CN-121972632-A - Balanced runner and injection speed control method of multi-cavity die

CN121972632ACN 121972632 ACN121972632 ACN 121972632ACN-121972632-A

Abstract

The invention relates to the technical field of metal casting, and discloses a balanced runner and injection speed control method of a multi-cavity die, which is used for solving the problem of insufficient accuracy of real-time injection speed self-adaptive control in the traditional method; the method comprises the steps of firstly collecting parameters such as melt pressure and temperature after a die casting machine is started and transmitting the parameters to a control system, aligning and comparing the parameters with a preset balanced runner model to finish difference analysis and unbalanced positioning, further generating a shot speed adjusting instruction and transmitting the shot speed adjusting instruction to a shot mechanism for execution, enabling an injection plunger speed curve to be switched between a slow stage and a fast stage according to conditions, comparing the feedback data with a target balanced state in an observation window by the control system to finish convergence, persistence and execution consistency judgment, selectively iterating until the cycle is finished according to residual errors, simultaneously forming a cycle file and updating cycle-crossing parameters and versions, and being suitable for high-pressure die casting of aluminum alloy steering knuckles and the like, and ensuring process stability and adaptability.

Inventors

LI SONGTAO
YANG BO
YI BO
ZHANG PING
CHEN XIAOQIANG
ZHENG QIHENG

Assignees

重庆市明鑫机械制造有限公司

Dates

Publication Date: 20260505
Application Date: 20260121

Claims (10)

1. A method for controlling the equalizing runner and injection speed of a multi-cavity die is characterized by comprising the following steps: s1, after a die casting machine is started, acquiring key parameters of melt flow in real time through sensors arranged in a runner and a cavity of a multi-cavity die so as to acquire initial flow state data; s2, transmitting the parameters acquired in real time to a control system, comparing the parameters with a preset balanced runner model, analyzing the difference between the parameters to identify potential areas of unbalanced melt flow, and providing adjustment basis for follow-up; S3, generating an injection speed adjusting instruction based on a difference analysis result, and optimizing the flow requirement among multiple cavities according to the influence of melt viscosity and mold resistance; s4, sending an adjusting instruction to the injection mechanism, and dynamically adjusting the speed curve of the injection plunger by the injection mechanism according to the instruction, and transitioning from a slow stage to a fast stage so as to adapt to real-time flowing conditions; S5, continuously feeding back the change of the melt parameters in real time through a sensor in the adjustment process, and comparing the feedback data with a target equilibrium state by a control system to confirm the adjustment continuity and accuracy; and S6, repeating the feedback and adjustment processes until the whole die casting period is finished, and recording all parameter changes by the system to optimize initial setting for the next cycle.
2. The method of controlling a speed of equalizing flow passage and injection of a multichamber die as in claim 1, wherein after die casting machine is started, acquiring critical parameters of melt flow in real time by sensors disposed in the multichamber die flow passage and cavity to obtain initial flow state data, comprising: before injection, judging heat balance based on a temperature measuring point sequence, and solidifying a temperature difference threshold value, a fluctuation threshold value and a stability judging period into a parameter version; embedding and arranging pressure sensors and temperature sensors in a main runner inlet, a shunt node and each cavity inlet in a flush manner, adopting high-temperature-resistant sealing and limiting fixation, calibrating and self-detecting sensor links, and performing degradation compensation on abnormal measuring points; In the injection stage, synchronously sampling each measuring point under a unified acquisition clock, adding a time stamp, managing sampling configuration according to versions, and carrying out jitter removal judgment on the start and stop of an acquisition window according to the state of a plunger and the inlet pressure threshold of a main runner; And after conditioning the acquired signals, performing outlier rejection, short-time jitter suppression and drift compensation to generate a data set carrying pressure attenuation characteristics, pressure difference characteristics and variation trend thereof and carrying version labels.
3. The method for controlling the speed of injection and equalization of a multichamber mold as in claim 1 wherein said method comprises the steps of: the data in the acquisition window is packaged into a data packet, and the data packet is sent to the control system through a wired link or a wireless link, wherein the data packet carries a unified time stamp sequence, a measuring point health state label, a threshold version label and a sampling configuration version label; Performing field integrity check and time sequence consistency check on the received data packet, and performing discarding or retransmitting processing on the data packet when the check fails; under the condition of the deficiency allowing the filling, filling the deficiency interval according to the packet loss tolerance rule, and generating a filling mark.
4. The method of controlling an equalization runner and injection rate of a multichamber mold as in claim 1 wherein analyzing the difference between parameters to identify potential areas of melt flow imbalance as compared to a predetermined equalization runner model provides an adjustment basis for a subsequent step comprising: Screening measurement point data according to the measurement point health state label, replacing the data of the abnormal measurement point by adopting adjacent measurement point data, or estimating the missing data according to the topological constraint of the flow channel, and recording the replacement source and the estimation mode; establishing a mapping relation between the measuring points and nodes or runner segments of the balanced runner model, and aligning the measuring point data to a uniform time grid; calculating pressure deviation, temperature deviation and variation trend thereof, and performing overrun judgment according to a deviation threshold value and a persistence judgment window; and positioning according to the flow channel topology and the adjacent node deviation propagation relationship, and outputting the structured difference analysis data.
5. The method for controlling the speed of injection and equalization flow channels of a multichamber mold as in claim 1 wherein generating an injection speed adjustment command based on the differential analysis results comprises: Reading version labels in the difference analysis result, and generating an adjustment task based on the node or runner segment identification, wherein the adjustment task at least has deviation amount, persistence index and confidence index fields; shunting the adjustment tasks according to the confidence level grading rule, applying amplitude limiting and weight attenuation to the low confidence level adjustment tasks, writing a rechecking mark, and processing the rest adjustment tasks according to the preset priority order.
6. The method of controlling a balanced runner and shot velocity of a multichamber die as recited in claim 1 wherein optimizing flow requirements between the multichambers based on the effects of melt viscosity and die drag comprises: The control system determines a viscosity correction factor according to the temperature deviation and determines a resistance correction factor according to the pressure drop deviation; Fusing the viscosity correction factor and the resistance correction factor according to the influence factor weight to obtain a comprehensive correction; solving a segmentation speed set value, a segmentation switching condition and a speed change slope parameter in a feasible region defined by the constraint set; and carrying out position segment association consistency check according to the target node or the target runner segment identifier, generating a structured shot velocity adjustment instruction, carrying an instruction number, a version identifier, a target segment identifier and a velocity track parameter, and setting validity conditions.
7. The method for controlling the speed of injection and equalization of a multichamber mold as in claim 1 wherein said step of sending an adjustment command to said injection mechanism comprises: transmitting an instruction frame through an industrial field communication link or an isolated input/output link, wherein the instruction frame carries an instruction number, a serial number, a version field, a check field, a speed track parameter set and a switching condition mark; performing pre-verification according to the validity condition of the instruction, and completing issuing confirmation by adopting a handshake mechanism; when response timeout or verification failure occurs, the control system executes retransmission according to a retransmission threshold value configured by the process parameter table; When the injection mechanism returns the reject code, the control system records the reject code and triggers the re-solving or switching of the security policy.
8. The method of controlling the speed of injection and equalizing flow passage of a multichamber mold as in claim 1 wherein said injection mechanism dynamically adjusts the speed profile of the injection plunger according to the command and transitions from a slow phase to a fast phase comprising: carrying out integrity check and version consistency check on the instruction frame, carrying out duplication removal and sequence check on the instruction number and the serial number, writing speed track parameters into an execution buffer area when the verification passes, and carrying out limited slope shaping and limited acceleration shaping on the segmented speed track according to the constraint set; Triggering phase switching according to displacement conditions, timing conditions or pressure state conditions to switch a speed curve from a slow phase to a fast phase; And executing closed-loop tracking control based on the speed feedback and the displacement feedback, performing criterion monitoring on tracking errors, and executing degradation control or starting a safe speed curve by the injection mechanism and generating an execution log feedback control system when the error criterion is met.
9. The method of controlling an equalization runner and injection speed of a multichamber mold as in claim 1 wherein during the adjusting process, continuing to feed back the melt parameter variation in real time via the sensor, the control system comparing the feedback data to a target equalization state to confirm the persistence and accuracy of the adjustment, comprising: The observation window is determined by the execution start-stop time mark, the phase switching trigger record and the instruction number; synchronously acquiring and standardizing according to sampling configuration in an observation window, and writing a threshold version label, a sampling configuration version label and a measuring point health state label; Respectively carrying out convergence judgment, persistence judgment and consistency judgment execution according to the target equilibrium state to obtain a corresponding judgment result; and generating a residual error input set and a rechecking mark, and packaging the judging result into a confirmation report and writing the confirmation report into a feedback buffer area.
10. The method of controlling the speed of injection and equalization of a multichamber mold as in claim 1 wherein repeating the feedback and adjustment process until the entire die casting cycle is completed, the system and recording all parameter changes, optimizing the initial settings for the next cycle, comprises: determining a control round according to the confirmation report and the residual error set, and repeatedly executing acquisition, difference analysis, solving and instruction issuing in the round; When the die casting period is finished, the control system generates a period level file, and records a model version, a threshold version and a sampling configuration version; The control system updates the model parameters based on the multi-period periodic level archive and generates a corresponding threshold version identification.

Description

Balanced runner and injection speed control method of multi-cavity die Technical Field The invention relates to the technical field of metal casting, in particular to a balanced runner and injection speed control method of a multi-cavity die. Background In the field of die casting, the multi-cavity die is widely applied to mass production of high-precision products such as automobile parts, electronic shells and the like, and the balanced runner design and the injection speed control method directly influence melt filling uniformity, product defect rate and production efficiency; in the traditional die casting process, the injection speed is usually regulated by presetting fixed parameters to realize the balanced distribution of melts among multiple cavities, however, along with the development of complexity and material diversification of products, the existing control method is difficult to cope with real-time variables such as melt temperature fluctuation, die abrasion or alloy composition change, so that filling imbalance, air holes or cold insulation defects are increased, and further the quality and the yield of products are affected; for example, the invention patent CN102717488a discloses a mold runner structure comprising a first runner plate and a second runner plate, which are connected by a multi-layer runner to realize uniform distribution of melt, the patent has the advantages of optimizing the geometry of a static runner, reducing the pressure loss at a branching point and improving the consistency of multi-cavity filling, however, the method depends on the preset runner design, the injection speed cannot be dynamically adjusted to respond to real-time process variation, the difference of melt flow resistance is amplified in the high-pressure die casting process, the filling precision is limited, and CN106378432a discloses a knuckle aluminum alloy die casting method, which realizes the control of the filling speed by adjusting the injection speed and the cross section of an ingate and sets the mold temperature in the range of 150-280 ℃. The multi-stage injection speed regulation (such as low-speed propulsion and high-speed filling) is introduced, so that the sputtering and premature coagulation risks are effectively reduced, and the compactness of the product is improved; The prior art improves the control of the equalizing runner and the injection speed to a certain extent, but generally has the problem of insufficient precision of the self-adaptive control of the real-time injection speed, and particularly, the existing preset parameter method cannot accurately respond to instantaneous process fluctuation, so that the filling of a multi-cavity die is unbalanced, the defects of products are increased and the production efficiency is low, so that a control method capable of monitoring in real time and adaptively adjusting the injection speed is needed to improve the precision and the reliability of multi-cavity die casting. Disclosure of Invention Aiming at the defects of the prior art, the invention provides a method for controlling the equalizing runner and the injection speed of a multi-cavity die, which is used for solving the problem of insufficient accuracy of the self-adaptive control of the real-time injection speed in the traditional method. In order to achieve the purpose of improving the precision and reliability of multi-cavity die casting in the background art, the invention provides the following technical scheme: a method for controlling the equalizing runner and injection speed of a multi-cavity die comprises the following steps: s1, after a die casting machine is started, acquiring key parameters of melt flow in real time through sensors arranged in a runner and a cavity of a multi-cavity die so as to acquire initial flow state data; s2, transmitting the parameters acquired in real time to a control system, comparing the parameters with a preset balanced runner model, analyzing the difference between the parameters to identify potential areas of unbalanced melt flow, and providing adjustment basis for follow-up; S3, generating an injection speed adjusting instruction based on a difference analysis result, and optimizing the flow requirement among multiple cavities according to the influence of melt viscosity and mold resistance; s4, sending an adjusting instruction to the injection mechanism, and dynamically adjusting the speed curve of the injection plunger by the injection mechanism according to the instruction, and transitioning from a slow stage to a fast stage so as to adapt to real-time flowing conditions; S5, continuously feeding back the change of the melt parameters in real time through a sensor in the adjustment process, and comparing the feedback data with a target equilibrium state by a control system to confirm the adjustment continuity and accuracy; and S6, repeating the feedback and adjustment processes until the whole die casting period is finished, and record