US 12,358,047 B2
Data mining-based method for real-time production quality prediction of aluminum alloy casting, electronic device, and computer-readable storage medium
Weipeng Liu, Hangzhou (CN); Tao Peng, Hangzhou (CN); Jun Wu, Hangzhou (CN); Xuxia Zhang, Hangzhou (CN); Anping Wan, Hangzhou (CN); Ting Chen, Hangzhou (CN); and Luoke Hu, Hangzhou (CN)
Assigned to HANGZHOU CITY UNIVERSITY, Hangzhou (CN)
Filed by HANGZHOU CITY UNIVERSITY, Hangzhou (CN)
Filed on Jul. 31, 2023, as Appl. No. 18/361,930.
Claims priority of application No. 202310792988.9 (CN), filed on Jun. 30, 2023.
Prior Publication US 2025/0001492 A1, Jan. 2, 2025
Int. Cl. B22D 46/00 (2006.01); B22D 21/00 (2006.01)
CPC B22D 46/00 (2013.01) [B22D 21/007 (2013.01)] 13 Claims
OG exemplary drawing
 
1. A data mining-based method for real-time production quality prediction of an aluminum alloy casting, the method comprising:
(1) based on mold flow analysis results, installing sensors on a casting mold; wherein the sensors include at least one temperature sensor, at least one pressure sensor, at least one contact sensor, and a multi-functional gas sensor;
the number of the at least one temperature sensor is N, and the N temperature sensors are used to measure temperatures of aluminum liquid at different locations in a mold cavity of the casting mold; the number of the at least one pressure sensor is M, and the M pressure sensors are used to measure pressures of the aluminum liquid at different locations in the mold cavity; the number of the at least one contact sensor is Q, and the Q contact sensors are used to record times when the aluminum liquid first reaches the Q contact sensors; the number of the multi-functional gas sensor is one, and the multi-functional gas sensor is used to measure pressure, composition, humidity, and temperature of gas inside the mold cavity; N, M, and Q are natural numbers and equal to or greater than one;
the multi-functional gas sensor is installed at a gas discharge outlet of a movable plate or stationary plate of the casting mold; the at least one temperature sensor, the at least one pressure sensor, and the at least one contact sensor are installed on surfaces of a mold core of the casting mold and the mold cavity contacting the aluminum liquid; based on the mold flow analysis results, the at least one temperature sensor is installed at locations with hot nodes, locations prone to air bubbles, and locations prone to surface quality problems; the at least one pressure sensor is installed at overflow slots, locations prone to shrinkage, and locations prone to air entrapment; the at least one contact sensor is installed at gates, locations prone to incomplete casting, locations prone to air entrapment, overflow slots, and gas outlets;
(2) during casting production, real-time collecting temperatures of the aluminum liquid, pressures of the aluminum liquid, and contact times of the aluminum liquid at a plurality of locations of the casting mold, and pressure, composition, humidity, and temperature of gas in the mold cavity, by the installed sensors, for constructing an aluminum alloy casting process parameter set; and
(3) inputting the aluminum alloy casting process parameter set to a production quality prediction model for an aluminum alloy casting process; wherein the production quality prediction model is used to judge whether a production quality of an aluminum alloy casting is qualified or not; the production quality prediction model is obtained by mining a relationship between history parameters of the aluminum alloy casting process and aluminum alloy castings quality data.
 
7. An electronic device, comprising a memory and a processor; wherein the memory is coupled to the processor, and the memory is used to store program data, and the processor is used to execute the program data to implement the following methods:
(1) based on mold flow analysis results, installing sensors on a casting mold; wherein the sensors include at least one temperature sensor, at least one pressure sensor, at least one contact sensor, and a multi-functional gas sensor;
the number of the at least one temperature sensor is N, and the N temperature sensors are used to measure temperatures of aluminum liquid at different locations in a mold cavity of the casting mold; the number of the at least one pressure sensor is M, and the M pressure sensors are used to measure pressures of the aluminum liquid at different locations in the mold cavity; the number of the at least one contact sensor is Q, and the Q contact sensors are used to record times when the aluminum liquid first reaches the Q contact sensors; the number of the multi-functional gas sensor is one, and the multi-functional gas sensor is used to measure pressure, composition, humidity, and temperature of gas inside the mold cavity; N, M, and Q are natural numbers and equal to or greater than one;
the multi-functional gas sensor is installed at a gas discharge outlet of a movable plate or stationary plate of the casting mold; the at least one temperature sensor, the at least one pressure sensor, and the at least one contact sensor are installed on surfaces of a mold core of the casting mold and the mold cavity contacting the aluminum liquid; based on the mold flow analysis results, the at least one temperature sensor is installed at locations with hot nodes, locations prone to air bubbles, and locations prone to surface quality problems; the at least one pressure sensor is installed at overflow slots, locations prone to shrinkage, and locations prone to air entrapment; the at least one contact sensor is installed at gates, locations prone to incomplete casting, locations prone to air entrapment, overflow slots, and gas outlets;
(2) during casting production, real-time collecting temperatures of the aluminum liquid, pressures of the aluminum liquid, and contact times of the aluminum liquid at a plurality of locations of the casting mold, and pressure, composition, humidity, and temperature of gas in the mold cavity, by the installed sensors, for constructing an aluminum alloy casting process parameter set; and
(3) inputting the aluminum alloy casting process parameter set to a production quality prediction model for an aluminum alloy casting process; wherein the production quality prediction model is used to judge whether a production quality of an aluminum alloy casting is qualified or not; the production quality prediction model is obtained by mining a relationship between history parameters of the aluminum alloy casting process and aluminum alloy castings quality data.
 
13. A non-transitory computer-readable storage medium, storing a computer program; wherein the computer program, when executed by a processor, implements the following methods:
(1) based on mold flow analysis results, installing sensors on a casting mold; wherein the sensors include at least one temperature sensor, at least one pressure sensor, at least one contact sensor, and a multi-functional gas sensor;
the number of the at least one temperature sensor is N, and the N temperature sensors are used to measure temperatures of aluminum liquid at different locations in a mold cavity of the casting mold; the number of the at least one pressure sensor is M, and the M pressure sensors are used to measure pressures of the aluminum liquid at different locations in the mold cavity; the number of the at least one contact sensor is Q, and the Q contact sensors are used to record times when the aluminum liquid first reaches the Q contact sensors; the number of the multi-functional gas sensor is one, and the multi-functional gas sensor is used to measure pressure, composition, humidity, and temperature of gas inside the mold cavity; N, M, and Q are natural numbers and equal to or greater than one;
the multi-functional gas sensor is installed at a gas discharge outlet of a movable plate or stationary plate of the casting mold; the at least one temperature sensor, the at least one pressure sensor, and the at least one contact sensor are installed on surfaces of a mold core of the casting mold and the mold cavity contacting the aluminum liquid; based on the mold flow analysis results, the at least one temperature sensor is installed at locations with hot nodes, locations prone to air bubbles, and locations prone to surface quality problems; the at least one pressure sensor is installed at overflow slots, locations prone to shrinkage, and locations prone to air entrapment; the at least one contact sensor is installed at gates, locations prone to incomplete casting, locations prone to air entrapment, overflow slots, and gas outlets;
(2) during casting production, real-time collecting temperatures of the aluminum liquid, pressures of the aluminum liquid, and contact times of the aluminum liquid at a plurality of locations of the casting mold, and pressure, composition, humidity, and temperature of gas in the mold cavity, by the installed sensors, for constructing an aluminum alloy casting process parameter set; and
(3) inputting the aluminum alloy casting process parameter set to a production quality prediction model for an aluminum alloy casting process; wherein the production quality prediction model is used to judge whether a production quality of an aluminum alloy casting is qualified or not; the production quality prediction model is obtained by mining a relationship between history parameters of the aluminum alloy casting process and aluminum alloy castings quality data.