Classifications

• • 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
  • B22D2/006—Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass for the temperature of the molten metal
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
  • B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
  • B22D15/04—Machines or apparatus for chill casting
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
  • B22D30/00—Cooling castings, not restricted to casting processes covered by a single main group
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
  • B22D46/00—Controlling, supervising, not restricted to casting covered by a single main group, e.g. for safety reasons
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
  • B22D47/00—Casting plants

Definitions

• the invention relates to a method for controlling a
• the invention further relates to a casting plant with at least one mold, a casting plant system comprising this casting plant, a computer program and a computer program product.
• Engine components but also other components are nowadays produced in casting plants by a casting process.
• a solid material having a certain shape corresponding to the mold shape is formed from a liquid material after solidification of the material.
• a constant concern here is to make the production process efficient and, in particular, in addition to a reduction of
• the efficiency of the production process depends in particular on the solidification time, ie on the time in which the initially liquid material cools in a mold of the casting plant and solidifies, so that it can be removed from the mold.
• the solidification time determines the cycle time and thus the production rate of the
• the setting time is a constant one Period of time.
• a cast component is always removed from the mold after the same amount of time.
• the solidification time is designed to increase the production in general with regard to the operation of the casting plant under full load.
• the casting process is subject to several non-constant and not or only limited influenceable factors. This includes, for example, the ambient temperature of the casting plant or the temperature of the materials used.
• the previously derived and indicated object is achieved according to a first aspect of the invention by a method for controlling a casting plant with at least one mold for receiving a liquid material, wherein the liquid material during a solidification time in the
• Mold freezes comprising the steps of at least one during the production process
• Process parameters is detected and the solidification time is determined depending on the detected process parameters.
• the solidification time according to the invention is not considered to be a constant period of time
• a casting plant is controlled with at least one mold.
• a mold which basically any shape according to the
• the starting material may be a liquid metal. To liquefy a metal this becomes
• the filled into the mold liquid and hot material cools in the mold and solidifies into a solid
• the solidification time ie the time between the filling of the mold and the removal time of the cast Component, according to the invention in dependence of a detected during the production process process parameter
• a process parameter is to be understood as a parameter which is characteristic for the casting process or influences this directly or indirectly.
• the process parameter is a parameter which is characteristic for the solidification time or influences this directly or indirectly.
• the production rate and the efficiency of the production process can be increased significantly even under non-optimal operating conditions. In particular, interruptions of the production process and unavoidable influences by the
• inventive method are taken into account. Even small cycle time reductions in the second range lead to significantly higher production rates.
• the at least one process parameter can be detected at arbitrary times. According to a first
• a current process parameters can be detected during a casting process of a component to be manufactured.
• Casting process is a single casting process of a component to understand during the production process of a variety of components.
• at least one current process parameter is detected for each component to be cast during the casting process of the corresponding component.
• the solidification time for the (currently) produced component may preferably in dependence on the detected current
• Solidification time of the component to be cast may depend on a current process parameter.
• Current influences and in particular changes on the casting process can be determined.
• Process parameters in predetermined time intervals, in particular at periodic intervals, are detected.
• the time intervals can in particular be selected such that the measured values are sufficiently up-to-date in order, for example, to be able to sufficiently and timely take into account influences acting on the casting process.
• a value can be detected.
• Process parameters of the production process, in particular the casting process can be detected. different
• Process parameters can also be detected in different ways, that is continuously or at predefinable time intervals.
• determination of the solidification time according to a further embodiment of the invention
• Method be performed in dependence of a comparison of the detected process parameter with at least one desired process parameter.
• a target process parameter such as a
• Solidification time to be determined can be specified such that a
• Exceeding or falling short of the target process parameter by the current process parameter indicates the time from which the mold can be opened.
• at least one condition can be specified in such a way that, upon fulfillment of the condition, a sufficient solidification of the material has taken place and the cast component can be removed.
• at least two desired process parameters can be provided for a process parameter.
• a lower and an upper limit can be specified, which define a permissible range. Only if the current one
• Process parameters are in this range, the mold can be opened.
• further target criteria can be specified. For example, in the case of a continuously changing process parameter, it can be taken into account whether this changes (currently) in an increasing or decreasing manner.
• process parameters of the production process are suitable for determining the solidification time.
• process parameters can be detected which characterize or influence the solidification time.
• the temperature of the mold or the temperature of the material in the mold for the determination of the solidification time is particularly suitable. In particular, it can be deduced from the temperature of the material contained in the mold whether the initially liquid material has solidified (sufficiently) and the mold can be opened. It may preferably be a
• Setpoint temperature are specified, in which it is ensured that the liquid material used is solidified so far that a cast component can be removed. In other words, the optimal one for each component
• the removal time ie the variable solidification time
• the cycle time can be at the same time
• the temperature of the mold or the temperature of the material in the mold is falling or rising.
• the detected temperature initially rise and therefore initially below a desired value.
• the temperature profile can be taken into account. From a falling temperature history can closed, that the material cools and solidifies.
• the temperature profile is decreasing.
• the solidification time of the component to be produced can be determined as a function of the solidification time of at least one previously produced component.
• results from previous casting processes can be stored and taken into account. For example, an unusual mismatch between the current
• Sollerstarrungszeit be given.
• at least a minimum Sollerstarrungszeit be specified.
• the minimum roller shutter time can in particular be selected such that at least a sufficient
• a maximum Sollerstarrungszeit be specified.
• a faulty one Measurement of the at least one process parameter can not only lead to a condition, such as the achievement of a desired process parameter, being achieved too early, but also to the fact that a condition is not reached or is reached too late.
• a maximum Sollerstarrungszeit be specified, and when the maximum Sollerstarrungszeitzeit (always) the
• Mold open and the component can be removed. It is understood that such errors can be displayed to a user.
• the previously described criteria, in dependence of which the solidification time, that is the removal time of the cast component, can be determined, are taken into account in a formula.
• Formula be logically linked.
• the achievement of a setpoint temperature can be linked to the conditions that the temperature profile is falling and a minimum solidification time has been exceeded.
• Method of at least one desired process parameters are determined before the production process.
• all desired values in particular a previously described formula, can be determined before the production process.
• the at least one solidification time can be determined before the production process.
• the at least one desired process parameter can be determined as a function of the liquid material, the casting plant, the state of
• Casting and / or the mold shape are determined.
• the at least one target temperature may be different for different materials.
• the mold used for example, their size, diameter, etc., may require different desired process parameters in order to obtain optimum results. But also different
• Caster types and the condition of the caster can be
• Sollskencing can be used. It is also understood that in addition to a desired process parameter, a Sollerstarrungszeit can be determined in a similar manner.
• the at least one setpoint parameter can also be (re) determined at predetermined time intervals during the production process.
• Another aspect of the invention is a casting plant with at least one mold for receiving a liquid
• Sensor device configured to detect at least one process parameter provided during the production process and at least one control device configured to determine the solidification time depending on the detected process parameter provided.
• the casting plant is designed in particular for carrying out the method described above. Furthermore, the casting plant comprises at least one mold with a predeterminable shape. The shape depends in particular on the component to be produced.
• the mold may be filled with a liquid material such as a metal or the like. After solidification of the material, the mold can be opened and the solidified component can be removed.
• At least one suitable sensor device is provided to at least one previously mentioned
• control device is provided.
• Control device for example a microcomputer, a digital signal processor (DSP) or the like, is set up to process the acquired process parameter and, depending on the process parameter, the optimum one
• Solidification time ie the withdrawal time
• Production process can also be at non-optimal
• the sensor device can be a temperature sensor.
• the temperature sensor may in particular be arranged on or in the mold.
• Temperature sensor can be detected for the casting process essential process parameters.
• the temperature sensor can be arranged such that the temperature of the mold located in the mold
• the actually required solidification time depends, inter alia, on the temperature of the material in the mold. For example, the temperature of the material in the mold.
• Molds are measured. From this temperature, the temperature of the material contained in the mold can be derived.
• the at least one temperature sensor can be arranged such that the
• Temperature sensor directly contacted the material located in the mold. The temperature can be detected very accurately. As a result, the at least one
• Temperature setpoint can be set almost without a tolerance due to measurement inaccuracies.
• the cycle time can be significantly reduced without loss of quality.
• Another aspect of the invention is a casting system
• the casting system can also have two or more casting machines
• the central controller in particular a central processing device with a database, can be designed as a higher-level controller.
• information about the casting plant such as the condition of the casting plant, the shape of the mold, etc., and about the components to be manufactured and the starting materials may be stored. From this information, at least one optimal target process parameter, preferably one before
• Control connected casting plants are used to determine an optimal target process parameters, preferably a formula for determining the solidification time.
• Another aspect of the invention is a computer program having instructions executable on a processor such that a casting machine is controlled by the method described above.
• Yet another aspect of the invention is a
• Computer program product comprising a previously described computer program with instructions executable on one
• a method for controlling a casting plant with at least one mold for receiving a liquid material is provided, wherein the liquid material solidifies during a solidification time in the mold, wherein during the production process at least one process parameter is detected, and
• Process parameter is determined. According to another embodiment, during a
• Casting process of a component to be produced detects a current process parameters and the solidification time for the component to be produced in dependence of the detected
• the determination of the solidification time is dependent on a comparison of
• the process parameter is the temperature of the mold or the process parameter is the temperature of the material in the mold.
• the solidification time of the component to be produced is dependent on
• Solidification determined by at least one previously manufactured component is predetermined.
• Sollу depending on the material, the casting plant, the condition of the casting plant and / or the
• a casting plant with at least one mold for receiving a liquid
• Sensor device configured to detect at least one process parameter is provided during the production process and at least one control device
• Temperature sensor in particular on or in the mold
• the temperature sensor is arranged such that the temperature of the material located in the mold can be detected.
• Casting plant the casting plant according to the invention, the
• Fig. 1 is a schematic view of a first
• FIG. 1 shows a schematic view of a first one
• Embodiment of a casting plant system 2 with an exemplary casting plant 4 according to the present invention Embodiment of a casting plant system 2 with an exemplary casting plant 4 according to the present invention.
• the illustrated casting plant 4 is set up for
• liquid material 8 such as a liquid metal
• the metal may be aluminum or a
• the liquid material 8 is in a mold 10, too
• molding materials 12 can also for
• cores can be formed with the molded materials 12 in order to produce later cavities in the components 6.
• molding materials 12 for a core for example, suitable sands are used.
• the casting installation 4 has a control device 14.
• the controller 14 may be configured to control the caster 4 and the casting process, respectively.
• Controller 14 may include suitable processing means 16, such as a processor, memory means, interfaces, etc., for providing various control parameters for the controller
• Specify casting process For example, cooling parameters, heating parameters for heating mold parts of the tool mold and / or suitable gating and feeding parameters can be specified.
• control device 14 is adapted to the solidification time, ie the removal time
• the casting plant 4 comprises in the present
• Embodiment a sensor device 18.
• Sensor device 18 is in particular a temperature sensor 18 for detecting the temperature of the mold 10 and / or the material located in the mold 10.
• the temperature of the material located in the mold 10 can be detected directly.
• a temperature sensor 18 may be arranged such that it is located in the mold 10
• the temperature of the mold 10 can be measured. For example, from this temperature, the temperature of the material located in the mold 10 can be derived.
• the temperature sensor 18 detects at predetermined intervals or continuously at least one of the aforementioned Temperatures.
• the recorded temperature values can be the
• Control device 14 in a suitable form for further
• a plurality of temperature sensors 18 may be provided to the temperature of the mold 10 and / or of the material in the mold
• further detection means may be provided, for example for detecting the ambient temperature and the like.
• the caster 4 may be in communication with a central controller 20.
• a wireless or wired communication connection can be provided.
• the central controller 20 may (not shown)
• Processing means and a database include. Furthermore, the central controller 20 may be connected to other casting machines (not shown).
• FIG. 2 shows a flow chart of an exemplary embodiment of a method for controlling a casting installation 4 according to FIG. 1
• a first step 201 first before the beginning of
• Production process ie before the casting process of a first component 4, at least a first desired process parameter be determined.
• the determination of the desired process parameter can in particular be derived from the material 8, the casting installation 4, the condition of the casting installation 4, the mold design, the
• Target process parameters can be determined.
• at least one limit value can be determined for at least one process parameter.
• Sollerstarrungszeit be given.
• a formula for determining the optimal solidification time can be determined, in particular as a function of the aforementioned criteria, the formula preferably being determined by a total solidification time, target process parameters and
• a minimum setpoint temperature a minimum setpoint temperature
• the temperature setpoint may be in the case of aluminum as a material, for example in the range between 350 ° C and 600 ° C.
• the minimum roller burn time can be in the range between 80s and 180s.
• the maximum roller burn time can be in the range between 100s and 250s.
• the determination of the at least one desired process parameter or of a formula can be performed by the control device 12 of FIG.
• Caster 4 are determined.
• a higher-level control device 20 for example a central control 20 with a database for determining the at least one desired process parameter, may preferably be provided.
• the higher-level control device 20 may in particular be adapted to monitor and control a plurality of casting machines.
• the liquid material can be filled into the mold 10.
• a next step 202 the liquid material can be filled into the mold 10.
• Timers are started. For example, starting the filling or the end of the filling, the timer can be started.
• the liquid material can cool and solidify.
• at least one process parameter can be detected. in the
• the temperature of the material located in the mold 10 is continuously detected by a sensor device 18. It is understood that the temperature is continuous throughout
• the control device 14 may in particular be adapted to compare the currently detected temperature of the material with the optimum setpoint temperature. If the control device 14 determines that the optimum setpoint temperature has been reached or fallen short of
• the value of the timer can be compared with the minimum total shutter time. If the conditions are met, the controller 14
• the mold 10 is opened and the component 6 is removed in a step 204. After removal of the component 6, the mold 10 can be closed again, the
• Step 202 continue.
• An alternative sampling condition may be reaching the maximum targeting time.
• the value of the timepiece can preferably be compared continuously with at least the maximum target set time. Even if the
• Component 6 done. In this case, in all likelihood, there is a measurement error.
• the mold 10 is not opened when the actual temperature of the material is below the target temperature, but the temperature profile is increasing. Likewise, the mold 10 is not opened in the present embodiment, although the actual temperature of the material, although below the target temperature, but the minimum
• the detection device 18 may be defective.
• the mold 10 can be opened in step 204. Then the
• Production process interrupted or terminated (step 205). Appropriate measures for the elimination of the technical error can be taken.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Mold Materials And Core Materials (AREA)
• Molds, Cores, And Manufacturing Methods Thereof (AREA)
• Casting Or Compression Moulding Of Plastics Or The Like (AREA)
• Feedback Control In General (AREA)
• Continuous Casting (AREA)
• Manufacture And Refinement Of Metals (AREA)

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Publications (1)

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Citations (2)

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• 2011
  • 2011-10-07 EP EP11184325.6A patent/EP2578333A1/de not_active Ceased
• 2012
  • 2012-09-17 BR BR112014008244A patent/BR112014008244A2/pt not_active Application Discontinuation
  • 2012-09-17 MX MX2014004229A patent/MX2014004229A/es unknown
  • 2012-09-17 US US14/349,844 patent/US20140374051A1/en not_active Abandoned
  • 2012-09-17 UA UAA201403379A patent/UA109499C2/ru unknown
  • 2012-09-17 CA CA2851201A patent/CA2851201A1/en not_active Abandoned
  • 2012-09-17 CN CN201280049266.4A patent/CN103958092A/zh active Pending
  • 2012-09-17 WO PCT/EP2012/068262 patent/WO2013050237A1/de active Application Filing
  • 2012-09-17 IN IN741KON2014 patent/IN2014KN00741A/en unknown
  • 2012-09-17 JP JP2014533822A patent/JP2014528358A/ja active Pending
  • 2012-09-17 RU RU2014113165/02A patent/RU2014113165A/ru not_active Application Discontinuation

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