CN116994682B - Control method and system of aluminum alloy smelting and casting integrated equipment - Google Patents
Control method and system of aluminum alloy smelting and casting integrated equipment Download PDFInfo
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- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 702
- 238000005266 casting Methods 0.000 title claims abstract description 338
- 238000003723 Smelting Methods 0.000 title claims abstract description 294
- 238000000034 method Methods 0.000 title claims abstract description 61
- 230000007547 defect Effects 0.000 claims abstract description 142
- 238000005094 computer simulation Methods 0.000 claims abstract description 119
- 238000011282 treatment Methods 0.000 claims abstract description 46
- 238000005457 optimization Methods 0.000 claims abstract description 9
- 238000012545 processing Methods 0.000 claims description 31
- 238000004458 analytical method Methods 0.000 claims description 25
- 238000002844 melting Methods 0.000 claims description 24
- 230000008018 melting Effects 0.000 claims description 24
- 238000000137 annealing Methods 0.000 claims description 21
- 238000001514 detection method Methods 0.000 claims description 18
- 230000006872 improvement Effects 0.000 claims description 16
- 230000002159 abnormal effect Effects 0.000 claims description 15
- 230000010354 integration Effects 0.000 claims description 12
- 239000011148 porous material Substances 0.000 claims description 11
- 238000004088 simulation Methods 0.000 claims description 10
- 238000010276 construction Methods 0.000 claims description 9
- 238000001816 cooling Methods 0.000 claims description 9
- 238000012360 testing method Methods 0.000 claims description 9
- 238000012163 sequencing technique Methods 0.000 claims description 8
- 230000001276 controlling effect Effects 0.000 claims description 7
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- 238000013461 design Methods 0.000 claims description 5
- 238000007405 data analysis Methods 0.000 claims description 4
- 229910001338 liquidmetal Inorganic materials 0.000 claims description 4
- 238000004140 cleaning Methods 0.000 claims description 3
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- 230000008901 benefit Effects 0.000 description 3
- 239000012535 impurity Substances 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000001914 filtration Methods 0.000 description 2
- 230000006870 function Effects 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000011418 maintenance treatment Methods 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
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- 238000005516 engineering process Methods 0.000 description 1
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- 239000012466 permeate Substances 0.000 description 1
- 238000007781 pre-processing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000000523 sample Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 230000009466 transformation 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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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
- C22C1/026—Alloys based on aluminium
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Abstract
The invention discloses a control method and a system of aluminum alloy smelting and casting integrated equipment, comprising the following steps: the method comprises the steps of constructing a dynamic simulation model of aluminum alloy smelting and casting integrated equipment, performing simulated casting on the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment, obtaining external defect parameters and internal defect parameters of a three-dimensional model of an aluminum alloy finished product, formulating an aluminum alloy smelting and casting adjustment scheme by analyzing the external defect parameters and the internal defect parameters, adjusting the aluminum alloy smelting and casting integrated equipment, and performing optimization treatment on the aluminum alloy smelting and casting adjustment scheme by detecting the conductivity of the aluminum alloy finished product.
Description
Technical Field
The invention relates to the field of smelting and casting, in particular to a control method and a control system of aluminum alloy smelting and casting integrated equipment.
Background
The aluminum alloy is an alloy formed by mixing aluminum with other metal or nonmetal elements according to a certain proportion, is widely used for vehicles such as automobiles, aerospace, railway transportation and the like, and has excellent electric conductivity and thermal conductivity. The aluminum alloy smelting and casting integrated equipment can be used for realizing the production of the aluminum alloy, and impurities possibly permeate into the aluminum alloy in the smelting process, so that the electric conductivity and the heat conductivity of the aluminum alloy are poor; during the casting process, pores and cracks may be formed in the aluminum alloy, and problems such as rupturable and shape deformation may occur in the aluminum alloy. Based on the problems, the aluminum alloy smelting and casting integrated equipment needs to be controlled in a modeling simulation control mode, and then the controlled parameters are led into the aluminum alloy smelting and casting integrated equipment for debugging.
Disclosure of Invention
The invention overcomes the defects of the prior art and provides a control method and a control system of aluminum alloy smelting and casting integrated equipment.
In order to achieve the above purpose, the invention adopts the following technical scheme:
the first aspect of the invention provides a control method of aluminum alloy smelting and casting integrated equipment, which comprises the following steps:
constructing a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment based on engineering drawings and working parameters of the aluminum alloy smelting and casting integrated equipment;
performing simulated casting in the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment to generate a three-dimensional model of an aluminum alloy finished product, and performing model integration analysis on the three-dimensional model of the aluminum alloy finished product to obtain external shape defect parameters of the aluminum alloy finished product;
analyzing and processing external shape defect parameters of the aluminum alloy finished product, performing model adjustment on a dynamic simulation model of aluminum alloy smelting and casting integrated equipment according to defect analysis and processing results, and generating an external perfect three-dimensional model of the aluminum alloy finished product;
performing internal defect detection on the aluminum alloy finished product external intact three-dimensional model to obtain internal defect parameters, and correcting working parameters of a dynamic simulation model of aluminum alloy smelting and casting integrated equipment based on the internal defect parameters;
Based on working parameters of a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment, correcting the aluminum alloy smelting and casting integrated equipment, and conducting conductivity test on an aluminum alloy finished product manufactured by the corrected aluminum alloy smelting and casting integrated equipment.
Further, in a preferred embodiment of the present invention, the construction of the dynamic simulation model of the aluminum alloy melting and casting integrated equipment based on the engineering drawing and the working parameters of the aluminum alloy melting and casting integrated equipment specifically comprises:
obtaining an engineering drawing according to aluminum alloy smelting and casting integrated equipment, and obtaining size data, shape data and characteristic data of the aluminum alloy smelting and casting integrated equipment on the engineering drawing;
constructing a three-dimensional coordinate system, importing size data, shape data and characteristic data of the aluminum alloy smelting and casting integrated equipment into the three-dimensional coordinate system for model construction to obtain an aluminum alloy smelting and casting integrated equipment model, and converting the aluminum alloy smelting and casting integrated equipment model into aluminum alloy smelting and casting integrated equipment model data information;
installing a working parameter sensor in the aluminum alloy smelting and casting integrated equipment, acquiring various working parameters of the aluminum alloy smelting and casting integrated equipment, and importing various working parameters of the aluminum alloy smelting and casting integrated equipment and data information of the aluminum alloy smelting and casting integrated equipment model into three-dimensional simulation software to obtain a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment.
Further, in a preferred embodiment of the present invention, the performing simulation casting in the dynamic simulation model of the aluminum alloy melting and casting integrated equipment generates a three-dimensional model of an aluminum alloy finished product, and performing model integration analysis on the three-dimensional model of the aluminum alloy finished product to obtain external shape defect parameters of the aluminum alloy finished product, specifically includes:
acquiring aluminum alloy smelting and casting material data information based on historical data retrieval, and introducing the aluminum alloy smelting and casting material data information into an aluminum alloy smelting and casting integrated equipment dynamic simulation model, wherein the aluminum alloy smelting and casting integrated equipment dynamic simulation model performs simulated casting to generate an aluminum alloy finished product data stream;
performing data cleaning treatment on the aluminum alloy finished product data stream, calculating the data standard deviation of the aluminum alloy finished product data stream, defining the data standard deviation of the aluminum alloy finished product data stream which is not in the preset standard deviation range as an abnormal value, and eliminating the abnormal value;
analyzing data points of the aluminum alloy finished product data stream after abnormal values are removed, performing difference compensation on the data points after the abnormal values are removed to obtain a complete aluminum alloy finished product data stream, and guiding the complete aluminum alloy finished product data stream into a three-dimensional coordinate system for model construction to obtain a three-dimensional model of the aluminum alloy finished product;
Presetting a standard aluminum alloy finished product three-dimensional model, and carrying out data integration comparison on the aluminum alloy finished product three-dimensional model and the standard aluminum alloy finished product three-dimensional model to obtain preliminary defect information of the aluminum alloy finished product, wherein the preliminary defect information of the aluminum alloy finished product is an external shape defect parameter of the aluminum alloy finished product.
Further, in a preferred embodiment of the present invention, the analysis and processing are performed on external shape defect parameters of the aluminum alloy finished product, and according to the result of the defect analysis and processing, a model adjustment is performed on a dynamic simulation model of an integrated aluminum alloy smelting and casting device, and an external perfect three-dimensional model of the aluminum alloy finished product is generated, specifically:
sorting the external shape defect parameter pairs of the aluminum alloy finished product according to the severity of the external shape defect of the aluminum alloy finished product, generating an external shape defect parameter sorting primary table, carrying out data analysis on the external shape defect parameter sorting primary table, and eliminating the external shape defect parameters within a preset range to obtain an external shape defect parameter sorting table;
analyzing the aluminum alloy finished product according to the severity degree of the external shape defect parameters from large to small based on the external shape defect parameter sorting table, wherein the external shape defects of the aluminum alloy finished product comprise surface pits and surface warpage;
When the aluminum alloy finished product has surface concave and surface warpage, various aluminum alloy smelting and casting adjusting schemes are generated, and the aluminum alloy smelting and casting adjusting scheme comprises the following adjusting steps: adjusting the smelting temperature of the aluminum alloy in a proper temperature range, adjusting the casting speed of the liquid metal of the aluminum alloy, adjusting the design of an aluminum alloy casting mold and controlling the cooling time;
introducing various aluminum alloy smelting and casting regulation schemes into a dynamic simulation model of aluminum alloy smelting and casting integrated equipment for simulation regulation, correspondingly generating an aluminum alloy finished product external improvement three-dimensional model by each aluminum alloy smelting and casting regulation scheme, carrying out model comparison on all aluminum alloy finished product external improvement three-dimensional models and a standard aluminum alloy finished product three-dimensional model to obtain model external deviation values, sequencing the model deviation values, selecting an aluminum alloy smelting and casting regulation scheme with the minimum regulated model deviation value, and outputting the aluminum alloy smelting and casting regulation scheme into the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment;
selecting an aluminum alloy finished product external improvement three-dimensional model with the minimum model deviation value, analyzing the model deviation value to obtain model external flatness parameters, sequencing the external flatness parameters of each surface of the aluminum alloy finished product to obtain a surface with the minimum external flatness parameters, and calculating the surface flatness difference value of the surface with the minimum external flatness parameters;
If the surface flatness difference value of the minimum surface of the external flatness parameters is smaller than a preset value, defining a corresponding external improved three-dimensional model of the aluminum alloy finished product as an external intact three-dimensional model of the aluminum alloy finished product;
if the surface flatness difference value of the minimum surface of the external flatness parameter is larger than a preset value, a pressurizing procedure is needed to be added into a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment, the surface flatness difference value of the minimum surface of the external flatness parameter is led into the pressurizing procedure of the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment, the pressurizing procedure of the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment carries out pressurizing treatment on the external improved three-dimensional model of the aluminum alloy finished product, and the pressurizing procedure is arranged in the aluminum alloy smelting and casting integrated equipment.
Further, in a preferred embodiment of the present invention, the internal defect detection is performed on the external intact three-dimensional model of the aluminum alloy finished product to obtain internal defect parameters, and the working parameters of the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment are corrected based on the internal defect parameters, specifically:
converting the aluminum alloy finished product external perfect three-dimensional model into a text format through a JSON data exchange format, wherein the text format comprises internal defect parameters of the aluminum alloy finished product external perfect three-dimensional model, and the internal defect parameters are internal air hole concentration and internal crack concentration;
If the internal crack concentration of the aluminum alloy finished product external sound three-dimensional model is within a preset range, analyzing the internal air hole concentration of the aluminum alloy finished product external sound three-dimensional model, and if the internal air hole concentration is within the preset range, defining the aluminum alloy finished product external sound three-dimensional model as an aluminum alloy finished product sound model, wherein the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment is not required to be corrected;
if the internal crack concentration of the aluminum alloy finished product external intact three-dimensional model is within a preset range, but the internal pore concentration is larger than a preset value, setting a secondary pressurizing treatment step in the aluminum alloy smelting and casting integrated equipment dynamic simulation model, enabling the aluminum alloy finished product external intact three-dimensional model to execute secondary pressurizing treatment, if the internal pore concentration of the aluminum alloy finished product external intact three-dimensional model after secondary pressurizing is smaller than the preset value, defining the aluminum alloy finished product external intact three-dimensional model as an aluminum alloy finished product intact model, acquiring parameters of the aluminum alloy smelting and casting integrated equipment dynamic simulation model secondary pressurizing step, and setting parameters of the aluminum alloy smelting and casting integrated equipment dynamic simulation model secondary pressurizing step into a secondary pressurizing procedure of the aluminum alloy smelting and casting integrated equipment;
If the air hole concentration in the aluminum alloy finished product external sound three-dimensional model after the secondary pressurization is larger than a preset value, defining the aluminum alloy finished product external sound three-dimensional model as a model;
defining an aluminum alloy finished product external intact three-dimensional model with internal crack concentration not within a preset range as a second model, setting an annealing treatment step in a dynamic simulation model of aluminum alloy smelting and casting integrated equipment, and performing annealing treatment on the first model and the second model to obtain three models, if the internal crack concentration of the three models is smaller than a preset value, defining the three models as the aluminum alloy finished product intact model, and setting annealing treatment parameters in the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment into an annealing procedure of the aluminum alloy smelting and casting integrated equipment;
if the internal crack concentration of the three models is still larger than the preset value, optimizing the aluminum alloy smelting and casting adjustment scheme, correcting the aluminum alloy smelting and casting integrated equipment dynamic simulation model, and acquiring corrected aluminum alloy smelting and casting integrated equipment dynamic simulation model parameters.
Further, in a preferred embodiment of the present invention, the working parameters based on the dynamic simulation model of the aluminum alloy melting and casting integrated equipment are used for correcting the aluminum alloy melting and casting integrated equipment, and conducting conductivity test on the aluminum alloy finished product manufactured by the corrected aluminum alloy melting and casting integrated equipment, specifically:
Adjusting the aluminum alloy smelting and casting integrated equipment based on the corrected aluminum alloy smelting and casting integrated equipment dynamic simulation model parameters, and enabling the adjusted aluminum alloy smelting and casting integrated equipment to produce and obtain an aluminum alloy finished product;
connecting four-lead resistance measuring instruments at two ends of the aluminum alloy finished product, measuring the resistance value of the aluminum alloy finished product, obtaining the size and the geometric shape of the aluminum alloy finished product, and calculating to obtain the resistivity of the aluminum alloy finished product;
and (3) connecting conductivity meters at two ends of the aluminum alloy finished product, measuring the conductivity of the aluminum alloy finished product, and combining the resistivity and the conductivity of the aluminum alloy finished product to obtain the conductivity of the aluminum alloy finished product, and performing secondary optimization treatment on an aluminum alloy smelting and casting regulation scheme when the conductivity of the aluminum alloy finished product is smaller than a preset range.
The second aspect of the present invention also provides a control system of an aluminum alloy melting and casting integrated apparatus, the control system comprising a memory and a processor, wherein a control program is stored in the memory, and when the control program is executed by the processor, the following steps are implemented:
constructing a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment based on engineering drawings and working parameters of the aluminum alloy smelting and casting integrated equipment;
Performing simulated casting in the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment to generate a three-dimensional model of an aluminum alloy finished product, and performing model integration analysis on the three-dimensional model of the aluminum alloy finished product to obtain external shape defect parameters of the aluminum alloy finished product;
analyzing and processing external shape defect parameters of the aluminum alloy finished product, performing model adjustment on a dynamic simulation model of aluminum alloy smelting and casting integrated equipment according to defect analysis and processing results, and generating an external perfect three-dimensional model of the aluminum alloy finished product;
performing internal defect detection on the aluminum alloy finished product external intact three-dimensional model to obtain internal defect parameters, and correcting working parameters of a dynamic simulation model of aluminum alloy smelting and casting integrated equipment based on the internal defect parameters;
based on working parameters of a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment, correcting the aluminum alloy smelting and casting integrated equipment, and conducting conductivity test on an aluminum alloy finished product manufactured by the corrected aluminum alloy smelting and casting integrated equipment.
The invention solves the technical defects in the background technology, and has the following beneficial effects: the method comprises the steps of constructing a dynamic simulation model of aluminum alloy smelting and casting integrated equipment, performing simulated casting on the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment, obtaining external defect parameters and internal defect parameters of a three-dimensional model of an aluminum alloy finished product, formulating an aluminum alloy smelting and casting adjustment scheme by analyzing the external defect parameters and the internal defect parameters, adjusting the aluminum alloy smelting and casting integrated equipment, and performing optimization treatment on the aluminum alloy smelting and casting adjustment scheme by detecting the conductivity of the aluminum alloy finished product. According to the invention, the regulation and control of the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment can be realized by continuously optimizing the aluminum alloy smelting and casting regulation scheme, so that the regulation and control plays an important role in efficiently realizing the smelting and casting of the aluminum alloy, and is beneficial to economic benefit and reduction of human resource waste.
Drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, it being obvious that the drawings in the following description are only some embodiments of the invention, and that other embodiments of the drawings can be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 shows a flow chart of a control method of an aluminum alloy melting and casting integrated apparatus;
FIG. 2 shows a flow chart of an analysis process for external shape defect parameters of an aluminum alloy finished product;
FIG. 3 shows a flow chart for internal defect detection and correction of an externally sound three-dimensional model of the finished aluminum alloy product;
fig. 4 shows a program diagram of a control system of an aluminum alloy melting and casting integrated apparatus.
Detailed Description
In order that the above-recited objects, features and advantages of the present invention will be more clearly understood, a more particular description of the invention will be rendered by reference to the appended drawings and appended detailed description. It should be noted that, in the case of no conflict, the embodiments of the present application and the features in the embodiments may be combined with each other.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention, however, the present invention may be practiced in other ways than those described herein, and therefore the scope of the present invention is not limited to the specific embodiments disclosed below.
Fig. 1 shows a flow chart illustrating a control method of an aluminum alloy melting and casting integrated apparatus, comprising the steps of:
s102: constructing a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment based on engineering drawings and working parameters of the aluminum alloy smelting and casting integrated equipment;
s104: performing simulated casting in the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment to generate a three-dimensional model of an aluminum alloy finished product, and performing model integration analysis on the three-dimensional model of the aluminum alloy finished product to obtain external shape defect parameters of the aluminum alloy finished product;
s106: analyzing and processing external shape defect parameters of the aluminum alloy finished product, performing model adjustment on a dynamic simulation model of aluminum alloy smelting and casting integrated equipment according to defect analysis and processing results, and generating an external perfect three-dimensional model of the aluminum alloy finished product;
s108: performing internal defect detection on the aluminum alloy finished product external intact three-dimensional model to obtain internal defect parameters, and correcting working parameters of a dynamic simulation model of aluminum alloy smelting and casting integrated equipment based on the internal defect parameters;
S110: based on working parameters of a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment, correcting the aluminum alloy smelting and casting integrated equipment, and conducting conductivity test on an aluminum alloy finished product manufactured by the corrected aluminum alloy smelting and casting integrated equipment.
The aluminum alloy smelting and casting integrated equipment has the functions of mixing, heating and smelting aluminum alloy raw materials and other alloy elements according to a proportion, and pouring, cooling and demoulding the smelted molten aluminum alloy. The control of the aluminum alloy smelting and casting integrated equipment needs to adjust the working parameters of the aluminum alloy smelting and casting integrated equipment, so that the aluminum alloy smelting and casting integrated equipment reaches the optimal working state.
Further, in a preferred embodiment of the present invention, the construction of the dynamic simulation model of the aluminum alloy melting and casting integrated equipment based on the engineering drawing and the working parameters of the aluminum alloy melting and casting integrated equipment specifically comprises:
obtaining an engineering drawing according to aluminum alloy smelting and casting integrated equipment, and obtaining size data, shape data and characteristic data of the aluminum alloy smelting and casting integrated equipment on the engineering drawing;
Constructing a three-dimensional coordinate system, importing size data, shape data and characteristic data of the aluminum alloy smelting and casting integrated equipment into the three-dimensional coordinate system for model construction to obtain an aluminum alloy smelting and casting integrated equipment model, and converting the aluminum alloy smelting and casting integrated equipment model into aluminum alloy smelting and casting integrated equipment model data information;
installing a working parameter sensor in the aluminum alloy smelting and casting integrated equipment, acquiring various working parameters of the aluminum alloy smelting and casting integrated equipment, and importing various working parameters of the aluminum alloy smelting and casting integrated equipment and data information of the aluminum alloy smelting and casting integrated equipment model into three-dimensional simulation software to obtain a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment.
According to the data such as various size parameters on the engineering drawing of the aluminum alloy smelting and casting integrated equipment, various size parameters can be converted into an aluminum alloy smelting and casting integrated equipment model in a three-dimensional drawing tool, the aluminum alloy smelting and casting integrated equipment model is converted into aluminum alloy smelting and casting integrated equipment model data information, the purpose of the aluminum alloy smelting and casting integrated equipment model is to enable the aluminum alloy smelting and casting integrated equipment model to be imported into three-dimensional simulation software for three-dimensional simulation, and meanwhile various working parameters of the aluminum alloy smelting and casting integrated equipment are imported into the three-dimensional simulation software, so that the aluminum alloy smelting and casting integrated equipment dynamic simulation model can be obtained. The three-dimensional simulation software includes SolidWorks, CATIA and Rhino. According to the invention, the simulation processing can be realized by constructing the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment, the waste of processing resources is reduced, the processing efficiency is improved, the environment is protected, and the economic benefit is improved.
Further, in a preferred embodiment of the present invention, the performing simulation casting in the dynamic simulation model of the aluminum alloy melting and casting integrated equipment generates a three-dimensional model of an aluminum alloy finished product, and performing model integration analysis on the three-dimensional model of the aluminum alloy finished product to obtain external shape defect parameters of the aluminum alloy finished product, specifically includes:
acquiring aluminum alloy smelting and casting material data information based on historical data retrieval, and introducing the aluminum alloy smelting and casting material data information into an aluminum alloy smelting and casting integrated equipment dynamic simulation model, wherein the aluminum alloy smelting and casting integrated equipment dynamic simulation model performs simulated casting to generate an aluminum alloy finished product data stream;
performing data cleaning treatment on the aluminum alloy finished product data stream, calculating the data standard deviation of the aluminum alloy finished product data stream, defining the data standard deviation of the aluminum alloy finished product data stream which is not in the preset standard deviation range as an abnormal value, and eliminating the abnormal value;
analyzing data points of the aluminum alloy finished product data stream after abnormal values are removed, performing difference compensation on the data points after the abnormal values are removed to obtain a complete aluminum alloy finished product data stream, and guiding the complete aluminum alloy finished product data stream into a three-dimensional coordinate system for model construction to obtain a three-dimensional model of the aluminum alloy finished product;
Presetting a standard aluminum alloy finished product three-dimensional model, and carrying out data integration comparison on the aluminum alloy finished product three-dimensional model and the standard aluminum alloy finished product three-dimensional model to obtain preliminary defect information of the aluminum alloy finished product, wherein the preliminary defect information of the aluminum alloy finished product is an external shape defect parameter of the aluminum alloy finished product.
The method is characterized in that a result generated by performing simulated casting in the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment is a data stream, wherein the data stream comprises various size parameters, shape parameters and the like of a three-dimensional model of an aluminum alloy finished product, and abnormal data can be generated in the data stream due to the influence of objective factors in the generation process of the data stream, and the data of the aluminum alloy finished product is required to be cleaned, so that abnormal data is removed and vacant data is filled. The external shape defect parameters of the aluminum alloy finished product are obtained by comparing the three-dimensional model of the aluminum alloy finished product with a preset model. The invention can obtain the external shape defect parameters of the aluminum alloy by processing the aluminum alloy finished product data stream.
Further, in a preferred embodiment of the present invention, the working parameters based on the dynamic simulation model of the aluminum alloy melting and casting integrated equipment are used for correcting the aluminum alloy melting and casting integrated equipment, and conducting conductivity test on the aluminum alloy finished product manufactured by the corrected aluminum alloy melting and casting integrated equipment, specifically:
Adjusting the aluminum alloy smelting and casting integrated equipment based on the corrected aluminum alloy smelting and casting integrated equipment dynamic simulation model parameters, and enabling the adjusted aluminum alloy smelting and casting integrated equipment to produce and obtain an aluminum alloy finished product;
connecting four-lead resistance measuring instruments at two ends of the aluminum alloy finished product, measuring the resistance value of the aluminum alloy finished product, obtaining the size and the geometric shape of the aluminum alloy finished product, and calculating to obtain the resistivity of the aluminum alloy finished product;
and (3) connecting conductivity meters at two ends of the aluminum alloy finished product, measuring the conductivity of the aluminum alloy finished product, and combining the resistivity and the conductivity of the aluminum alloy finished product to obtain the conductivity of the aluminum alloy finished product, and performing secondary optimization treatment on an aluminum alloy smelting and casting regulation scheme when the conductivity of the aluminum alloy finished product is smaller than a preset range.
It should be noted that, the conductivity of the aluminum alloy finished product is obtained by combining the resistivity and the conductivity, and other impurities may be mixed with the aluminum alloy during the smelting and casting processes of the aluminum alloy finished product, and when the purity of the aluminum alloy finished product is low, the rigidity, the strength, the conductivity and the like of the aluminum alloy are reduced, and the work efficiency is affected by the reduction of the conductivity of the aluminum alloy finished product. According to the conductivity of the aluminum alloy finished product, the purity of the aluminum alloy finished product can be judged, and the regulation optimization of aluminum alloy smelting and casting is realized. According to the invention, the conductivity of the aluminum alloy finished product can be tested to judge whether the impurity concentration in the aluminum alloy finished product is too high, so that the aluminum alloy smelting and casting integrated equipment is adjusted and optimized.
FIG. 2 shows a flow chart of analysis processing of external shape defect parameters of an aluminum alloy finished product, comprising the steps of:
s202: obtaining an external shape defect parameter ranking table, and formulating an aluminum alloy smelting and casting adjustment scheme according to the external shape defect parameter ranking table;
s204: selecting an aluminum alloy smelting and casting regulation scheme and generating an aluminum alloy finished product external improvement three-dimensional model;
s206: and carrying out model external flatness analysis treatment on the external improved three-dimensional model of the aluminum alloy finished product to generate an external intact three-dimensional model of the aluminum alloy finished product.
Further, in a preferred embodiment of the present invention, the method for obtaining the external shape defect parameter ranking table, and making an aluminum alloy smelting and casting adjustment scheme according to the external shape defect parameter ranking table specifically comprises:
sorting the external shape defect parameter pairs of the aluminum alloy finished product according to the severity of the external shape defect of the aluminum alloy finished product, generating an external shape defect parameter sorting primary table, carrying out data analysis on the external shape defect parameter sorting primary table, and eliminating the external shape defect parameters within a preset range to obtain an external shape defect parameter sorting table;
Analyzing the aluminum alloy finished product according to the severity degree of the external shape defect parameters from large to small based on the external shape defect parameter sorting table, wherein the external shape defects of the aluminum alloy finished product comprise surface pits and surface warpage;
when the aluminum alloy finished product has surface concave and surface warpage, various aluminum alloy smelting and casting adjusting schemes are generated, and the aluminum alloy smelting and casting adjusting scheme comprises the following adjusting steps: adjusting the smelting temperature of the aluminum alloy in a proper temperature range, adjusting the casting speed of the liquid metal of the aluminum alloy, adjusting the design of an aluminum alloy casting mold and controlling the cooling time.
It should be noted that, the reason that the aluminum alloy finished product generates the surface dent is that the temperature of the melted aluminum alloy is unstable, so that the shrinkage is uneven when the aluminum alloy is solidified, the casting speed in the die is too high, the metal flow is unsmooth due to the unreasonable design of the die, and the dent is easy to generate. When the warping of the aluminum alloy finished product is caused, the aluminum alloy finished product is warped due to uneven cooling on the basis of the above reasons. When the severity of the external shape defect of the aluminum alloy finished product is smaller, no influence is caused on the aluminum alloy finished product, so that the part with smaller severity of the external shape defect does not need to be regulated, the external shape defect parameters in the preset range are removed from the primary table of the external shape defect parameters, and the aluminum alloy smelting and casting integrated equipment is regulated by acquiring an aluminum alloy smelting and casting regulation scheme based on the external shape defect parameter table. According to the invention, an aluminum alloy smelting and casting adjustment scheme can be formulated according to the external shape defect parameter ranking table.
Further, in a preferred embodiment of the present invention, the aluminum alloy melting and casting adjustment scheme is selected and an external improved three-dimensional model of the aluminum alloy finished product is generated, specifically:
and introducing various aluminum alloy smelting and casting adjustment schemes into a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment for simulation adjustment, correspondingly generating an aluminum alloy finished product external improvement three-dimensional model by each aluminum alloy smelting and casting adjustment scheme, carrying out model comparison on all aluminum alloy finished product external improvement three-dimensional models and a standard aluminum alloy finished product three-dimensional model to obtain model external deviation values, sequencing the model deviation values, selecting the aluminum alloy smelting and casting adjustment scheme with the minimum model deviation value after adjustment, and outputting the aluminum alloy smelting and casting adjustment scheme to the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment.
The aluminum alloy smelting and casting adjustment scheme has various adjustment methods, different adjustment functions on the aluminum alloy smelting and casting integrated equipment are different, model analysis is needed to be carried out on aluminum alloy finished products produced by the aluminum alloy smelting and casting integrated equipment after various adjustment schemes are applied, and a scheme for minimizing deviation values of the aluminum alloy finished products is selected as the adjustment scheme of the aluminum alloy smelting and casting integrated equipment. After the aluminum alloy smelting and casting adjustment scheme is output, only the external shape defect of the aluminum alloy finished product is adjusted, and the external defect of the aluminum alloy finished product also comprises external flatness, so that the model obtained by simulated casting is an external improved three-dimensional model of the aluminum alloy finished product. According to the invention, the aluminum alloy smelting and casting adjustment scheme with the best effect can be obtained by obtaining the model deviation value of the aluminum alloy finished product three-dimensional model, and the aluminum alloy finished product external improvement three-dimensional model is obtained.
Further, in a preferred embodiment of the present invention, the external flatness analysis processing is performed on the external improved three-dimensional model of the aluminum alloy finished product to generate an external perfect three-dimensional model of the aluminum alloy finished product, specifically:
selecting an aluminum alloy finished product external improvement three-dimensional model with the minimum model deviation value, analyzing the model deviation value to obtain model external flatness parameters, sequencing the external flatness parameters of each surface of the aluminum alloy finished product to obtain a surface with the minimum external flatness parameters, and calculating the surface flatness difference value of the surface with the minimum external flatness parameters;
if the surface flatness difference value of the minimum surface of the external flatness parameters is smaller than a preset value, defining a corresponding external improved three-dimensional model of the aluminum alloy finished product as an external intact three-dimensional model of the aluminum alloy finished product;
if the surface flatness difference value of the minimum surface of the external flatness parameter is larger than a preset value, a pressurizing procedure is needed to be added into a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment, the surface flatness difference value of the minimum surface of the external flatness parameter is led into the pressurizing procedure of the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment, the pressurizing procedure of the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment carries out pressurizing treatment on the external improved three-dimensional model of the aluminum alloy finished product, and the pressurizing procedure is arranged in the aluminum alloy smelting and casting integrated equipment.
It should be noted that after the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment is adjusted by the aluminum alloy smelting and casting adjusting scheme, the surface of the obtained aluminum alloy finished product model may have abnormal external flatness. The minimum surface of the external flatness parameter means that the flatness of the surface is worst, when the surface flatness difference value of the minimum surface of the external flatness parameter is smaller than a preset value, the flatness of each surface of the aluminum alloy finished product external improvement three-dimensional model is proved to be in accordance with the requirements, the aluminum alloy finished product improvement three-dimensional model with the external flatness at the preset value is defined as an external perfect three-dimensional model of the aluminum alloy finished product, the external defect-free of the aluminum alloy finished product three-dimensional model is proved, and then the detection of the next step can be continued. When the surface flatness difference value of the minimum surface of the external flatness parameters is larger than a preset value, the external flatness of at least one surface of the aluminum alloy finished product external improved three-dimensional model is proved to be unsatisfactory, and the external flatness can be adjusted in a pressurizing treatment mode, so that a pressurizing procedure is required to be set in aluminum alloy smelting and casting integrated equipment. According to the invention, the external flatness of the external improved three-dimensional model of the aluminum alloy finished product can be analyzed, and the external improved three-dimensional model of the aluminum alloy finished product is processed, so that the external intact three-dimensional model of the aluminum alloy finished product is obtained.
FIG. 3 shows a flow chart for internal defect detection and correction of an externally intact three-dimensional model of the aluminum alloy finished product, comprising the steps of:
s302: converting the aluminum alloy finished product external intact three-dimensional model into text data, and obtaining internal defect data of the aluminum alloy finished product external intact three-dimensional model;
s304: analyzing and processing the aluminum alloy finished product external intact three-dimensional model with the internal crack concentration within a preset range;
s306: and analyzing and processing the aluminum alloy finished product external intact three-dimensional model with the internal crack concentration not within the preset range.
Further, in a preferred embodiment of the present invention, the converting the aluminum alloy finished product external perfect three-dimensional model into text data, and obtaining internal defect data of the aluminum alloy finished product external perfect three-dimensional model specifically includes:
and converting the aluminum alloy finished product external perfect three-dimensional model into a text format through a JSON data exchange format, wherein the text format comprises internal defect parameters of the aluminum alloy finished product external perfect three-dimensional model, and the internal defect parameters are internal air hole concentration and internal crack concentration.
It should be noted that, the internal defect parameters of the external perfect three-dimensional model of the aluminum alloy finished product need to be obtained, the external perfect three-dimensional model of the aluminum alloy finished product needs to be converted into text data, and the text data is analyzed to obtain the external perfect three-dimensional model. The JSON data exchange format is used for converting the model structure into a text format with good readability, and is convenient for obtaining the internal defect parameters of the external perfect three-dimensional model of the aluminum alloy finished product. According to the invention, the internal defect parameters of the external perfect three-dimensional model of the aluminum alloy finished product can be obtained through JSON data exchange format.
Further, in a preferred embodiment of the present invention, the analyzing and processing are performed on the aluminum alloy finished product external perfect three-dimensional model with internal crack concentration within a preset range, specifically:
if the internal crack concentration of the aluminum alloy finished product external sound three-dimensional model is within a preset range, analyzing the internal air hole concentration of the aluminum alloy finished product external sound three-dimensional model, and if the internal air hole concentration is within the preset range, defining the aluminum alloy finished product external sound three-dimensional model as an aluminum alloy finished product sound model, wherein the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment is not required to be corrected;
if the internal crack concentration of the aluminum alloy finished product external intact three-dimensional model is within a preset range, but the internal pore concentration is larger than a preset value, setting a secondary pressurizing treatment step in the aluminum alloy smelting and casting integrated equipment dynamic simulation model, enabling the aluminum alloy finished product external intact three-dimensional model to execute secondary pressurizing treatment, if the internal pore concentration of the aluminum alloy finished product external intact three-dimensional model after secondary pressurizing is smaller than the preset value, defining the aluminum alloy finished product external intact three-dimensional model as an aluminum alloy finished product intact model, acquiring parameters of the aluminum alloy smelting and casting integrated equipment dynamic simulation model secondary pressurizing step, and setting parameters of the aluminum alloy smelting and casting integrated equipment dynamic simulation model secondary pressurizing step into a secondary pressurizing procedure of the aluminum alloy smelting and casting integrated equipment;
And if the air hole concentration in the aluminum alloy finished product external sound three-dimensional model after the secondary pressurization is larger than a preset value, defining the aluminum alloy finished product external sound three-dimensional model as a model.
The internal crack concentration in the internal defect parameter is the internal crack severity of the external intact three-dimensional model of the aluminum alloy finished product, and the excessive internal crack concentration can influence the rigidity, the strength and other characteristics of the aluminum alloy finished product, so that the aluminum alloy finished product is a defective product. The internal cracks are generated because the cooling is uneven and the internal cracks are easy to generate in the cooling process of the aluminum alloy finished product. The concentration of the internal air holes is too large, the rigidity, the strength and other characteristics of the aluminum alloy finished product can be reduced, the mechanical properties of the aluminum alloy finished product are influenced, residual gas in the melt of the original operation and maintenance aluminum alloy finished product formed by the internal air holes cannot be completely removed, small holes can be formed in the aluminum alloy finished product, and the severity of cracks in the aluminum alloy finished product is higher than that of the internal air holes.
In addition, when the internal crack concentration of the external intact three-dimensional model of the aluminum alloy finished product is within a preset range, the external intact three-dimensional model of the aluminum alloy finished product is proved to be a semi-qualified product, and whether the internal pore concentration meets the requirement is detected. And (3) performing simulation correction on the aluminum alloy finished product external intact three-dimensional model with the internal air hole concentration not meeting the requirement, wherein the correction method is secondary pressurization treatment. During the first pressurization, the external flatness of the aluminum alloy finished product is corrected, and the secondary pressurization treatment can close or reduce the internal air holes. Firstly, performing simulated secondary pressurization in a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment, and then introducing data simulating the secondary pressurization into the solid aluminum alloy smelting and casting integrated equipment to realize the adjustment of the aluminum alloy smelting and casting integrated equipment. When the internal air hole concentration of the complete three-dimensional model outside the aluminum alloy finished product after the secondary pressurization treatment is still larger than a preset value, the next treatment is needed. The invention can make an adjusting scheme of the aluminum alloy smelting and casting integrated equipment by analyzing the internal crack concentration and the internal pore concentration of the external intact three-dimensional model of the aluminum alloy finished product.
Further, in a preferred embodiment of the present invention, the analyzing and processing are performed on the aluminum alloy finished product exterior perfect three-dimensional model with the internal crack concentration not within the preset range, specifically:
defining an aluminum alloy finished product external intact three-dimensional model with internal crack concentration not within a preset range as a second model, setting an annealing treatment step in a dynamic simulation model of aluminum alloy smelting and casting integrated equipment, and performing annealing treatment on the first model and the second model to obtain three models, if the internal crack concentration of the three models is smaller than a preset value, defining the three models as the aluminum alloy finished product intact model, and setting annealing treatment parameters in the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment into an annealing procedure of the aluminum alloy smelting and casting integrated equipment;
if the internal crack concentration of the three models is still larger than the preset value, optimizing the aluminum alloy smelting and casting adjustment scheme, correcting the aluminum alloy smelting and casting integrated equipment dynamic simulation model, and acquiring corrected aluminum alloy smelting and casting integrated equipment dynamic simulation model parameters.
It should be noted that when the internal crack concentration of the three-dimensional model with the intact exterior of the aluminum alloy finished product is not within the preset range, the three-dimensional model is defined as a second model, and the first model and the second model are annealed. The annealing treatment is a process of heating the aluminum alloy finished product to a certain temperature and then slowly cooling to room temperature, so that the residual stress in the aluminum alloy can be eliminated, and cracks and air holes are repaired. When the internal crack concentration is large and still is larger than a preset value after annealing treatment, secondary optimization treatment is needed to be carried out on the aluminum alloy smelting and casting adjustment scheme. And if the first model and the second model after the annealing treatment are qualified, setting parameters of the annealing treatment step in an annealing procedure of the solid aluminum alloy smelting and casting integrated equipment. According to the invention, the first model and the second model can be annealed, so that the regulation and control of aluminum alloy smelting and casting integrated equipment can be realized, and the aluminum alloy smelting and casting regulation scheme is optimized.
In addition, the control method of the aluminum alloy smelting and casting integrated equipment further comprises the following steps:
the adjusted aluminum alloy smelting and casting integrated equipment is produced to obtain an aluminum alloy secondary finished product, and a camera and an ultrasonic flaw detector are used for carrying out scanning identification and ultrasonic flaw detection on the aluminum alloy secondary finished product;
a camera is used for obtaining a surface image of the aluminum alloy secondary finished product, and the surface image is subjected to image graying treatment to obtain a surface graying image;
performing wavelet decomposition on the surface graying image to obtain a high-frequency band and a low-frequency band, extracting the high-frequency band, obtaining a high-frequency band wavelet coefficient, presetting a wavelet coefficient threshold, setting the high-frequency band wavelet coefficient smaller than the wavelet coefficient threshold to be 0, and reserving the high-frequency band wavelet coefficient not smaller than the wavelet coefficient threshold;
performing wavelet decomposition operation on a high-frequency band with the wavelet coefficient not smaller than a wavelet coefficient threshold for multiple times, stopping wavelet decomposition when the wavelet decomposition times reach a preset value to obtain a denoised frequency band wavelet coefficient, and performing wavelet inverse transformation on the denoised frequency band wavelet coefficient to obtain an aluminum alloy secondary finished product surface graying noise reduction image;
An ultrasonic probe of an ultrasonic flaw detector is tightly attached to the surface of the aluminum alloy secondary finished product and transmits ultrasonic pulses, ultrasonic signals reflected by the interior of metal are received, and filtering and amplifying treatment are carried out on the signals to obtain internal parameters of the aluminum alloy secondary finished product;
and combining the aluminum alloy secondary product surface graying noise reduction image and the aluminum alloy secondary product internal parameters to construct an aluminum alloy secondary product three-dimensional model, carrying out model analysis and comparison on the aluminum alloy secondary product three-dimensional model and the aluminum alloy product perfect model to obtain a model difference value, and if the model difference value is not in a preset range, carrying out three-time optimization on an aluminum alloy smelting and casting adjustment scheme.
After the aluminum alloy smelting and casting adjustment scheme is secondarily optimized, the aluminum alloy secondary finished product produced by the aluminum alloy smelting and casting integrated equipment is qualified. Modeling the aluminum alloy secondary finished product, wherein the purpose of the surface image graying treatment of the aluminum alloy secondary finished product in the modeling process is to reduce the image memory and improve the image speed; the purpose of wavelet decomposition is to make the image noise reduction, the internal parameters can be obtained by an ultrasonic flaw detector, and after the internal parameters are processed by a filtering method, the internal parameters are combined with the image to obtain the three-dimensional model of the aluminum alloy secondary finished product. Comparing the aluminum alloy secondary finished product three-dimensional model with an aluminum alloy finished product perfect model obtained by analog processing of a dynamic simulation model of aluminum alloy smelting and casting integrated equipment, analyzing whether differences exist between the models and whether the differences are in a normal range, if the model difference value is out of a preset range, continuing to regulate the aluminum alloy smelting and casting integrated equipment, and optimizing an aluminum alloy smelting and casting regulation scheme for three times. The invention can realize the three-time optimization of the aluminum alloy smelting and casting regulation scheme by modeling the aluminum alloy secondary finished product and comparing the aluminum alloy secondary finished product with the aluminum alloy perfect three-dimensional model.
In addition, the control method of the aluminum alloy smelting and casting integrated equipment further comprises the following steps:
after the aluminum alloy smelting and casting adjustment scheme is optimized for three times, an aluminum alloy three-time finished product is produced and obtained through aluminum alloy smelting and casting integrated equipment, and quality detection is carried out on the aluminum alloy three-time finished product, wherein the quality detection comprises the following steps: hardness detection, strength detection, conductivity detection and appearance breakage detection;
if the aluminum alloy tertiary finished product detection is not qualified, performing image modeling on the aluminum alloy tertiary finished product to obtain an aluminum alloy tertiary finished product model, and converting the aluminum alloy tertiary finished product model into a text format through a JSON data format to obtain an aluminum alloy tertiary finished product model data stream;
acquiring an aluminum alloy finished product sound model data stream, performing data superposition comparison on the aluminum alloy three-time finished product model data stream and the aluminum alloy finished product sound model data stream, and calculating Euclidean distance between data corresponding to the aluminum alloy three-time finished product model data stream and the aluminum alloy finished product sound model data stream;
marking data in the aluminum alloy three-time finished product model data stream with the Euclidean distance out of a preset range, and modeling the marked aluminum alloy three-time finished product model data stream to obtain a marked aluminum alloy three-time finished product model;
Judging fault sub-equipment of the aluminum alloy smelting and casting integrated equipment according to the marked aluminum alloy three-time finished product model, and maintaining the fault sub-equipment;
if the three-time finished product model of the aluminum alloy still has the marking data after the maintenance treatment of the fault sub-equipment, defining the area where the marking data is located as a defect sub-area, acquiring real-time environment parameters and real-time processing parameters after the maintenance treatment of the sub-equipment, and correlating the real-time environment parameters with the real-time processing parameters by a gray correlation method to obtain correlation information;
and analyzing the association information, and regulating and controlling the real-time environment parameters based on the association information until no marking data exists in the aluminum alloy three-time finished product model.
After the aluminum alloy smelting and casting adjustment scheme is optimized for three times, theoretically, products produced by the aluminum alloy smelting and casting integrated equipment should be in an ideal state, and if the aluminum alloy three-time finished product is not in the ideal state, environmental factors and whether the aluminum alloy smelting and casting integrated equipment has faults are needed to be judged. The Euclidean distance between the data can reflect the similarity between the data, and if the Euclidean distance between the data is too large, the similarity of the data is smaller, and the fault sub-equipment of the environment and aluminum alloy smelting and casting integrated equipment is required to be regulated and controlled under the condition that the corresponding area of the aluminum alloy tertiary finished product is not in an ideal state. The invention can realize the adjustment of aluminum alloy smelting and casting integrated equipment by comparing the Euclidean distance between the aluminum alloy three-time finished product model data stream and the aluminum alloy finished product perfect model data stream.
As shown in fig. 4, the second aspect of the present invention further provides a program diagram of a control system of an aluminum alloy melting and casting integrated apparatus, the control system includes a memory 41 and a processor 42, the memory 41 stores a control program, and when the control program is executed by the processor 42, the following steps are implemented:
acquiring a surface image of aluminum alloy smelting and casting integrated equipment, performing image preprocessing on the surface image, and constructing a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment;
performing simulated casting in the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment to generate a three-dimensional model of an aluminum alloy finished product, and performing model integration analysis on the three-dimensional model of the aluminum alloy finished product to obtain external shape defect parameters of the aluminum alloy finished product;
analyzing and processing external shape defect parameters of the aluminum alloy finished product, performing model adjustment on a dynamic simulation model of aluminum alloy smelting and casting integrated equipment according to defect analysis and processing results, and generating an external perfect three-dimensional model of the aluminum alloy finished product;
performing internal defect detection on the aluminum alloy finished product external intact three-dimensional model to obtain internal defect parameters, and correcting working parameters of a dynamic simulation model of aluminum alloy smelting and casting integrated equipment based on the internal defect parameters;
And correcting the aluminum alloy smelting and casting integrated equipment, and conducting conductivity test on the aluminum alloy finished product manufactured by the corrected aluminum alloy smelting and casting integrated equipment.
The foregoing is merely illustrative embodiments of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can easily think about variations or substitutions within the technical scope of the present invention, and the invention should be covered. Therefore, the protection scope of the invention is subject to the protection scope of the claims.
Claims (5)
1. The control method of the aluminum alloy smelting and casting integrated equipment is characterized by comprising the following steps of:
constructing a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment based on engineering drawings and working parameters of the aluminum alloy smelting and casting integrated equipment;
performing simulated casting in the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment to generate a three-dimensional model of an aluminum alloy finished product, and performing model integration analysis on the three-dimensional model of the aluminum alloy finished product to obtain external shape defect parameters of the aluminum alloy finished product;
analyzing and processing external shape defect parameters of the aluminum alloy finished product, performing model adjustment on a dynamic simulation model of aluminum alloy smelting and casting integrated equipment according to defect analysis and processing results, and generating an external perfect three-dimensional model of the aluminum alloy finished product;
Performing internal defect detection on the aluminum alloy finished product external intact three-dimensional model to obtain internal defect parameters, and correcting working parameters of a dynamic simulation model of aluminum alloy smelting and casting integrated equipment based on the internal defect parameters;
correcting the aluminum alloy smelting and casting integrated equipment based on working parameters of a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment, and conducting conductivity test on an aluminum alloy finished product manufactured by the corrected aluminum alloy smelting and casting integrated equipment;
the method comprises the steps of analyzing and processing external shape defect parameters of an aluminum alloy finished product, carrying out model adjustment on a dynamic simulation model of aluminum alloy smelting and casting integrated equipment according to defect analysis and processing results, and generating an external intact three-dimensional model of the aluminum alloy finished product, wherein the method comprises the following specific steps:
sorting the external shape defect parameter pairs of the aluminum alloy finished product according to the severity of the external shape defect of the aluminum alloy finished product, generating an external shape defect parameter sorting primary table, carrying out data analysis on the external shape defect parameter sorting primary table, and eliminating the external shape defect parameters within a preset range to obtain an external shape defect parameter sorting table;
Analyzing the aluminum alloy finished product according to the severity degree of the external shape defect parameters from large to small based on the external shape defect parameter sorting table, wherein the external shape defects of the aluminum alloy finished product comprise surface pits and surface warpage;
when the aluminum alloy finished product has surface concave and surface warpage, various aluminum alloy smelting and casting adjusting schemes are generated, and the aluminum alloy smelting and casting adjusting scheme comprises the following adjusting steps: adjusting the smelting temperature of the aluminum alloy in a proper temperature range, adjusting the casting speed of the liquid metal of the aluminum alloy, adjusting the design of an aluminum alloy casting mold and controlling the cooling time;
introducing various aluminum alloy smelting and casting regulation schemes into a dynamic simulation model of aluminum alloy smelting and casting integrated equipment for simulation regulation, correspondingly generating an aluminum alloy finished product external improvement three-dimensional model by each aluminum alloy smelting and casting regulation scheme, carrying out model comparison on all aluminum alloy finished product external improvement three-dimensional models and a standard aluminum alloy finished product three-dimensional model to obtain model external deviation values, sequencing the model deviation values, selecting an aluminum alloy smelting and casting regulation scheme with the minimum regulated model deviation value, and outputting the aluminum alloy smelting and casting regulation scheme into the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment;
Selecting an aluminum alloy finished product external improvement three-dimensional model with the minimum model deviation value, analyzing the model deviation value to obtain model external flatness parameters, sequencing the external flatness parameters of each surface of the aluminum alloy finished product to obtain a surface with the minimum external flatness parameters, and calculating the surface flatness difference value of the surface with the minimum external flatness parameters;
if the surface flatness difference value of the minimum surface of the external flatness parameters is smaller than a preset value, defining a corresponding external improved three-dimensional model of the aluminum alloy finished product as an external intact three-dimensional model of the aluminum alloy finished product;
if the surface flatness difference value of the minimum surface of the external flatness parameter is larger than a preset value, a pressurizing procedure is needed to be added into a dynamic simulation model of aluminum alloy smelting and casting integrated equipment, the surface flatness difference value of the minimum surface of the external flatness parameter is led into the pressurizing procedure of the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment, the pressurizing procedure of the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment carries out pressurizing treatment on an external improved three-dimensional model of an aluminum alloy finished product, and the pressurizing procedure is arranged into the aluminum alloy smelting and casting integrated equipment;
The method comprises the steps of detecting internal defects of an aluminum alloy finished product external intact three-dimensional model to obtain internal defect parameters, and correcting working parameters of a dynamic simulation model of aluminum alloy smelting and casting integrated equipment based on the internal defect parameters, wherein the working parameters are specifically as follows:
converting the aluminum alloy finished product external perfect three-dimensional model into a text format through a JSON data exchange format, wherein the text format comprises internal defect parameters of the aluminum alloy finished product external perfect three-dimensional model, and the internal defect parameters are internal air hole concentration and internal crack concentration;
if the internal crack concentration of the aluminum alloy finished product external sound three-dimensional model is within a preset range, analyzing the internal air hole concentration of the aluminum alloy finished product external sound three-dimensional model, and if the internal air hole concentration is within the preset range, defining the aluminum alloy finished product external sound three-dimensional model as an aluminum alloy finished product sound model, wherein the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment is not required to be corrected;
if the internal crack concentration of the aluminum alloy finished product external intact three-dimensional model is within a preset range, but the internal pore concentration is larger than a preset value, setting a secondary pressurizing treatment step in the aluminum alloy smelting and casting integrated equipment dynamic simulation model, enabling the aluminum alloy finished product external intact three-dimensional model to execute secondary pressurizing treatment, if the internal pore concentration of the aluminum alloy finished product external intact three-dimensional model after secondary pressurizing is smaller than the preset value, defining the aluminum alloy finished product external intact three-dimensional model as an aluminum alloy finished product intact model, acquiring parameters of the aluminum alloy smelting and casting integrated equipment dynamic simulation model secondary pressurizing step, and setting parameters of the aluminum alloy smelting and casting integrated equipment dynamic simulation model secondary pressurizing step into a secondary pressurizing procedure of the aluminum alloy smelting and casting integrated equipment;
If the air hole concentration in the aluminum alloy finished product external sound three-dimensional model after the secondary pressurization is larger than a preset value, defining the aluminum alloy finished product external sound three-dimensional model as a model;
defining an aluminum alloy finished product external intact three-dimensional model with internal crack concentration not within a preset range as a second model, setting an annealing treatment step in a dynamic simulation model of aluminum alloy smelting and casting integrated equipment, and performing annealing treatment on the first model and the second model to obtain three models, if the internal crack concentration of the three models is smaller than a preset value, defining the three models as the aluminum alloy finished product intact model, and setting annealing treatment parameters in the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment into an annealing procedure of the aluminum alloy smelting and casting integrated equipment;
if the internal crack concentration of the three models is still larger than the preset value, optimizing the aluminum alloy smelting and casting adjustment scheme, correcting the aluminum alloy smelting and casting integrated equipment dynamic simulation model, and acquiring corrected aluminum alloy smelting and casting integrated equipment dynamic simulation model parameters.
2. The control method of the aluminum alloy smelting and casting integrated equipment according to claim 1, wherein the construction of the aluminum alloy smelting and casting integrated equipment dynamic simulation model based on engineering drawings and working parameters of the aluminum alloy smelting and casting integrated equipment is specifically as follows:
Obtaining an engineering drawing according to aluminum alloy smelting and casting integrated equipment, and obtaining size data, shape data and characteristic data of the aluminum alloy smelting and casting integrated equipment on the engineering drawing;
constructing a three-dimensional coordinate system, importing size data, shape data and characteristic data of the aluminum alloy smelting and casting integrated equipment into the three-dimensional coordinate system for model construction to obtain an aluminum alloy smelting and casting integrated equipment model, and converting the aluminum alloy smelting and casting integrated equipment model into aluminum alloy smelting and casting integrated equipment model data information;
installing a working parameter sensor in the aluminum alloy smelting and casting integrated equipment, acquiring various working parameters of the aluminum alloy smelting and casting integrated equipment, and importing various working parameters of the aluminum alloy smelting and casting integrated equipment and data information of the aluminum alloy smelting and casting integrated equipment model into three-dimensional simulation software to obtain a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment.
3. The method for controlling an integrated aluminum alloy melting and casting apparatus according to claim 1, wherein the performing simulated casting in a dynamic simulation model of the integrated aluminum alloy melting and casting apparatus generates a three-dimensional model of an aluminum alloy finished product, and performing model integration analysis on the three-dimensional model of the aluminum alloy finished product to obtain external shape defect parameters of the aluminum alloy finished product comprises:
Acquiring aluminum alloy smelting and casting material data information based on historical data retrieval, and introducing the aluminum alloy smelting and casting material data information into an aluminum alloy smelting and casting integrated equipment dynamic simulation model, wherein the aluminum alloy smelting and casting integrated equipment dynamic simulation model performs simulated casting to generate an aluminum alloy finished product data stream;
performing data cleaning treatment on the aluminum alloy finished product data stream, calculating the data standard deviation of the aluminum alloy finished product data stream, defining the data standard deviation of the aluminum alloy finished product data stream which is not in the preset standard deviation range as an abnormal value, and eliminating the abnormal value;
analyzing data points of the aluminum alloy finished product data stream after abnormal values are removed, performing difference compensation on the data points after the abnormal values are removed to obtain a complete aluminum alloy finished product data stream, and guiding the complete aluminum alloy finished product data stream into a three-dimensional coordinate system for model construction to obtain a three-dimensional model of the aluminum alloy finished product;
presetting a standard aluminum alloy finished product three-dimensional model, and carrying out data integration comparison on the aluminum alloy finished product three-dimensional model and the standard aluminum alloy finished product three-dimensional model to obtain preliminary defect information of the aluminum alloy finished product, wherein the preliminary defect information of the aluminum alloy finished product is an external shape defect parameter of the aluminum alloy finished product.
4. The method for controlling an integrated aluminum alloy melting and casting apparatus according to claim 1, wherein the method is characterized in that the integrated aluminum alloy melting and casting apparatus is modified based on the working parameters of the dynamic simulation model of the integrated aluminum alloy melting and casting apparatus, and the conductivity test is performed on the aluminum alloy finished product manufactured by the modified integrated aluminum alloy melting and casting apparatus, specifically:
adjusting the aluminum alloy smelting and casting integrated equipment based on the corrected aluminum alloy smelting and casting integrated equipment dynamic simulation model parameters, and enabling the adjusted aluminum alloy smelting and casting integrated equipment to produce and obtain an aluminum alloy finished product;
connecting four-lead resistance measuring instruments at two ends of the aluminum alloy finished product, measuring the resistance value of the aluminum alloy finished product, obtaining the size and the geometric shape of the aluminum alloy finished product, and calculating to obtain the resistivity of the aluminum alloy finished product;
and (3) connecting conductivity meters at two ends of the aluminum alloy finished product, measuring the conductivity of the aluminum alloy finished product, and combining the resistivity and the conductivity of the aluminum alloy finished product to obtain the conductivity of the aluminum alloy finished product, and performing secondary optimization treatment on an aluminum alloy smelting and casting regulation scheme when the conductivity of the aluminum alloy finished product is smaller than a preset range.
5. The control system of the aluminum alloy smelting and casting integrated equipment is characterized by comprising a memory and a processor, wherein a control program is stored in the memory, and when the control program is executed by the processor, the following steps are realized:
constructing a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment based on engineering drawings and working parameters of the aluminum alloy smelting and casting integrated equipment;
performing simulated casting in the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment to generate a three-dimensional model of an aluminum alloy finished product, and performing model integration analysis on the three-dimensional model of the aluminum alloy finished product to obtain external shape defect parameters of the aluminum alloy finished product;
analyzing and processing external shape defect parameters of the aluminum alloy finished product, performing model adjustment on a dynamic simulation model of aluminum alloy smelting and casting integrated equipment according to defect analysis and processing results, and generating an external perfect three-dimensional model of the aluminum alloy finished product;
performing internal defect detection on the aluminum alloy finished product external intact three-dimensional model to obtain internal defect parameters, and correcting working parameters of a dynamic simulation model of aluminum alloy smelting and casting integrated equipment based on the internal defect parameters;
Correcting the aluminum alloy smelting and casting integrated equipment based on working parameters of a dynamic simulation model of the aluminum alloy smelting and casting integrated equipment, and conducting conductivity test on an aluminum alloy finished product manufactured by the corrected aluminum alloy smelting and casting integrated equipment;
the method comprises the steps of analyzing and processing external shape defect parameters of an aluminum alloy finished product, carrying out model adjustment on a dynamic simulation model of aluminum alloy smelting and casting integrated equipment according to defect analysis and processing results, and generating an external intact three-dimensional model of the aluminum alloy finished product, wherein the method comprises the following specific steps:
sorting the external shape defect parameter pairs of the aluminum alloy finished product according to the severity of the external shape defect of the aluminum alloy finished product, generating an external shape defect parameter sorting primary table, carrying out data analysis on the external shape defect parameter sorting primary table, and eliminating the external shape defect parameters within a preset range to obtain an external shape defect parameter sorting table;
analyzing the aluminum alloy finished product according to the severity degree of the external shape defect parameters from large to small based on the external shape defect parameter sorting table, wherein the external shape defects of the aluminum alloy finished product comprise surface pits and surface warpage;
When the aluminum alloy finished product has surface concave and surface warpage, various aluminum alloy smelting and casting adjusting schemes are generated, and the aluminum alloy smelting and casting adjusting scheme comprises the following adjusting steps: adjusting the smelting temperature of the aluminum alloy in a proper temperature range, adjusting the casting speed of the liquid metal of the aluminum alloy, adjusting the design of an aluminum alloy casting mold and controlling the cooling time;
introducing various aluminum alloy smelting and casting regulation schemes into a dynamic simulation model of aluminum alloy smelting and casting integrated equipment for simulation regulation, correspondingly generating an aluminum alloy finished product external improvement three-dimensional model by each aluminum alloy smelting and casting regulation scheme, carrying out model comparison on all aluminum alloy finished product external improvement three-dimensional models and a standard aluminum alloy finished product three-dimensional model to obtain model external deviation values, sequencing the model deviation values, selecting an aluminum alloy smelting and casting regulation scheme with the minimum regulated model deviation value, and outputting the aluminum alloy smelting and casting regulation scheme into the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment;
selecting an aluminum alloy finished product external improvement three-dimensional model with the minimum model deviation value, analyzing the model deviation value to obtain model external flatness parameters, sequencing the external flatness parameters of each surface of the aluminum alloy finished product to obtain a surface with the minimum external flatness parameters, and calculating the surface flatness difference value of the surface with the minimum external flatness parameters;
If the surface flatness difference value of the minimum surface of the external flatness parameters is smaller than a preset value, defining a corresponding external improved three-dimensional model of the aluminum alloy finished product as an external intact three-dimensional model of the aluminum alloy finished product;
if the surface flatness difference value of the minimum surface of the external flatness parameter is larger than a preset value, a pressurizing procedure is needed to be added into a dynamic simulation model of aluminum alloy smelting and casting integrated equipment, the surface flatness difference value of the minimum surface of the external flatness parameter is led into the pressurizing procedure of the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment, the pressurizing procedure of the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment carries out pressurizing treatment on an external improved three-dimensional model of an aluminum alloy finished product, and the pressurizing procedure is arranged into the aluminum alloy smelting and casting integrated equipment;
the method comprises the steps of detecting internal defects of an aluminum alloy finished product external intact three-dimensional model to obtain internal defect parameters, and correcting working parameters of a dynamic simulation model of aluminum alloy smelting and casting integrated equipment based on the internal defect parameters, wherein the working parameters are specifically as follows:
converting the aluminum alloy finished product external perfect three-dimensional model into a text format through a JSON data exchange format, wherein the text format comprises internal defect parameters of the aluminum alloy finished product external perfect three-dimensional model, and the internal defect parameters are internal air hole concentration and internal crack concentration;
If the internal crack concentration of the aluminum alloy finished product external sound three-dimensional model is within a preset range, analyzing the internal air hole concentration of the aluminum alloy finished product external sound three-dimensional model, and if the internal air hole concentration is within the preset range, defining the aluminum alloy finished product external sound three-dimensional model as an aluminum alloy finished product sound model, wherein the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment is not required to be corrected;
if the internal crack concentration of the aluminum alloy finished product external intact three-dimensional model is within a preset range, but the internal pore concentration is larger than a preset value, setting a secondary pressurizing treatment step in the aluminum alloy smelting and casting integrated equipment dynamic simulation model, enabling the aluminum alloy finished product external intact three-dimensional model to execute secondary pressurizing treatment, if the internal pore concentration of the aluminum alloy finished product external intact three-dimensional model after secondary pressurizing is smaller than the preset value, defining the aluminum alloy finished product external intact three-dimensional model as an aluminum alloy finished product intact model, acquiring parameters of the aluminum alloy smelting and casting integrated equipment dynamic simulation model secondary pressurizing step, and setting parameters of the aluminum alloy smelting and casting integrated equipment dynamic simulation model secondary pressurizing step into a secondary pressurizing procedure of the aluminum alloy smelting and casting integrated equipment;
If the air hole concentration in the aluminum alloy finished product external sound three-dimensional model after the secondary pressurization is larger than a preset value, defining the aluminum alloy finished product external sound three-dimensional model as a model;
defining an aluminum alloy finished product external intact three-dimensional model with internal crack concentration not within a preset range as a second model, setting an annealing treatment step in a dynamic simulation model of aluminum alloy smelting and casting integrated equipment, and performing annealing treatment on the first model and the second model to obtain three models, if the internal crack concentration of the three models is smaller than a preset value, defining the three models as the aluminum alloy finished product intact model, and setting annealing treatment parameters in the dynamic simulation model of the aluminum alloy smelting and casting integrated equipment into an annealing procedure of the aluminum alloy smelting and casting integrated equipment;
if the internal crack concentration of the three models is still larger than the preset value, optimizing the aluminum alloy smelting and casting adjustment scheme, correcting the aluminum alloy smelting and casting integrated equipment dynamic simulation model, and acquiring corrected aluminum alloy smelting and casting integrated equipment dynamic simulation model parameters.
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| CN110976830A (en) * | 2019-12-06 | 2020-04-10 | 北京科技大学 | Control method for casting defects of aluminum alloy gear shifting hub |
| CN113823359A (en) * | 2021-09-18 | 2021-12-21 | 南京工业大学 | Method for optimizing casting cooling process parameters of aluminum alloy steering gear valve shell |
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| CN110976830A (en) * | 2019-12-06 | 2020-04-10 | 北京科技大学 | Control method for casting defects of aluminum alloy gear shifting hub |
| CN113823359A (en) * | 2021-09-18 | 2021-12-21 | 南京工业大学 | Method for optimizing casting cooling process parameters of aluminum alloy steering gear valve shell |
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