CN115365478B - Nonlinear pressurization control method and system for casting and forming complex metal component - Google Patents
Nonlinear pressurization control method and system for casting and forming complex metal component Download PDFInfo
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- CN115365478B CN115365478B CN202210970217.XA CN202210970217A CN115365478B CN 115365478 B CN115365478 B CN 115365478B CN 202210970217 A CN202210970217 A CN 202210970217A CN 115365478 B CN115365478 B CN 115365478B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/08—Controlling, supervising, e.g. for safety reasons
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention discloses a nonlinear pressurization control method and a nonlinear pressurization control system for casting and forming complex metal components, comprising the following steps of generating a nonlinear pressurization process preset control program and corresponding optimal control parameters, initializing each zone bit after detecting that a tank locking ring is locked in place, determining the type of the metal component to be cast, and collecting the corresponding preset nonlinear pressurization process preset control program and the corresponding optimal control parameters in an upper computer according to the type of the metal component to be cast; pressurizing the casting equipment tank body to achieve tracking control of the pressure difference target value; and ending the control until each technological process of the metal component to be cast is judged to be finished. The pressurizing process of the liquid level can adjust the filling pressure according to a preset program, so that the molten metal is always filled in a laminar flow mode, and the problems of irregular filling, serious gas coiling and the like caused by large section change of a complex casting cavity are effectively avoided.
Description
Technical Field
The invention belongs to the technical field of pressure control in casting molding, and particularly relates to a nonlinear pressurization control method and system for casting molding of complex metal components.
Background
When the complex metal component is molded by adopting the differential pressure casting process, the pressure intensity of the pressurizing pressure is required to be adjusted at any time according to the structure of the complex metal component when the differential pressure casting equipment is used for molding in order to keep the molding liquid level stable all the time because the complex metal component is uneven in structure, and the molding speed of the metal liquid is further changed. However, existing counter-pressure casting processes typically give a linear pressurization curve through inherent experience and rough calculations, and vary the rate of mold filling based on the linear pressurization curve. The pressurizing mode can not change the filling rate of molten metal in real time at the structural abrupt position of the complex metal member. In addition, the control accuracy of the pressurization mode is insufficient, and the stability of the filling mode cannot be ensured. More seriously, when the error of rough calculation is too large, the error of the former pressurizing stage is accumulated to the latter pressurizing stage, and when the error is accumulated too much, the molten metal cannot fill the cavity of the casting mold, thereby causing the failure of molding.
Disclosure of Invention
The invention aims to provide a nonlinear pressurization control method and a nonlinear pressurization control system for casting and forming complex metal components, which are used for solving the problem that the forming quality of the complex metal components is poor due to the adoption of a linear pressurization mode in the conventional differential pressure casting process.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
in a first aspect, the present invention provides a nonlinear pressurization control method for casting forming of a complex metal member, comprising the steps of:
generating a nonlinear pressurization process preset control program and corresponding optimal control parameters:
presetting control parameters for different interface change rates in the nonlinear pressurizing process according to the inflection point of the casting mold filling speed aiming at each process of casting molding of a specific metal component;
acquiring a plurality of groups of control parameters of the nonlinear pressurizing process aiming at different interface change rates, and acquiring optimal control parameters; forming a nonlinear pressurization process preset control program according to the optimal control parameters; uploading a preset control program and corresponding optimal control parameters to an upper computer for standby;
when a casting cavity section change signal is detected in the casting process, adjusting the filling pressure according to the preset program and the corresponding optimal control parameters;
and carrying out metal component casting by adopting the generated nonlinear pressurization process preset control program and the corresponding optimal control parameters:
after detecting that the tank locking ring is locked in place, starting pressure control;
initializing each zone bit, determining the type of the metal component to be cast, and collecting a corresponding preset nonlinear pressurizing process preset control program and a corresponding optimal control parameter in an upper computer according to the type of the metal component to be cast;
acquiring current casting cavity process parameters, calculating a process curve target value step by step, and giving a corresponding pressure difference target value according to the nonlinear pressurization process preset control program and a corresponding optimal control parameter;
acquiring a real-time pressure value of a current casting cavity, comparing the acquired difference value of a pressure difference target value and an actual pressure process value, tracking and controlling the difference value, analyzing an output value acquired through calculation of a tracking and controlling a digital combination valve according to a nonlinear pressurization process preset control program and a corresponding optimal control parameter, and pressurizing the casting equipment tank body to achieve tracking and controlling of the pressure difference target value;
and (5) ending the control and completing the pouring until each technological process of the metal component to be cast is judged to be completed.
According to the technology, the filling pressure can be regulated according to a preset program in the liquid level pressurizing process, so that the molten metal is always filled in a laminar flow mode, and the problems of turbulence in filling, serious gas coiling and the like caused by large section change of a complex casting cavity are effectively avoided; solves the problem of poor molding quality of complex metal components caused by the adoption of a linear pressurizing mode in the existing differential pressure casting process.
In one possible design, the inflection point of the casting filling speed is obtained by embedding a plurality of liquid level detection contacts in the casting cavity in advance, and the liquid level detection contacts are positioned at the section change position of the casting cavity.
In one possible design, the processes of the metal component to be cast include a liquid lifting process, a mold filling process, a crust pressurizing process, a crystallization pressurizing process and a crystallization pressurizing process.
The invention provides a nonlinear pressurization control system for casting and forming complex metal components, which comprises a casting mold-filling speed inflection point acquisition module, a control parameter setting module, a program generation module, a data uploading module, a ring locking detection module, an initialization module, a metal component determination module, a program acquisition module, a process parameter acquisition module, a pressure difference target value calculation module, a pressure value acquisition module, a pressure tracking analysis module and a digital combination valve control module;
the casting mold filling speed inflection point acquisition module is used for acquiring casting mold filling speed inflection points in each technological process of casting and forming of the metal component;
the control parameter setting module is used for presetting control parameters aiming at different interface change rates in the nonlinear pressurizing process according to the inflection point of the casting mold filling speed;
the program generation module is used for acquiring a plurality of groups of control parameters of the nonlinear pressurizing process aiming at different interface change rates, acquiring optimal control parameters from the control parameters, forming a nonlinear pressurizing process preset control program according to the optimal control parameters, and then transmitting the nonlinear pressurizing process preset control program and the corresponding optimal control parameters to the data uploading module;
the data uploading module is used for uploading a preset control program and corresponding optimal control parameters to the upper computer for standby;
the ring locking detection module is used for detecting whether the locking ring of the tank body is locked in place or not, and starting pressure control;
the initialization module is used for initializing each zone bit after the tank locking ring is locked in place;
the metal component determining module is used for determining the type of the metal component to be cast and transmitting the type of the metal component to be cast to the program collecting module;
the program acquisition module is used for acquiring a corresponding preset nonlinear pressurization process preset control program and a corresponding optimal control parameter in the upper computer according to the type of the metal member to be cast;
the process parameter acquisition module is used for acquiring the process parameters of the current casting cavity and transmitting the process parameters of the current casting cavity to the pressure difference target value calculation module;
the pressure difference target value calculation module is used for calculating the target value of the process curve step by step according to the process parameters of the current casting cavity, giving out a corresponding pressure difference target value according to the nonlinear pressurization process preset control program and the corresponding optimal control parameters, and transmitting the pressure difference target value to the pressure tracking analysis module;
the pressure value acquisition module is used for acquiring the real-time pressure value of the current casting cavity and transmitting the real-time pressure value of the current casting cavity to the pressure tracking analysis module;
the pressure tracking analysis module is used for comparing the pressure difference target value with the current real-time pressure value of the casting cavity to obtain a difference value between the pressure difference target value and the actual pressure process value, tracking and controlling the difference value, analyzing the output value through an output value obtained by calculation of a tracking control algorithm, acquiring digital combination valve control information according to the nonlinear pressurization process preset control program and the corresponding optimal control parameter, and transmitting the digital combination valve control information to the digital combination valve control module;
the digital combined valve control module is used for controlling corresponding switching actions of the digital combined valve according to the digital combined valve control information; and (3) finishing control until all the technological processes of the metal component to be cast are finished, and finishing pouring.
In one possible design, the casting mold filling speed inflection point acquisition module is characterized in that a plurality of liquid level detection contacts are embedded in the casting cavity in advance, and the liquid level detection contacts are positioned at the section change position of the casting cavity.
In one possible design, the high-pressure gas tank is communicated with a gas inlet valve through a pipeline, the gas inlet valve is simultaneously communicated with a first digital combination valve and a second digital combination valve, the first digital combination valve is communicated with an upper cavity of a metal component casting tank body through a pipeline, and the second digital combination valve is communicated with a lower cavity of the metal component casting tank body; an exhaust valve is arranged between the air inlet valve and the first digital combination valve; a first communicating valve is connected between one end of the first digital combination valve communicated metal member casting tank body and one end of the second digital combination valve communicated metal member casting tank body; the upper cavity of the metal member casting tank body is communicated with a first vacuum valve through a pipeline, the lower cavity of the metal member casting tank body is communicated with a second vacuum valve through a pipeline, and one ends of the first vacuum valve and the second vacuum valve, which are far away from the metal member casting tank body, are connected with a gas recovery tank; the gas recovery tank is provided with a vacuum pump; a second communicating valve is communicated between one ends of the first vacuum valve and the second vacuum valve, which are close to the metal member casting tank body; the air inlet valve, the first digital combination valve, the second digital combination valve, the air outlet valve, the first communicating valve, the second communicating valve, the first vacuum valve, the second vacuum valve and the vacuum pump are electrically connected with the control cabinet.
In one possible design, the exhaust valve is a ball valve.
In one possible design, the exhaust valve communicates with a gas impurity removal device.
In one possible design, the mounting cabinet of the control valve is provided in a closed structure, and is provided with a ventilation channel, and the positive pressure environment is maintained in the control cabinet.
In one possible design, the high pressure gas tank stores an inert gas, which is argon.
The beneficial effects are that: the pressurizing process of the liquid level can adjust the filling pressure according to a preset program, so that the molten metal is always filled in a laminar flow mode, and the problems of irregular filling, serious gas coiling and the like caused by large section change of a complex casting cavity are effectively avoided.
Drawings
FIG. 1 is a flow chart of one specific example of an embodiment;
FIG. 2 is a schematic diagram of the connection relationship of the valves in one possible system hardware in an embodiment.
Detailed Description
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the present invention will be briefly described below with reference to the accompanying drawings and the description of the embodiments or the prior art, and it is obvious that the following description of the structure of the drawings is only some embodiments of the present invention, and other drawings can be obtained according to these drawings without inventive effort to a person skilled in the art. It should be noted that the description of these examples is for aiding in understanding the present invention, but is not intended to limit the present invention.
Examples:
in a first aspect, the present embodiment provides a nonlinear pressurization control method for casting molding of a complex metal member, including the steps of:
generating a nonlinear pressurization process preset control program and corresponding optimal control parameters:
presetting control parameters for different interface change rates in the nonlinear pressurizing process according to the inflection point of the casting mold filling speed aiming at each process of casting molding of a specific metal component;
acquiring a plurality of groups of control parameters of the nonlinear pressurizing process aiming at different interface change rates, and acquiring optimal control parameters; forming a nonlinear pressurization process preset control program according to the optimal control parameters; uploading a preset control program and corresponding optimal control parameters to an upper computer for standby;
when a casting cavity section change signal is detected in the casting process, adjusting the filling pressure according to the preset program and the corresponding optimal control parameters;
and carrying out metal component casting by adopting the generated nonlinear pressurization process preset control program and the corresponding optimal control parameters:
after detecting that the tank locking ring is locked in place, starting pressure control;
initializing each zone bit, determining the type of the metal component to be cast, and collecting a corresponding preset nonlinear pressurizing process preset control program and a corresponding optimal control parameter in an upper computer according to the type of the metal component to be cast;
acquiring current casting cavity process parameters, calculating a process curve target value step by step, and giving a corresponding pressure difference target value according to the nonlinear pressurization process preset control program and a corresponding optimal control parameter;
acquiring a real-time pressure value of a current casting cavity, comparing the acquired difference value of a pressure difference target value and an actual pressure process value, tracking and controlling the difference value, analyzing an output value acquired through calculation of a tracking and controlling a digital combination valve according to a nonlinear pressurization process preset control program and a corresponding optimal control parameter, and pressurizing the casting equipment tank body to achieve tracking and controlling of the pressure difference target value;
and (5) ending the control and completing the pouring until each technological process of the metal component to be cast is judged to be completed.
In the concrete implementation, the section of the cavity of the complex casting has larger change, and the smooth filling of metal is affected. According to the results of the influence rule of the cross-section structure on the filling flow behavior, the filling speed design principle of castings with different structures and the like, a control system of a liquid level pressurizing process is designed to be in a form with a nonlinear pressurizing function, a speed inflection point can be preset by adopting human-computer interface software, when a variable cross-section signal is detected, the filling pressure is regulated according to a preset program, so that the molten metal is always filled in a laminar flow mode, and the entrainment of oxidized impurities is prevented; the key of the nonlinear pressurizing technology is detection of inflection points and selection of nonlinear pressurizing processes adopted for different interface change rates, wherein the speed inflection points can be detected by a liquid level contact point embedded in the casting mold in advance, and the nonlinear pressurizing processes need to be set preliminarily according to previous experience and principles.
In a specific implementation example, as shown in fig. 1, after the control system detects that the tank locking ring is locked in place, a start button is pressed, a PLC is used as a controller, the PLC starts to initialize each zone bit of the control system, process parameters preset by an upper computer are collected, and corresponding pressure difference target values are given through step-by-step calculation of process curve target value program blocks. The method comprises the steps of collecting a real-time pressure value of a pressure sensor through an analog quantity collection module, comparing a difference value of a pressure target value and an actual pressure process value, inputting the difference value into a tracking control program, analyzing an output value obtained through calculation of a tracking control algorithm, converting the output value into a corresponding switch action of a digital combination valve, pressurizing the inside of a casting equipment tank body, achieving tracking control of the pressure difference target value until the processes of liquid lifting, filling, crust formation pressurization, crystallization pressurization and crystallization pressurization are all completed according to set process parameters, and jumping out of the main control program to complete casting operation.
In one possible implementation mode, the inflection point of the casting filling speed is obtained by embedding a plurality of liquid level detection contacts in the casting cavity in advance, and the liquid level detection contacts are positioned at the section change position of the casting cavity.
In a second aspect, the embodiment provides a nonlinear pressurization control system for casting and forming a complex metal member, which comprises a casting mold-filling speed inflection point acquisition module, a control parameter setting module, a program generation module, a data uploading module, a ring locking detection module, an initialization module, a metal member determination module, a program acquisition module, a process parameter acquisition module, a pressure difference target value calculation module, a pressure value acquisition module, a pressure tracking analysis module and a digital combination valve control module;
the casting mold filling speed inflection point acquisition module is used for acquiring casting mold filling speed inflection points in each technological process of casting and forming of the metal component;
the control parameter setting module is used for presetting control parameters aiming at different interface change rates in the nonlinear pressurizing process according to the inflection point of the casting mold filling speed;
the program generation module is used for acquiring a plurality of groups of control parameters of the nonlinear pressurizing process aiming at different interface change rates, acquiring optimal control parameters from the control parameters, forming a nonlinear pressurizing process preset control program according to the optimal control parameters, and then transmitting the nonlinear pressurizing process preset control program and the corresponding optimal control parameters to the data uploading module;
the data uploading module is used for uploading a preset control program and corresponding optimal control parameters to the upper computer for standby;
the ring locking detection module is used for detecting whether the locking ring of the tank body is locked in place or not, and starting pressure control;
the initialization module is used for initializing each zone bit after the tank locking ring is locked in place;
the metal component determining module is used for determining the type of the metal component to be cast and transmitting the type of the metal component to be cast to the program collecting module;
the program acquisition module is used for acquiring a corresponding preset nonlinear pressurization process preset control program and a corresponding optimal control parameter in the upper computer according to the type of the metal member to be cast;
the process parameter acquisition module is used for acquiring the process parameters of the current casting cavity and transmitting the process parameters of the current casting cavity to the pressure difference target value calculation module;
the pressure difference target value calculation module is used for calculating the target value of the process curve step by step according to the process parameters of the current casting cavity, giving out a corresponding pressure difference target value according to the nonlinear pressurization process preset control program and the corresponding optimal control parameters, and transmitting the pressure difference target value to the pressure tracking analysis module;
the pressure value acquisition module is used for acquiring the real-time pressure value of the current casting cavity and transmitting the real-time pressure value of the current casting cavity to the pressure tracking analysis module;
the pressure tracking analysis module is used for comparing the pressure difference target value with the current real-time pressure value of the casting cavity to obtain a difference value between the pressure difference target value and the actual pressure process value, tracking and controlling the difference value, analyzing the output value through an output value obtained by calculation of a tracking control algorithm, acquiring digital combination valve control information according to the nonlinear pressurization process preset control program and the corresponding optimal control parameter, and transmitting the digital combination valve control information to the digital combination valve control module;
the digital combined valve control module is used for controlling corresponding switching actions of the digital combined valve according to the digital combined valve control information; and (3) finishing control until all the technological processes of the metal component to be cast are finished, and finishing pouring.
In one possible implementation mode, the casting mold filling speed inflection point acquisition module is characterized in that a plurality of liquid level detection contacts are embedded in the casting cavity in advance, and the liquid level detection contacts are positioned at the section change position of the casting cavity.
In one possible embodiment, as shown in fig. 2, the high-pressure gas tank 7 is included, the high-pressure gas tank is communicated with a gas inlet valve 5 through a pipeline, the gas inlet valve is communicated with a first digital combination valve 2 and a second digital combination valve 4 at the same time, the first digital combination valve is communicated with an upper cavity 11 of a metal member casting tank body through a pipeline 3, and the second digital combination valve is communicated with a lower cavity 12 of the metal member casting tank body; an exhaust valve 1 is arranged between the air inlet valve and the first digital combination valve; a first intercommunication valve 6 is connected between one end of the first digital combination valve communicated metal member casting tank body and one end of the second digital combination valve communicated metal member casting tank body; the upper cavity of the metal member casting tank body is communicated with a first vacuum valve 14 through a pipeline, the lower cavity of the metal member casting tank body is communicated with a second vacuum valve 15 through a pipeline, and one ends of the first vacuum valve and the second vacuum valve, which are far away from the metal member casting tank body, are connected with a gas recovery tank 16; the gas recovery tank is provided with a vacuum pump 17; a second communicating valve 13 is communicated between one ends of the first vacuum valve and the second vacuum valve, which are close to the metal member casting tank body; the air inlet valve, the first digital combination valve, the second digital combination valve, the air outlet valve, the first communicating valve, the second communicating valve, the first vacuum valve, the second vacuum valve and the vacuum pump are electrically connected with the control cabinet 8. By controlling the opening of each valve, the inflation and the exhaust of the working cabin (the upper cavity of the casting tank) and the lower tank body in the casting process are realized, and the casting mold filling speed and the environmental pressure during solidification are controlled.
In a specific example, turbulence is easy to occur at abrupt change positions of the cross section of a cavity of a complex component, nonlinear liquid level pressurization control is adopted to ensure stable filling of the melt, a speed inflection point can be preset by control software, and when a variable cross section signal is detected, the filling pressure is regulated according to a preset program, so that the melt is always filled in a laminar flow mode, and the entrainment of oxide inclusions is prevented. The working pressure of the multi-field pressurizing casting machine is 0.6MPa, the volume of the working cabin is 30m3, and the volume of the lower tank is 20m3. In the non-linear liquid level pressurizing process, the upper tank and the lower tank respectively adopt independent digital combination valves and independent vacuum valves, namely the first digital combination valve and the second digital combination valve, and the first vacuum valve and the second vacuum valve, so that the functions of synchronous pressure establishment, upper tank exhaust, lower tank pressure maintaining and the like are realized. The gas at the gas inlet end is clean, the gas inlet valve adopts a digital valve group, the reaction speed is high, and the control is accurate; the exhaust end has a large amount of gas dust and dust pollution, so that the exhaust valve adopts a corrosion-resistant ball valve structure. In order to improve corrosion resistance, the valve body and the pipeline are made of copper valve cores or stainless steel materials; the mounting cabinet of control valve sets up to airtight structure to establish the passageway of taking a breath, guarantee to keep the malleation environment in the control cabinet, have fresh air to go into all the time, prevent that foundry environment atmosphere from getting into in the control cabinet, corrode valve body and sensor.
Specifically, the exhaust valve is communicated with a gas impurity removing device. Avoiding the pollution of exhaust dust.
Specifically, the high-pressure gas tank stores inert gas, and the inert gas is argon.
The nonlinear pressurization control method and system mainly uses a signal contact pre-buried in a cavity, simultaneously uses a plurality of groups of sensors to monitor the pressure in the heat preservation furnace and the working cabin, and uses pressurization or pressure relief to precisely control the air pressure in the heat preservation furnace and the working cabin, thereby controlling the casting mold filling speed and the environmental pressure during solidification.
Advantages are: the pressurizing process of the liquid level can adjust the filling pressure according to a preset program, so that the molten metal is always filled in a laminar flow mode, and the problems of irregular filling, serious gas coiling and the like caused by large section change of a complex casting cavity are effectively avoided.
Finally, it should be noted that: the foregoing description is only of the preferred embodiments of the invention and is not intended to limit the scope of the invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. A nonlinear pressurization control method for casting and forming a complex metal member is characterized by comprising the following steps:
generating a nonlinear pressurization process preset control program and corresponding optimal control parameters:
presetting control parameters for different interface change rates in the nonlinear pressurizing process according to inflection points of casting mold filling speed aiming at each process of casting molding of various specific metal components;
acquiring a plurality of groups of control parameters of the nonlinear pressurizing process aiming at different interface change rates, and acquiring optimal control parameters; forming a nonlinear pressurization process preset control program according to the optimal control parameters; uploading a nonlinear pressurization process preset control program and corresponding optimal control parameters to an upper computer for standby;
when a casting cavity section change signal is detected in the casting process, the mold filling pressure is regulated according to the nonlinear pressurizing process preset control program and the corresponding optimal control parameters;
and carrying out metal component casting by adopting the generated nonlinear pressurization process preset control program and the corresponding optimal control parameters:
after detecting that the tank locking ring is locked in place, starting pressure control;
initializing each zone bit, determining the type of the metal component to be cast, and collecting a corresponding preset nonlinear pressurizing process preset control program and a corresponding optimal control parameter in an upper computer according to the type of the metal component to be cast;
acquiring current casting cavity process parameters, calculating a process curve target value step by step, and giving a corresponding pressure difference target value according to the nonlinear pressurization process preset control program and a corresponding optimal control parameter;
acquiring a real-time pressure value of a current casting cavity, comparing the acquired difference value of a pressure difference target value and an actual pressure process value, tracking and controlling the difference value, analyzing an output value acquired through calculation of a tracking and controlling a digital combination valve according to a nonlinear pressurization process preset control program and a corresponding optimal control parameter, and pressurizing the casting equipment tank body to achieve tracking and controlling of the pressure difference target value;
and (5) ending the control and completing the pouring until each technological process of the metal component to be cast is judged to be completed.
2. The nonlinear pressurization control method for casting forming of the complex metal member according to claim 1, wherein the inflection point of the casting filling speed is determined by embedding a plurality of liquid level detection contacts in the casting cavity in advance, and the liquid level detection contacts are positioned at the section change of the casting cavity.
3. The nonlinear pressurization control method for casting forming of a complex metal member according to claim 1, wherein each process of the metal member to be cast includes a liquid lifting process, a mold filling process, a crust pressurizing process, a crystallization pressurizing process and a crystallization pressurizing process.
4. The nonlinear pressurization control system for casting and forming the complex metal component is characterized by comprising a casting mold filling speed inflection point acquisition module, a control parameter setting module, a program generation module, a data uploading module, a ring locking detection module, an initialization module, a metal component determination module, a program acquisition module, a process parameter acquisition module, a pressure difference target value calculation module, a pressure value acquisition module, a pressure tracking analysis module and a digital combination valve control module;
the casting mold filling speed inflection point acquisition module is used for acquiring casting mold filling speed inflection points in each technological process of casting and forming of the metal component;
the control parameter setting module is used for presetting control parameters aiming at different interface change rates in the nonlinear pressurizing process according to the inflection point of the casting mold filling speed;
the program generation module is used for acquiring a plurality of groups of control parameters of the nonlinear pressurizing process aiming at different interface change rates, acquiring optimal control parameters from the control parameters, forming a nonlinear pressurizing process preset control program according to the optimal control parameters, and then transmitting the nonlinear pressurizing process preset control program and the corresponding optimal control parameters to the data uploading module;
the data uploading module is used for uploading a preset control program and corresponding optimal control parameters to the upper computer for standby;
the ring locking detection module is used for detecting whether the locking ring of the tank body is locked in place or not, and starting pressure control;
the initialization module is used for initializing each zone bit after the tank locking ring is locked in place;
the metal component determining module is used for determining the type of the metal component to be cast and transmitting the type of the metal component to be cast to the program collecting module;
the program acquisition module is used for acquiring a corresponding preset nonlinear pressurization process preset control program and a corresponding optimal control parameter in the upper computer according to the type of the metal member to be cast;
the process parameter acquisition module is used for acquiring the process parameters of the current casting cavity and transmitting the process parameters of the current casting cavity to the pressure difference target value calculation module;
the pressure difference target value calculation module is used for calculating the target value of the process curve step by step according to the process parameters of the current casting cavity, giving out a corresponding pressure difference target value according to the nonlinear pressurization process preset control program and the corresponding optimal control parameters, and transmitting the pressure difference target value to the pressure tracking analysis module;
the pressure value acquisition module is used for acquiring the real-time pressure value of the current casting cavity and transmitting the real-time pressure value of the current casting cavity to the pressure tracking analysis module;
the pressure tracking analysis module is used for comparing the pressure difference target value with the current real-time pressure value of the casting cavity to obtain a difference value between the pressure difference target value and the actual pressure process value, tracking and controlling the difference value, analyzing the output value through an output value obtained by calculation of a tracking control algorithm, acquiring digital combination valve control information according to the nonlinear pressurization process preset control program and the corresponding optimal control parameter, and transmitting the digital combination valve control information to the digital combination valve control module;
the digital combined valve control module is used for controlling corresponding switching actions of the digital combined valve according to the digital combined valve control information; and (3) finishing control until all the technological processes of the metal component to be cast are finished, and finishing pouring.
5. The nonlinear pressurization control system for casting forming of the complex metal component according to claim 4, wherein the casting filling speed inflection point acquisition module is characterized in that a plurality of liquid level detection contacts are embedded in the casting cavity in advance, and the liquid level detection contacts are positioned at the section change position of the casting cavity.
6. The nonlinear pressurization control system for casting and forming a complex metal member according to claim 4, comprising a high-pressure gas tank, wherein the high-pressure gas tank is communicated with an air inlet valve through a pipeline, the air inlet valve is simultaneously communicated with a first digital combination valve and a second digital combination valve, the first digital combination valve is communicated with an upper cavity of a metal member casting tank body through a pipeline, and the second digital combination valve is communicated with a lower cavity of the metal member casting tank body; an exhaust valve is arranged between the air inlet valve and the first digital combination valve; a first communicating valve is connected between one end of the first digital combination valve communicated metal member casting tank body and one end of the second digital combination valve communicated metal member casting tank body; the upper cavity of the metal member casting tank body is communicated with a first vacuum valve through a pipeline, the lower cavity of the metal member casting tank body is communicated with a second vacuum valve through a pipeline, and one ends of the first vacuum valve and the second vacuum valve, which are far away from the metal member casting tank body, are connected with a gas recovery tank; the gas recovery tank is provided with a vacuum pump; a second communicating valve is communicated between one ends of the first vacuum valve and the second vacuum valve, which are close to the metal member casting tank body; the air inlet valve, the first digital combination valve, the second digital combination valve, the air outlet valve, the first communicating valve, the second communicating valve, the first vacuum valve, the second vacuum valve and the vacuum pump are electrically connected with the control cabinet.
7. The nonlinear pressurization control system for casting forming of a complex metal member according to claim 6, wherein the exhaust valve is a spherical valve.
8. The nonlinear pressurization control system for casting forming of complex metal members according to claim 6, wherein the exhaust valve is in communication with a gas impurity removal device.
9. The nonlinear pressurization control system for casting forming of complex metal members according to claim 6, wherein the installation cabinet of the control valve is provided in a closed structure, and a ventilation passage is provided, and a positive pressure environment is maintained in the control cabinet.
10. The nonlinear pressurization control system for casting forming of a complex metal member according to claim 6, wherein the high-pressure gas tank stores an inert gas, and the inert gas is argon.
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| CN113434984A (en) * | 2021-07-08 | 2021-09-24 | 上海交通大学 | Method and device for adjusting filling stage, electronic equipment and storage medium |
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| JPH05228604A (en) * | 1992-02-17 | 1993-09-07 | Isuzu Seisakusho:Kk | Suction pressurized casting apparatus |
| EP1481748A1 (en) * | 2003-05-28 | 2004-12-01 | Bayerische Motoren Werke Aktiengesellschaft | Apparatus and process for casting metal |
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