CN115401173B - Aluminum wheel casting molding process acquisition system and process characterization method - Google Patents
Aluminum wheel casting molding process acquisition system and process characterization method Download PDFInfo
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- CN115401173B CN115401173B CN202211361541.8A CN202211361541A CN115401173B CN 115401173 B CN115401173 B CN 115401173B CN 202211361541 A CN202211361541 A CN 202211361541A CN 115401173 B CN115401173 B CN 115401173B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D2/00—Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/08—Controlling, supervising, e.g. for safety reasons
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
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Abstract
The invention relates to the technical field of wheel casting, in particular to an aluminum wheel casting molding process acquisition system and a process characterization method, wherein the acquisition system comprises the following components: the invention continuously collects the temperature of a plurality of key positions of the mould, the opening and closing signals of a cooling pipeline, the pressure of a casting hearth, the opening and closing signals of casting equipment, the casting process and the time related data information according to fixed frequency, stores the data of the same wheel production process, and establishes a process diagram of the casting forming process of the aluminum wheel with the time as a unified measure. The invention solves the technical problem that the low-pressure casting process of the aluminum wheel cannot be visually characterized, carries out digital accurate description on the low-pressure casting process of the aluminum wheel, provides a quantification basis for casting process adjustment, greatly simplifies the casting process optimization process and improves the casting process optimization efficiency.
Description
Technical Field
The invention relates to the technical field of wheel casting, in particular to a process acquisition system and a process characterization method for casting and forming of aluminum wheels.
Background
In the production of automobile parts, the casting of aluminum wheels is the most critical ring, the aluminum wheels are directly hooked with the safety of automobiles, and the aluminum wheels have multiple casting process parameters and multiple factors influencing the stability of the casting process because of various product models, so that the influence of the factors on the casting process is intuitively represented, and the timely adjustment of the process or the waste treatment is necessary.
Chinese patent publication No. CN109128131a discloses a detection alarm device for casting mould, including first temperature sensor, second temperature sensor, signal conditioning module, central processing unit, alarm module, timing module and display module, first temperature sensor is used for gathering the temperature signal in the mould, second temperature sensor is used for adopting the temperature signal outside the mould, first temperature sensor and second temperature sensor are all connected with central processing unit through signal conditioning module, alarm module, timing module and display module all are connected with central processing unit respectively. The device can detect the internal and external temperatures in the casting mold and send out an alarm at regular time.
In the prior art, most of temperature collection of the die in the casting process is timed collection, a casting time node is set to collect the temperature in the casting process, then data analysis is carried out on the temperature collected by the time node, and the collection process is not continuous enough. Under the condition that the direct association relation between the temperature of the die and the casting process cannot be intuitively represented, the casting process can be adjusted manually only by experience subjectively, and the conditions of long adjustment time and increased waste are easily caused.
Aiming at the problem that the casting forming process of the aluminum wheel cannot be visually represented in the related technology, no effective solution is found at present.
Disclosure of Invention
Therefore, the invention provides a process acquisition system and a process characterization method for casting and forming aluminum wheels, which are used for solving the problem that the casting and forming process of the aluminum wheels cannot be intuitively characterized in the prior art.
In order to achieve the above purpose, the invention provides a collecting system for a casting and molding process of an aluminum wheel, comprising:
casting a wheel mold, wherein a temperature acquisition position is arranged on the wheel mold;
the communication acquisition module acquires a plurality of position temperatures of a casting wheel mold, a cooling pipeline opening and closing signal, a casting equipment opening and closing signal, a casting process and recording time of a casting process of a target wheel according to fixed frequency through communication between an industrial Ethernet and a casting equipment PLC, wherein the plurality of position temperatures of the mold comprise temperatures of a top mold, a bottom mold and a plurality of key hot or cold joint positions of a side mold;
The storage module is connected with the communication acquisition module and used for storing the data acquired by the communication acquisition module; the storage module is used for storing the acquired data in a database according to the casting process of the single wheel by using a unique ID (identity) based on the acquired mold opening and closing signals of the casting equipment so as to search all casting process data of the single wheel;
the processing module is respectively connected with the communication acquisition module and the storage module and is used for processing acquired data;
and the input and output module is connected with the processing module and used for displaying the data information processed by the processing module.
Further, the casting wheel mold locations include: the device comprises a top die flange position, a top die spoke middle position, a bottom die riser position, a bottom die spoke and rim transition position, a side die outer rim position and a side die inner rim position, wherein a thermocouple is arranged at each position and used for temperature acquisition.
Further, the processing module calculates temperature control parameters based on the collected temperature data and the time process to form a temperature control process for precisely controlling the casting process.
Further, the thermocouple arranged at the flange position of the top die is a first thermocouple, the thermocouple arranged at the middle position of the spoke of the top die is a second thermocouple, the thermocouple arranged at the inner rim position of the side die is a third thermocouple, the thermocouple arranged at the outer rim position of the side die is a fourth thermocouple, the thermocouple arranged at the riser position of the bottom die is a fifth thermocouple, and the thermocouple arranged at the transition position of the spoke of the bottom die and the rim is a sixth thermocouple.
Further, the lower end face of the fourth thermocouple hole positioned at the outer rim position of the side die is overlapped with the horizontal line of the end point of the R angle of the wheel well; the inner rim of the side die is positioned at the inner rim of the side die, and the upper end face of the third thermocouple hole is overlapped with the horizontal line of the end point of the R angle of the inner rim of the side die;
if the distance between the lower end face of the thermocouple and the machining reference surface is a non-integer value, rounding and rounding are adopted.
Further, a demoulding ejector rod hole is formed in the position of the top mould flange, and the first thermocouple is arranged in the demoulding ejector rod hole;
the middle position of the top die spoke is positioned at the outer side of the T4 cooling channel, the middle positions of two side walls of the material drawing pit are arranged, and the distance between the center line of the second thermocouple hole and the center line of the T4 cooling channel air pipe is 15mm-20mm.
Further, the distance between each thermocouple hole bottom and the die cavity surface is 3-7mm from the nearest point of the circular arc ends of all thermocouple hole bottoms to the die cavity surface, and all distances are the same on one set of die; the bottom of each thermocouple hole is hemispherical, the diameter is 4mm-6mm, the top end is a hollow cylinder, and the diameter and the size are the same as those of the hole bottom.
The invention also provides a characterization method of the casting and forming process of the aluminum wheel, which adopts the acquisition system of the casting and forming process of the aluminum wheel and comprises the following steps:
Step 1, continuously acquiring related data information of a plurality of key position temperatures, cooling pipeline opening and closing signals, casting hearth pressure, casting equipment opening and closing signals, casting process and time of a mold in the wheel casting process through an upper computer system according to fixed frequency;
step 2, based on the acquired mold opening and closing signals of the casting equipment, slicing continuously acquired data by taking a single wheel as a unit, and uniformly assigning the data in the same wheel production process with a unique ID (identity) for storage;
step 3, carrying out data retrieval on a single wheel production process, sequencing the acquired temperatures of key positions of each die according to the acquisition time sequence, and then carrying out time sequence-based temperature data noise reduction by using a moving window method;
step 4, establishing a multidimensional matrix based on the processed temperature and the corresponding acquisition time, and obtaining a temperature variation corresponding to the acquisition time through matrix transformation;
and 5, establishing a casting forming process diagram of the aluminum wheel with the same ID and the single wheel with the time as a unified measure.
Further, the cooling pipeline switching signal, the casting furnace pressure, the casting equipment die opening and closing signal, the upper computer system for the collection application of casting technology establishes connection with the casting equipment PLC through the industrial Ethernet to collect, and the data information content of the collection includes: the cooling pipeline opening and closing signals correspond to point position opening and closing Boolean values, the casting furnace pressure corresponds to point position numerical values, the casting equipment opening and closing mode signals correspond to point position Boolean values and the casting process corresponds to point position numerical values.
Further, in the step 5, the process diagram of the casting and molding process of the aluminum wheel comprises the following steps:
a curve for characterizing the temperature of the mold at a critical location during the casting of aluminum wheels;
a bar graph image for representing the opening and closing interval of a mold cooling pipeline in the aluminum wheel casting process;
a hearth pressure process node line for representing the casting process of the aluminum wheel;
a curve for representing the temperature variation of the mold in the casting process of the aluminum wheel and a heating auxiliary marking;
and the label is used for representing the action of equipment in the aluminum wheel casting process.
Furthermore, the acquired time data information is the system time of the upper computer, and is convenient for corresponding to the cooling pipeline opening and closing signals, the casting furnace pressure, the casting equipment opening and closing signals and the casting process acquired data.
After the die with the thermocouple is installed to the casting equipment, the thermocouple is connected to a temperature acquisition module of a Programmable Logic Controller (PLC) of the casting equipment through a thermocouple extension line.
Further, a communication acquisition module of the upper computer system is used for establishing connection with a casting device PLC through an industrial Ethernet, and acquiring a temperature value, a cooling pipeline opening and closing Boolean value, a casting furnace pressure value, a casting device opening and closing mold Boolean value and a casting process value of relevant PLC points according to a fixed frequency of 1-10 Hz.
Further, in the step 2, the stored casting process data of each wheel includes: collecting time, thermocouple temperature value at the time, casting furnace pressure at the time, cooling channel opening and closing Boolean value at the time, casting process and time.
In step 3, the stored temperature data is subjected to noise reduction processing according to the stored temperature data.
Further, carrying out data retrieval on the temperature data in a single wheel production process, and sequencing the acquired temperature and the temperature of each die key position according to time sequence;
further, the temperature data noise reduction based on the time sequence is carried out by a moving window method;
further, the temperature data after noise reduction processing is subjected to data storage according to the unique ID and the acquisition time in the step 2.
In step 4, the transform matrix process is as follows:
wherein t1 is the first detection time, x1 is the temperature data of the first detection time, t2 is the second detection time, x2 is the temperature data of the second detection time, tn is the nth detection time, xn is the temperature data of the nth detection time,
and then performing matrix transformation to finally obtain a temperature change matrix corresponding to the acquisition time:
Further, the abscissa range of the aluminum wheel casting process is the collection time range from the start of casting mold closing to the start of next casting mold closing of the single wheel.
The temperature curve used for representing the key positions of the mold in the aluminum wheel casting process is characterized in that the abscissa is the acquisition time, the ordinate is the temperature, the temperature value used by the curve is the temperature value processed in the step 3, and 6 temperature curves are formed at each key position of the mold independently.
Further, the temperature curve is formed by connecting data points formed by corresponding temperature values of each acquisition time with adjacent two points by using a straight line. Each temperature curve is illustrated.
The bar-shaped image used for representing the opening and closing interval of the cooling pipeline of the mold in the aluminum wheel casting process is characterized in that the abscissa is the acquisition time, each cooling pipeline forms a respective bar-shaped image, the opening time point and the closing time point of the cooling pipeline are taken, and the two time points are connected in a straight line along the direction of the parallel abscissa to form the bar-shaped image of the opening and closing interval of the cooling pipeline.
Further, each stick image is legged. Each legend position is in the vicinity of a corresponding stick image.
The hearth pressure change node line used for representing the casting process of the aluminum wheel is characterized in that the abscissa is the acquisition time, 5 time points of the pressure boost completion, the casting pressure completion, the boost pressure completion, the holding pressure completion and the pressure release die opening of the casting hearth are taken, and a plurality of straight lines penetrating through the whole casting forming process diagram of the aluminum wheel are formed along the direction vertical to the abscissa;
further, each pressure change node line has a legend, and each legend position is in the vicinity of the corresponding pressure change node line.
The curve for representing the temperature variation of the mold in the aluminum wheel casting process is characterized in that the abscissa is the acquisition time, the ordinate is the temperature variation, the temperature variation value used by the curve is the temperature variation value processed in the step 4, and each key position of the mold forms one total 6 temperature variation curves.
Further, the temperature change amount curve is formed by connecting data points formed by corresponding temperature change amount values of each acquisition time with adjacent two points by using straight lines. Each temperature variation curve is illustrated.
The auxiliary marking for representing the temperature rise of the mold in the aluminum wheel casting process is based on the temperature variation curve, and 1 straight line penetrating through the whole aluminum wheel casting forming process diagram is formed in parallel with the abscissa at the position of 0 ordinate.
The temperature curve used for representing the key position of the mold in the aluminum wheel casting process, the bar-shaped image used for representing the opening and closing interval of the cooling pipeline of the mold in the aluminum wheel casting process, the hearth pressure change node line used for representing the aluminum wheel casting process, the curve used for representing the temperature change of the mold in the aluminum wheel casting process and the heating auxiliary marking line, and the mark used for representing the action of equipment in the aluminum wheel casting process are all suitable for not covering other images and curves.
Further, based on the temperature curve representing the key position of the mold in the casting process of the aluminum wheel, the temperature condition of the position in the whole casting process can be represented by a single curve value, and the time-varying condition of the temperature field of the whole mold can be represented by a plurality of curves;
further, based on the bar graph images representing the opening and closing intervals of the mold cooling pipelines in the aluminum wheel casting process, the position relationship between each cooling bar graph image and the casting hearth pressure finishing and mold opening signals can represent the action condition of the cooling channel, and the relationship with the temperature curve near the cooling pipelines can represent the temperature influence effect of the cooling on the mold;
further, based on the curve for representing the temperature variation of the mold in the aluminum wheel casting process and the heating auxiliary marking, the intersection point of each temperature variation curve and the heating auxiliary marking in the region of the completion of pressurizing of the casting hearth and the completion of pressurizing of the casting hearth represents the time point of the aluminum liquid reaching the position of the mold, and particularly, the intersection point of the temperature variation curve of the inner rim of the side mold and the position of the relation between the temperature variation curve of the mold and the heating auxiliary marking represents the actual time point of the completion of casting and filling, and the comparison relation between the temperature variation curve and the temperature auxiliary marking and the completion of casting pressure of the casting hearth can provide guidance for optimizing the pressure process.
Compared with the prior art, the method has the beneficial effects that the method collects the temperatures of a plurality of positions of the die, the opening and closing signals of the cooling pipeline, the pressure of the casting hearth, the opening and closing signals of the casting equipment, the casting process and the time of the casting process of the target wheel according to the fixed frequency, wherein the temperatures of the plurality of positions of the die comprise the temperatures of a plurality of key hot joints or cold joint positions of a top die, a bottom die and a side die; based on the acquired mold opening and closing signals of the casting equipment, storing the acquired data in a database according to the casting process of the single wheel with a unique ID so as to search all casting process data of the single wheel; noise reduction processing is carried out on the acquired temperature data based on the acquired temperature data; establishing a multidimensional matrix based on the processed temperature and the corresponding acquisition time, and transforming the matrix to obtain the temperature variation under unit time; the casting process data and the processed data collected by the single wheel with the same ID are based on to establish a casting forming process diagram of the aluminum wheel with the time as a unified measure, so that the technical problem that the casting forming process of the aluminum wheel can not be visually characterized is solved, the low-pressure casting process of the aluminum wheel can be accurately described in a digitalized mode, a quantification basis for casting process adjustment is provided, the casting process optimization process is greatly simplified, and the casting process optimization efficiency is improved.
Drawings
FIG. 1 is a block diagram of a process collection system for casting aluminum wheels in accordance with an embodiment of the present invention;
FIG. 2 is a schematic view of a mold for casting a wheel in accordance with an embodiment of the present invention;
FIG. 3 is a flow chart of a method for characterizing a casting process of an aluminum wheel in accordance with an embodiment of the present invention;
FIG. 4 is a graph of the noise reduction effect of the model temperature data in an embodiment of the present invention;
FIG. 5 is a graph of the calculation result of the mold temperature variation and a graph of the mold temperature noise reduction data in an embodiment of the present invention;
fig. 6 is a diagram of a casting process of an aluminum wheel in accordance with an embodiment of the present invention.
Detailed Description
In order that the objects and advantages of the invention will become more apparent, the invention will be further described with reference to the following examples; it should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
Preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are merely for explaining the technical principles of the present invention, and are not intended to limit the scope of the present invention.
It should be noted that, in the description of the present invention, terms such as "upper," "lower," "left," "right," "inner," "outer," and the like indicate directions or positional relationships based on the directions or positional relationships shown in the drawings, which are merely for convenience of description, and do not indicate or imply that the apparatus or elements must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as limiting the present invention.
Furthermore, it should be noted that, in the description of the present invention, unless explicitly specified and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be either fixedly connected, detachably connected, or integrally connected, for example; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention can be understood by those skilled in the art according to the specific circumstances.
Referring to fig. 1-2, fig. 1 is a block diagram illustrating a collection system for a process of casting an aluminum wheel according to an embodiment of the present invention, and fig. 2 is a schematic diagram illustrating a structure of a mold for casting a wheel according to an embodiment of the present invention;
the invention provides an acquisition system for a casting molding process of an aluminum wheel, which comprises the following components:
casting a wheel mold, wherein a temperature acquisition position is arranged on the wheel mold;
the communication acquisition module 106 is used for acquiring a plurality of position temperatures of the casting wheel mold, a cooling pipeline opening and closing signal, a casting equipment opening and closing signal, a casting process and recording time in the casting process of the target wheel according to fixed frequency through communication between the industrial Ethernet and the casting equipment PLC, wherein the plurality of position temperatures of the mold comprise temperatures of a top mold, a bottom mold and a side mold of a plurality of key hot or cold joint positions;
The storage module 104 is connected with the communication acquisition module and is used for storing the data acquired by the communication acquisition module; the storage module is used for storing the acquired data in a database according to the casting process of the single wheel by using a unique ID (identity) based on the acquired mold opening and closing signals of the casting equipment so as to search all casting process data of the single wheel;
the processing module 102 is respectively connected with the communication acquisition module and the storage module and is used for processing the acquired data;
and the input/output module 108 is connected with the processing module and is used for displaying the data information processed by the processing module.
The storage module 104 may be used to store programs for operating a personal computer, such as software programs for application software and modules, such as an aluminum wheel casting process characterization system in an embodiment of the present invention, and the processing module 102 executes the programs stored in the storage module 104 to perform various functional applications and data processing, i.e., implement the above-described methods. The memory module 104 may include a high-speed random access memory module, and may also include a non-volatile memory module, such as one or more magnetic storage devices, flash memory, or other non-volatile solid-state memory. In some examples, the storage module 104 may further include a storage module remotely located relative to the processing module 102, which may be connected to a personal computer via a network. Examples of such networks include, but are not limited to, the internet, intranets, local area networks, mobile communication networks, and combinations thereof.
The communication acquisition module 106 is configured to receive or transmit data via a network. In one example, the communication acquisition module 106 includes a network adapter that can communicate with other network devices through a base station. In one example, the communication acquisition module 106 may be an ethernet module.
The plurality of temperature acquisition positions of the target wheel casting mold comprise temperatures of a plurality of key hot joint or cold joint positions of the top mold, the bottom mold and the side mold. The temperature acquisition of the temperatures of a plurality of key positions of the die is carried out by additionally arranging a temperature thermocouple at the corresponding position and connecting the thermocouple to a PLC temperature communication acquisition module of casting equipment for data acquisition. Referring to fig. 2, a schematic diagram of a mold for casting a wheel according to an embodiment of the present invention is shown, where a top mold 302, a bottom mold 304, and four side molds 306 form a complete mold structure for casting an aluminum wheel. The flange position 3021 and the spoke intermediate position 3022 of the top mold 302 are mold hot spot positions during casting, and thus thermocouples are added to the top mold flange position 3021 and the top mold spoke intermediate position 3022. The riser position of the bottom die 304 is a key position of a die for determining the completion of casting, and the root position of the spoke is a cold joint position of the die in the casting process, so that thermocouples are additionally arranged at the riser position 3041 of the bottom die and the transition position 3042 of the spoke and the rim of the bottom die. The inner rim position of the side mold 306 determines the filling mass and the outer rim position determines the rim mass, so thermocouples are added at the inner rim position 3061 and the outer rim position 3062 of the side mold. It will be appreciated by those of ordinary skill in the art that the configuration shown in fig. 2 is merely illustrative and is not intended to limit the configuration of the mold or the particular location of thermocouple placement described above. It will be appreciated by those skilled in the art that the cooling line open and close signals, the casting furnace pressure, the casting equipment open and close signals, the casting process, and the collection time may be different names in different factories, and different points may exist on different casting equipment PLCs, which do not limit the collected data.
Further, the lower end face of the fourth thermocouple hole positioned at the outer rim position of the side die is coincided with the horizontal line of the tail end point of the R angle 3072 of the wheel well; the inner rim of the side die is positioned at the inner rim of the side die, and the upper end face of the third thermocouple hole is overlapped with the horizontal line of the end point of the R angle 3071 of the inner rim of the side die;
if the distance between the lower end face of the thermocouple and the machining reference surface is a non-integer value, rounding and rounding are adopted.
Further, a demoulding ejector rod hole is formed in the position of the top mould flange, and the first thermocouple is arranged in the demoulding ejector rod hole;
the middle position of the top die spoke is positioned at the outer side of the T4 cooling channel, the middle position of two side walls of the material drawing nest is arranged, and the distance between the center line of the second thermocouple hole and the center line of the T4 cooling channel air pipe is 15mm-20mm.
Further, the distance between each thermocouple hole bottom and the die cavity surface is 3-7mm from the nearest point of the circular arc ends of all thermocouple hole bottoms to the die cavity surface, and all distances are the same on one set of die; the bottom of each thermocouple hole is hemispherical, the diameter is 4mm-6mm, the top end is a hollow cylinder, and the diameter and the size are the same as those of the hole bottom.
With continued reference to fig. 3, fig. 3 is a flowchart illustrating a process characterization method for casting and forming an aluminum wheel according to an embodiment of the present invention, where the process characterization method for casting and forming an aluminum wheel disclosed by the present invention includes:
Step 1, acquiring a plurality of position temperatures of a die, a die cooling pipeline opening and closing signal, a casting hearth pressure, a casting equipment opening and closing signal, a casting process and time of a target wheel casting process according to a fixed frequency of 1 Hz. In one implementation of this embodiment, the plurality of temperature acquisition locations of the target wheel casting mold includes temperatures of a plurality of critical hot or cold joint locations of the top mold, bottom mold, side mold. The temperature acquisition of the temperatures of a plurality of key positions of the die is carried out by additionally arranging a temperature thermocouple at the corresponding position and connecting the thermocouple to a PLC temperature communication acquisition module of casting equipment for data acquisition.
And 2, based on the acquired mold opening and closing signals of the casting equipment, storing the acquired data in a database with unique ID according to the casting process of the single wheel so as to facilitate searching. In one implementation of this embodiment, the data collected by the target wheel casting process is retrieved with "collect casting equipment number_clamp signal time" as the unique ID of the individual wheel.
And step 3, carrying out noise reduction treatment on the acquired temperature data of the key positions of the die. In one implementation manner of this embodiment, the temperature data of a certain mold position of a single wheel is obtained by searching the temperature data of a mold key position collected in the casting process of the target wheel, and is sorted according to the sequence of the collection time. And (3) carrying out time sequence-based temperature data noise reduction by adopting a moving window method, wherein the width of the moving window is set to be 5, the center of the window is set to be 3, and the closing condition of the end points of the window interval is controlled to be not closed. Referring to fig. 4, a mold Temperature data noise reduction effect diagram is shown, wherein Temperature is a top mold flange position Temperature data graph of a process of casting a wheel by a mold, the acquisition frequency is 1hz, temperature rolling is a Temperature data graph after noise reduction processing by a moving window method, and a pandas.dataframe.roll function of a pandas data processing packet is used for moving window processing, and a matplotlib.pyplot function of a matplotlib packet is used for image display. It will be appreciated by those skilled in the art that the above-described method of denoising temperature data is merely illustrative, and the programming language and function used are merely illustrative, and are not limited to the above-described method of denoising data.
And 4, establishing a multidimensional matrix based on the processed temperature and the corresponding acquisition time, and transforming the matrix to obtain the temperature variation corresponding to the acquisition time. In one implementation manner of this embodiment, after the noise reduction treatment is performed on the mold temperature data collected during the casting process of the target wheel, a multidimensional matrix is formed corresponding to the collection time, and the matrix is subjected to the following primary equivalent transformation:
and then performing matrix transformation to finally obtain a temperature change matrix corresponding to the acquisition time:
FIG. 5 is a graph of the calculation result of the mold temperature variation and the mold temperature noise reduction data in the embodiment of the present invention. Wherein Temperaturerolling is a temperature data curve 602 after noise reduction treatment by a moving window method, temperatureDerivative is a mold temperature variation curve 604 after matrix transformation, and the abscissa of the two curves can be unified by acquisition time. The intersection point 608 of the mold temperature change amount data curve and the mold temperature rising auxiliary marking is a characteristic point that the aluminum liquid reaches the temperature measuring position of the mold. It will be appreciated by those skilled in the art that the above-described method of calculating the temperature change amount is merely illustrative, and the method of calculating the temperature change amount is not limited thereto.
And 5, establishing an aluminum wheel casting forming process diagram taking the acquisition time as a unified measurement single abscissa based on the casting process data acquired by the single wheel with the same ID and the processed data. In one implementation mode of the embodiment, after the data acquired in the casting process of the target wheel is retrieved and processed, the data of the casting process of the wheel is obtained, the acquisition time is firstly established as a unified measurement abscissa, and then a curve for representing the temperature of a key position of a die in the casting process of the aluminum wheel, a bar graph image for representing the opening and closing interval of a cooling pipeline of the die in the casting process of the aluminum wheel, a hearth pressure process node line for representing the casting process of the aluminum wheel, a curve for representing the temperature variation of the die in the casting process of the aluminum wheel and a heating auxiliary marking line and a marking line for representing the action of equipment in the casting process of the aluminum wheel are drawn.
Referring to fig. 6, a process diagram of a casting process of an aluminum wheel according to an embodiment of the present invention is shown, wherein the 0s position is a mold closing signal 700 of the casting mold, which indicates that mold closing is completed, and the casting process of the wheel is started; casting hearth pressures 710-713 respectively represent 5 stages of pressurization completion (casting hearth pressurization completion 710), casting (casting hearth casting pressure completion 711), pressurization (casting hearth pressurization completion 712), pressure maintaining (casting hearth pressure completion 713) and pressure relief mold opening (mold opening signal 702) of the casting process;
The middle position temperature curve 720 of the top mold spoke, the inner rim position temperature curve 721 of the side mold, the riser position temperature curve 722 of the bottom mold, the transition position temperature curve 723 of the bottom mold spoke and the rim, the outer rim position temperature curve 724 of the side mold and the flange position temperature curve 725 of the top mold respectively represent the time-varying condition of the temperature of each key position on the mold, the temperature condition of the position in the whole casting process can be represented by a single curve value, and the time-varying condition of the temperature field of the whole mold can be represented by a plurality of curves;
the top mold split-flow cone water cooling opening section bar graph 730, the top mold flange air cooling opening section bar graph 731, the top mold inclined plane water cooling opening section bar graph 732, the top mold spoke middle air cooling opening section bar graph 733, the top mold spoke root air cooling opening section bar graph 734, the bottom mold vent air cooling opening section bar graph 735, the bottom mold spoke root air cooling opening section bar graph 736, and the side mold water cooling opening section bar graph 737 respectively represent the opening condition of each cooling pipeline on the mold, the abscissa value corresponding to the left end of the cooling bar graph image is the opening time point of the cooling pipeline, the abscissa value corresponding to the right end of the cooling bar graph image is the closing time point of the cooling pipeline, the cooling area bar graph length represents the opening time of the cooling pipeline, the text labels indicate the position and the cooling mode of the cooling pipeline, the positional relationship between the cooling pipeline and the casting hearth pressure maintaining pressure 713 and the mold opening signal 702 can represent the cooling action condition, and the temperature curve association near the cooling pipeline can represent the temperature influence effect of the mold;
In the process diagram of the casting and forming process of the aluminum wheel, temperature change amount curves of all monitoring positions are also displayed at the bottom, and the marked line 750 is a heating auxiliary marked line.
According to the embodiment, the upper computer system collects a plurality of data of the casting process of the target wheel according to the fixed frequency, casting process data collected by a single wheel with the same ID and processed data are used for establishing an aluminum wheel casting forming process diagram which takes time as a unified measure for representing the casting process, the technical problem that the low-pressure casting forming process of the aluminum wheel cannot be visually represented is solved, digital accurate description of the low-pressure casting process of the aluminum wheel is achieved, quantitative basis for casting process adjustment is provided, the casting process optimization process is greatly simplified, and the casting process optimization efficiency is improved.
From the description of the above embodiments, it will be clear to a person skilled in the art that the method according to the above embodiments may be implemented by means of a software system, but of course also by means of hardware, but in many cases the former is a preferred embodiment. With this understanding, the software system is stored in a storage medium, and includes instructions for causing an electronic device to perform the method according to the embodiments of the present invention.
The processing module of the characterization system of the casting and forming process of the aluminum wheel is provided with a top mold spoke middle position temperature standard curve function f (t 0), a side mold inner rim position temperature standard curve function f (t 1), a bottom mold riser position temperature standard curve function f (t 2), a bottom mold spoke and rim transition position temperature standard curve function f (t 3), a side mold outer rim position temperature standard curve function f (t 4) and a top mold flange position temperature standard curve function f (t 5), and the processing module respectively compares the acquired top mold spoke middle position temperature curve 720, side mold inner rim position temperature curve 721, bottom mold riser position temperature curve 722, bottom mold spoke and rim transition position temperature curve 723, side mold outer rim position temperature curve 724 and top mold flange position temperature curve 725 with corresponding standard curve functions, judges whether temperature deviation exists at each temperature acquisition position or not, and judges the quality of the low-pressure casting process according to the deviation.
When the temperature curve 72i is compared with the standard curve function f (ti), i=0, 1,2,3,4,5, the processing module selects any time tk corresponding to the temperature curve 72i and the standard curve function f (ti), the temperature value at the time tk in the temperature curve 72i is Pk, the temperature value at the time tk in the standard curve function f (ti) is Qk, the processing module calculates absolute values D, d= -Pk-Qk of differences between Pk and Qk, the processing module is provided with any time temperature difference evaluation value Dz, the processing module compares D with the temperature difference evaluation value Dz,
When D is less than or equal to Dz, the processing module judges that the temperature at the tk moment in the temperature curve 72i is in a normal interval;
when D > Dz, the processing module determines that the temperature at time tk in the temperature curve 72i is in the abnormal zone.
The processing module compares points at all times in the temperature curve 72i with the standard curve function f (ti) in the same way as the tk point temperature at any time.
When the temperature curve 72i has a time when the temperature is in the abnormal interval, the processing module integrates the time points in the abnormal interval, records the total abnormal temperature duration Ci of the temperature curve 72i, and for the total abnormal temperature duration evaluation parameter Cz set in the processing module of the temperature curve 72i, the processing module compares the total abnormal temperature duration Ci of the temperature curve 72i with the total abnormal temperature duration evaluation parameter Cz,
when Ci is less than or equal to Cz, the processing module judges that the abnormal temperature of the temperature curve 72i is in a reasonable range;
when Ci > Cz, the processing module determines that the abnormal temperature of the temperature curve 72i is in an unreasonable range, and the position corresponding to the temperature curve 72i may be at risk, and performs important quality detection.
When the temperature curve 72i does not exist at the time when the temperature is in the abnormal section, the processing module directly determines that the abnormal temperature of the temperature curve 72i is in a reasonable range.
When the values represented by the values of i in the temperature curve 72i are different, the value of the temperature difference evaluation value Dz is different from the value of the abnormal temperature total duration evaluation parameter Cz.
When the processing module determines that the abnormal temperature of the temperature curve 72i is within a reasonable range, the processing module calculates a similar deviation value Ei of the temperature curve 72i from the standard curve function f (ti),
wherein T is the monitoring time of the temperature curve 72i, the processing module is provided with a similar deviation value evaluation parameter Ez, the processing module compares the similar deviation value Ei with the similar deviation value evaluation parameter Ez,
when Ei is less than or equal to Ez, the processing module judges that the similar deviation value of the judging temperature curve 72i is in a reasonable range;
when Ei > Ez, the processing module determines that the similar deviation value of the temperature curve 72i is in an unreasonable range, and the position corresponding to the temperature curve 72i may have a risk, and performs the key quality detection.
By internally setting a standard curve function, whether the temperature change condition of each monitoring point is in a reasonable range or not is obtained, the quality of the produced product can be judged in advance, the later detection pressure is reduced, and the production flow is accelerated.
The processing module compares the acquired middle position temperature curve 720 of the spoke of the top die, the inner rim position temperature curve 721 of the side die, the riser position temperature curve 722 of the bottom die, the transition position temperature curve 723 of the spoke and the rim of the bottom die, the outer rim position temperature curve 724 of the side die and the flange position temperature curve 725 of the top die with the corresponding standard curve functions, integrates the total abnormal temperature duration and the similar deviation values of the curves, calculates the casting process score M of the single wheel after integration,
Wherein ai is a calculated compensation parameter of the total abnormal temperature duration Ci on the casting process score, bi is a calculated compensation parameter of a similar deviation value Ei on the casting process score, and when the values represented by i values are different, the ai and bi values are different, the calculated compensation parameter has two functions, namely, left and right dimension of a balance equation and the adjustment of a calculation result.
The processing module is internally provided with a first preset casting process scoring parameter M1 and a second preset casting process scoring parameter M2, the processing module compares the casting process scoring M with the first preset casting process scoring parameter M1 and the second preset casting process scoring parameter M2 respectively,
when M is less than or equal to M1, the processing module judges the corresponding wheel quality as a first grade;
when M1 is more than M and less than or equal to M2, the processing module judges that the corresponding wheel mass is of a second grade;
when M is more than M2, the processing module judges that the corresponding wheel quality is three-level;
the important attention is different when detecting wheels of different grades, the smaller the number of the grades is, the higher the quality of the casting process is, and the later quality detection can be put into less effort; the larger the number of stages, the lower the quality of the casting process, and the greater effort required for later quality detection.
The quality of the produced product can be judged in advance by calculating the score of the casting process, the later detection pressure is reduced, and the production flow is quickened.
Thus far, the technical solution of the present invention has been described in connection with the preferred embodiments shown in the drawings, but it is easily understood by those skilled in the art that the scope of protection of the present invention is not limited to these specific embodiments. Equivalent modifications and substitutions for related technical features may be made by those skilled in the art without departing from the principles of the present invention, and such modifications and substitutions will be within the scope of the present invention.
Claims (5)
1. The utility model provides an aluminium wheel casting forming technology process collection system which characterized in that includes:
casting a wheel mold, wherein a temperature acquisition position is arranged on the wheel mold;
the communication acquisition module acquires a plurality of position temperatures of a casting wheel mold, a cooling pipeline opening and closing signal, a casting equipment opening and closing signal, a casting process and recording time of a casting process of a target wheel according to fixed frequency through communication between an industrial Ethernet and a casting equipment PLC, wherein the plurality of position temperatures of the mold comprise temperatures of a top mold, a bottom mold and a plurality of key hot or cold joint positions of a side mold;
The storage module is connected with the communication acquisition module and used for storing the data acquired by the communication acquisition module; the storage module is used for storing the acquired data in a database according to the casting process of the single wheel by using a unique ID (identity) based on the acquired mold opening and closing signals of the casting equipment so as to search all casting process data of the single wheel;
the processing module is respectively connected with the communication acquisition module and the storage module and is used for processing acquired data;
the input/output module is connected with the processing module and used for displaying the data information processed by the processing module;
the wheel casting mold comprises a top mold flange position, a top mold spoke middle position, a bottom mold riser position, a spoke and rim transition position, a side mold outer rim position and a side mold inner rim position, wherein a thermocouple is respectively arranged at each position and used for temperature acquisition;
the processing module calculates temperature control parameters based on the acquired temperature data and time process to form a temperature control process for accurately controlling the casting process;
the processing module is provided with a top mold spoke middle position temperature standard curve function f (t 0), a side mold inner rim position temperature standard curve function f (t 1), a bottom mold riser position temperature standard curve function f (t 2), a bottom mold spoke and rim transition position temperature standard curve function f (t 3), a side mold outer rim position temperature standard curve function f (t 4) and a top mold flange position temperature standard curve function f (t 5), and the processing module respectively compares the acquired top mold spoke middle position temperature curve 720, side mold inner rim position temperature curve 721, bottom mold riser position temperature curve 722, bottom mold spoke and rim transition position temperature curve 723, side mold outer rim position temperature curve 724 and top mold flange position temperature curve 725 with corresponding standard curve functions, judges whether temperature deviation exists at each temperature acquisition position, and judges the quality of the low-pressure casting process according to the deviation;
When the temperature curve 72i is compared with the standard curve function f (ti), i=0, 1,2,3,4,5, the processing module selects any time tk corresponding to the temperature curve 72i and the standard curve function f (ti), the temperature value at the tk time in the temperature curve 72i is Pk, the temperature value at the tk time in the standard curve function f (ti) is Qk, the processing module calculates absolute values D, d= -Pk-Qk of differences between Pk and Qk, the processing module is provided with any time temperature difference evaluation value Dz, the processing module compares D with the temperature difference evaluation value Dz,
when D is less than or equal to Dz, the processing module judges that the temperature at the tk moment in the temperature curve 72i is in a normal interval;
when D > Dz, the processing module judges that the temperature at the tk moment in the temperature curve 72i is in an abnormal interval;
the processing module compares points at all moments in the temperature curve 72i with a standard curve function f (ti), and the comparison method is the same as the method for comparing temperatures at tk points at any moment;
when the temperature curve 72i has a time when the temperature is in the abnormal interval, the processing module integrates the time points in the abnormal interval, records the total abnormal temperature duration Ci of the temperature curve 72i, and for the total abnormal temperature duration evaluation parameter Cz set in the processing module of the temperature curve 72i, the processing module compares the total abnormal temperature duration Ci of the temperature curve 72i with the total abnormal temperature duration evaluation parameter Cz,
When Ci is less than or equal to Cz, the processing module judges that the abnormal temperature of the temperature curve 72i is in a reasonable range;
when Ci is larger than Cz, the processing module judges that the abnormal temperature of the temperature curve 72i is in an unreasonable range, and the position corresponding to the temperature curve 72i possibly has risks, and performs key quality detection on the abnormal temperature;
when the temperature curve 72i does not exist at the moment that the temperature is in the abnormal interval, the processing module directly judges that the abnormal temperature of the temperature curve 72i is in a reasonable range;
when the values represented by the i values in the temperature curve 72i are different, the values of the temperature difference evaluation value Dz and the abnormal temperature total duration evaluation parameter Cz are different;
when the processing module determines that the abnormal temperature of the temperature curve 72i is within a reasonable range, the processing module calculates a similar deviation value Ei of the temperature curve 72i from the standard curve function f (ti),
wherein T is the monitoring time of the temperature curve 72i, the processing module is provided with a similar deviation value evaluation parameter Ez, the processing module compares the similar deviation value Ei with the similar deviation value evaluation parameter Ez,
when Ei is less than or equal to Ez, the processing module judges that the similar deviation value of the temperature curve 72i is in a reasonable range;
when Ei > Ez, the processing module judges that the similar deviation value of the temperature curve 72i is in an unreasonable range, and the position corresponding to the temperature curve 72i possibly has risks, and performs key quality detection;
The thermocouples arranged at the flange positions of the top die are first thermocouples, the thermocouples arranged at the middle positions of the spokes of the top die are second thermocouples, the thermocouples arranged at the inner rim positions of the side die are third thermocouples, the thermocouples arranged at the outer rim positions of the side die are fourth thermocouples, the thermocouples arranged at the riser positions of the bottom die are fifth thermocouples, and the thermocouples arranged at the transition positions of the spokes of the bottom die and the rim are sixth thermocouples;
the lower end surface of the fourth thermocouple hole positioned at the outer rim position of the side die is overlapped with the horizontal line of the end point of the R angle of the wheel well; the inner rim of the side die is positioned at the inner rim of the side die, and the upper end face of the third thermocouple hole is overlapped with the horizontal line of the end point of the R angle of the inner rim of the side die;
if the distance between the lower end surface of the thermocouple and the machining reference surface is a non-integer value, rounding is adopted;
the top die flange is provided with a demoulding ejector rod hole, and the first thermocouple is arranged in the demoulding ejector rod hole;
the middle position of the top die spoke is positioned at the outer side of the T4 cooling channel, the middle positions of two side walls of the material drawing pit are arranged, and the distance between the center line of the second thermocouple hole and the center line of the T4 cooling channel air pipe is 15mm-20mm.
2. The aluminum wheel casting process collection system according to claim 1, wherein the distance between each thermocouple hole bottom and the die cavity surface is 3-7mm from the nearest point of the circular arc end of all thermocouple hole bottoms to the die cavity surface, and all distances are the same on one die; the bottom of each thermocouple hole is hemispherical, the diameter is 4mm-6mm, the top end is a hollow cylinder, and the diameter and the size are the same as those of the hole bottom.
3. A method for characterizing a casting process of an aluminum wheel, which adopts the collecting system for the casting process of the aluminum wheel according to any one of claims 1 to 2, and is characterized by comprising the following steps:
step 1, continuously acquiring related data information of a plurality of key position temperatures, cooling pipeline opening and closing signals, casting hearth pressure, casting equipment opening and closing signals, casting process and time of a mold in the wheel casting process through an upper computer system according to fixed frequency;
step 2, based on the acquired mold opening and closing signals of the casting equipment, slicing continuously acquired data by taking a single wheel as a unit, and uniformly assigning the data in the same wheel production process with a unique ID (identity) for storage;
step 3, carrying out data retrieval on a single wheel production process, sequencing the acquired temperatures of key positions of each die according to the acquisition time sequence, and then carrying out time sequence-based temperature data noise reduction by using a moving window method;
step 4, establishing a multidimensional matrix based on the processed temperature and the corresponding acquisition time, and obtaining a temperature variation corresponding to the acquisition time through matrix transformation;
and 5, establishing a casting forming process diagram of the aluminum wheel with the same ID and the single wheel with the time as a unified measure.
4. The method for characterizing a casting process for aluminum wheels according to claim 3,
the utility model discloses a casting equipment PLC, including casting equipment PLC, cooling pipeline switching signal, casting equipment die opening and closing signal, the collection of casting technology is used the host computer system to establish the connection through industry ethernet and casting equipment PLC and is gathered, and the data information content of gathering includes: the cooling pipeline opening and closing signals correspond to point position opening and closing Boolean values, the casting furnace pressure corresponds to point position numerical values, the casting equipment opening and closing mode signals correspond to point position Boolean values and the casting process corresponds to point position numerical values.
5. The method of characterizing a casting process for an aluminum wheel as recited in claim 4, wherein in said step 5, the casting process for an aluminum wheel comprises:
a curve for characterizing the temperature of the mold at a critical location during the casting of aluminum wheels;
a bar graph image for representing the opening and closing interval of a mold cooling pipeline in the aluminum wheel casting process;
a hearth pressure process node line for representing the casting process of the aluminum wheel;
a curve for representing the temperature variation of the mold in the casting process of the aluminum wheel and a heating auxiliary marking;
and the label is used for representing the action of equipment in the aluminum wheel casting process.
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