit is located, and the distance between the central line of the second thermocouple hole and the central line of an air pipe of the T4 cooling channel is 15-20 mm.
7. The aluminum wheel casting forming process collecting system of claim 6, wherein the distance between the bottom of each thermocouple hole and the cavity surface of the mold is 3-7mm from the closest point of the circular arc end of the bottom of each thermocouple hole to the cavity surface, and all distances are the same on one set of mold; the bottom of each thermocouple hole is hemispherical, the diameter of each thermocouple hole is 4-6 mm, the top end of each thermocouple hole is a hollow cylinder, and the diameter of each thermocouple hole is the same as that of the bottom of each thermocouple hole.
8. The method for characterizing the casting forming process of the aluminum wheel, which adopts the system for acquiring the casting forming process of the aluminum wheel as claimed in any one of claims 1 to 7, is characterized by comprising the following steps:
step 1, continuously acquiring relevant data information of temperatures of a plurality of key positions of a mold, opening and closing signals of a cooling pipeline, pressure of a casting hearth, opening and closing signals of casting equipment, a casting process and time in a wheel casting process through an upper computer system according to fixed frequency;
step 2, based on the acquired mold opening and closing signals of the casting equipment, carrying out data slicing processing on continuously acquired data by taking a single wheel as a unit, and uniformly giving unique IDs (identification) to the data in the same wheel production process for storage;
step 3, carrying out data retrieval on the production process of a single wheel, sequencing the acquired temperature of the key position of each mould according to the acquisition time sequence, and then carrying out temperature data noise reduction based on the time sequence by using a moving window method;
step 4, establishing a multidimensional matrix based on the processed temperature and the corresponding acquisition time, and obtaining the temperature variation corresponding to the acquisition time through matrix transformation;
and 5, establishing an aluminum wheel casting forming process diagram with the same ID of the single wheel and the time as a unified measurement.
9. The aluminum wheel foundry shape processing characterization method of claim 8 wherein,
the cooling pipeline switching signal, casting furnace pressure casting equipment mould signal that opens and shuts, the collection of casting technology uses host computer system to establish through industrial ethernet and casting equipment PLC and is connected and gather, and the data information content of gathering includes: the cooling pipeline opening and closing signal corresponds to a point position opening and closing Boolean value, the casting hearth pressure corresponds to a point position numerical value, the casting equipment opening and closing signal corresponds to a point position Boolean value, and the casting technology corresponds to a point position numerical value.
10. The method as claimed in claim 8, wherein in step 5, the aluminum wheel casting forming process map comprises:
a curve for characterizing the temperature of the mold at key locations during the aluminum wheel casting process;
a bar graph image used for representing the opening and closing section of the mold cooling pipeline in the aluminum wheel casting process;
the method is used for representing a furnace pressure process node line in the aluminum wheel casting process;
the temperature control device is used for representing a curve of the temperature variation of the mold in the aluminum wheel casting process and a temperature-rising auxiliary marking line;
and (3) a label for characterizing the action of the aluminum wheel casting process equipment.
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