CN115857457B - Intelligent monitoring method, system and storage medium for casting process - Google Patents
Intelligent monitoring method, system and storage medium for casting process Download PDFInfo
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Abstract
The invention belongs to the technical field of casting equipment, and provides an intelligent monitoring method, an intelligent monitoring system and a storage medium for casting technology, which can receive information such as products, molds, detailed production technological parameters and the like of each casting equipment in real time, and based on quality inspection results such as X-ray machines, appearance detection, machine adjustment detection and the like, on-site operators or technicians are assisted in adjusting the technological parameters, the system monitors the change of each technological parameter and pushes the change information of the technological parameters to relevant managers, and the system gathers and forms a history record of the complete history of the production technology change, thereby facilitating the process tracing of the relevant managers and forming effective accumulation of experience data. In the production process of the casting process, 50-70 production process parameters are involved, and the system monitors the production process automatically, so that the process point inspection operation of operators on each casting device every day is saved, the working efficiency of site operators is improved, and meanwhile, the data accumulation of casting process change is formed.
Description
Technical Field
The application relates to the technical field of casting equipment, in particular to an intelligent monitoring method and system for a casting process and a storage medium.
Background
In the production process of casting equipment, 50-70 process parameters are involved, each shift of an operator in a site casting process needs to perform process point inspection operation on the process parameters under each casting equipment, the operator checks and records the process parameter information one by means of manual recording, a large amount of manual time is wasted, and meanwhile, the accuracy of process parameter information checking cannot be ensured by manual detection. For the process scheduling operation in each production process, on-site operators can only record the process parameter information before the change and after the last process scheduling, and the parameters in the scheduling process cannot form complete process change histories, so that the on-site part of key process data is lost, and the usability of the process change parameter histories is reduced.
In addition, when the quality problem of the batch of products occurs, a technician needs to check whether factors such as a process, equipment and a die change one by one, and even if the quality problem of the products is caused by locking the process reasons, the current key information such as the changing time, the changing parameters and the changing person of the process cannot be traced, so that the quality problem of the batch of the products caused by the process change cannot be accurately analyzed by the technician.
Disclosure of Invention
The embodiment of the application provides an intelligent monitoring method, a system and a storage medium for casting process, which can receive information such as products, molds, detailed production process parameters and the like of each casting device in real time, and based on quality inspection results such as X-ray machines, appearance inspection, machine adjustment inspection and the like, help on-site operators or technicians to adjust the process parameters, monitor each process parameter change by the system, push each process parameter change information to relevant managers, start forming records from the first process parameter change and push the record to the relevant managers according to production process change logic in the on-site casting production process, gradually adjust and perfect the production process information according to the product quality inspection results along with the on-site operators or technicians, collect the complete histories of the production process change after waiting for continuous one hour of the production process parameter monitoring, form the histories of one-time process change in the system, and facilitate the process traceability of the relevant managers and form effective accumulation of experience data. In the production process of the casting process, 50-70 production process parameters are involved, the system monitors the production process automatically, so that the process point inspection operation of operators on each casting device every day is saved, the working efficiency of on-site operators is improved, meanwhile, the data accumulation of casting process change is realized, reliable original data experience is brought to intelligent machine adjustment, intelligent process big data and the like of the later casting process, and finally, remarkable effects are brought to the improvement of the production efficiency and the quality stability of the casting process.
In order to achieve the above purpose, the present invention provides the following technical solutions:
in a first aspect, an intelligent monitoring method for a casting process is provided, including the following steps: and receiving production process parameters of the casting equipment, production product information and mold information in real time, and adjusting the production process parameters of the field casting equipment by field operators or technicians according to quality inspection results such as X-ray inspection, appearance inspection or machine adjustment inspection.
When the system monitors that the production process parameters on the casting equipment are changed, the system starts to track and record the process change.
When the last production process parameter adjustment is completed for one hour, no process parameter change exists, the system can summarize and record the process parameter adjustment history, a complete process parameter adjustment result in the system is formed, later-stage related management staff selects or inputs a process change reason in the system according to the whole process record of the process adjustment result in the system, and corresponding reason analysis is written, so that reliability data accumulation of casting equipment process change adjustment is formed.
In some embodiments, the method comprises the steps of: in the process of adjusting the casting production process, accuracy of the process parameters is determined by quality inspection results of a plurality of links, and on-site operators or technicians are required to continuously perfect the casting process parameters according to the quality inspection results until the quality of the casting production product is stable.
In a complete casting process adjustment operation record, one or more process change adjustment operations exist, green color is injected into a machine which is not subjected to process adjustment in the system, when the system monitors that the process parameters of casting equipment are changed, the system changes the color label of the machine into yellow and pushes the color label to related personnel for alarm pushing, and when the process change adjustment operation exceeds 4 times in the casting process adjustment process, the system changes the color standard of the machine into red and pushes the color label to higher-level related management personnel for follow-up. And after the casting equipment process change adjustment operation is continuously stabilized for 1 hour, the system gathers all records of the casting process change to form a casting equipment process change history record.
The related manager needs to combine the casting process change record information, write the reason and reason analysis of the corresponding process adjustment, carry out closed-loop management on the casting process change record after checking and confirming by the higher-level manager of the system flow, and change the machine color label to be green again after checking and confirming the corresponding adjustment reason and reason analysis in the system.
In some embodiments, the method comprises the steps of: the system collects quality inspection result information, monitors information such as aluminum liquid temperature, filling pressure, filling time, mold cooling water flow, cooling air flow, cooling opening time, cooling duration and the like on the machine table in real time, pushes alarm information to relevant personnel at the first time when quality inspection result problems, machine table alarms and technological parameters exceed set values and the like, processes the alarm information by matching with site operators or technicians, and automatically associates the alarm information with a technological change record to form a casting technology adjustment history after the operators or technicians perform technology adjustment according to the alarms.
In some embodiments, the method comprises the steps of: after the complete record of the primary casting change process adjustment is carried out in the system, the system marks the historical record of the primary casting change process as an unprocessed state in the historical record and the system to be done until relevant management staff writes the reason and the reason analysis of the primary casting change process and completes the verification, and then the system changes the historical record of the primary casting change process into a completed state.
When the system starts to monitor the change of the casting process parameters, the system automatically forms a casting process change record under the machine, the state of the record is incomplete, and when the system monitors that no process parameters are changed for one hour continuously after the field operator or technician finishes the last process change, the system forms a historical record, and changes the state of the historical record into unprocessed state so as to facilitate relevant management personnel to write corresponding reasons and reason analysis.
In some embodiments, the method comprises the steps of: when relevant management personnel process the casting process change history record, the system can be matched with collected equipment abnormal states or alarm information to carry out filling of reason analysis, so that on-site operators can conveniently and rapidly locate problems.
The system background is linked with the intelligent casting machine adjusting system, and the intelligent casting machine adjusting system can automatically adjust the casting production process according to the set machine adjusting logic and the acquired quality inspection result. The system automatically records the process change history of the intelligent casting machine adjusting system, automatically adjusts the labeling state of the machine in the system according to the adjustment of the intelligent casting machine adjusting system to the casting process, and automatically records the reason of the process change as the intelligent casting machine after the process change adjustment is finished so as to be distinguished from the manual adjustment, and meanwhile, the system can be directly related to the intelligent casting machine adjusting system to check the specific reason of the process machine adjusting.
In some embodiments, the method comprises the steps of: the system is associated with the mold management system, the corresponding mold can be queried according to the casting process change history record, meanwhile, the mold account information is called, and the related casting process adjustment record is queried by taking the casting mold as a dimension in the system and is matched with related management personnel to analyze the process adjustment reason.
In some embodiments, the method comprises the steps of: the system is used for developing a mobile terminal function, supporting function release of an apple system and an android system, ensuring safety of data transmission based on field industrial network segment application, realizing access of an external network of a mobile phone terminal of the system through port mapping, and simultaneously realizing an alarm pushing function, a reason analysis function and an approval confirmation function through the mobile terminal.
The second aspect is that the information acquisition module is used for acquiring real-time information of casting equipment and quality inspection equipment in real time, knowing the production condition of the current cast product, the model of the mould, the technological parameter information, monitoring the product with abnormal quality inspection result and real-time monitoring of casting technological change, and simultaneously communicating the intelligent casting machine adjusting system and the mould management system to adjust relevant process parameters.
The processing module records the change record of each casting process and summarizes key information such as the adjustment result, the process parameters and the reason analysis of each casting process according to the on-site processing condition.
The analysis module is used for recording each process parameter change adjustment record, accumulating a process parameter adjustment process, analyzing reasons and adjusting machine experience to form a knowledge base, and improving accumulated reliability data for the later casting process.
In a third aspect, embodiments of the present application further provide a storage medium storing non-transitory computer readable logic that when executed performs any of the above logic.
In a fourth aspect, an embodiment of the present application further provides an intelligent monitoring system for a casting process, including:
A memory;
a processor;
one or more computer system modules stored in the memory and configured to be executed by the processor, the one or more computer system modules including logic to implement one of the methods described above, while recording each operational record for system post analysis to enhance the overall casting production process.
Compared with the prior art, the invention has the beneficial effects that:
the intelligent monitoring method, the intelligent monitoring system and the intelligent monitoring storage medium for the casting process can replace manual recording, checking and checking according to product, mould and production process information of each casting device acquired in real time, and form process point checking records of each casting device in each shift according to the set point checking time in the system, so that not only is the manual time saved greatly, but also the accuracy of data is ensured. The system forms a multidimensional management mode for casting process parameters by recording casting process changes and combining quality inspection results and mold account information, so that process parameter change process data are more comprehensive and accurate, process change traceability is realized, and meanwhile, change reasons of casting production processes can be analyzed by combining quality inspection results, mold account information and other angles, so that abundant and detailed basic data are accumulated for the integral improvement of the later casting process.
Drawings
In order to make the description of the technical solutions in the embodiments of the present application clearer, the logic described in the corresponding system is described in more detail with accompanying drawings, where the drawings in the following description are some embodiments of the present application, and other drawings may be obtained according to these drawings without any inventive effort for a person of ordinary skill in the art.
FIG. 1 is a schematic diagram of a casting process intelligent monitoring system;
FIG. 2 is a flow chart of an intelligent monitoring system for casting process of the present application;
FIG. 3 is a detailed flow chart II of a casting process intelligent monitoring system of the present application;
fig. 4 is a schematic structural diagram of an intelligent monitoring system for casting process according to the present application.
Detailed Description
The terms "first," "second," "third," and "fourth" and the like in the description and in the claims of this application and in the drawings, are used for distinguishing between different objects and not for describing a particular sequential order. Furthermore, the terms "comprise" and "have," as well as any variations thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, system, article, or apparatus that comprises a list of steps or elements is not limited to only those listed steps or elements but may include other steps or elements not listed or inherent to such process, method, article, or apparatus.
Reference herein to "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of the present application. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Those of skill in the art will explicitly and implicitly appreciate that the embodiments described herein may be combined with other embodiments.
In order to solve the problem that 50-70 process parameters are involved in the production process of casting equipment, on-site casting procedure operators need to perform process point inspection operation on the process parameters under each casting equipment in each shift, and the operators check and record the process parameter information one by means of manual recording, so that a great deal of manual time is wasted, and meanwhile, the accuracy of the process parameter information cannot be guaranteed. For the process scheduling operation in each production process, on-site operators can only record the process parameter information before the change and after the last process scheduling, and the parameters in the scheduling process cannot form complete process change histories, so that the on-site part of key process data is lost, and the usability of the process change parameter histories is reduced.
In a first aspect, an intelligent monitoring method for a casting process is provided, including the following steps: and receiving production process parameters of the casting equipment, production product information and mold information in real time, and adjusting the production process parameters of the field casting equipment by field operators or technicians according to quality inspection results such as X-ray inspection, appearance inspection or machine adjustment inspection.
When the system monitors that the production process parameters on the casting equipment are changed, the system starts to track and record the process change.
When the last production process parameter adjustment is completed for one hour, no process parameter change exists, the system can summarize and record the process parameter adjustment history, a complete process parameter adjustment result in the system is formed, later-stage related management staff selects or inputs a process change reason in the system according to the whole process record of the process adjustment result in the system, and corresponding reason analysis is written, so that reliability data accumulation of casting equipment process change adjustment is formed.
In some embodiments, the method comprises the steps of: in the process of adjusting the casting production process, accuracy of the process parameters is determined by quality inspection results of a plurality of links, and on-site operators or technicians are required to continuously perfect the casting process parameters according to the quality inspection results until the quality of the casting production product is stable.
In a complete casting process adjustment operation record, one or more process change adjustment operations exist, green color is injected into a machine which is not subjected to process adjustment in the system, when the system monitors that the process parameters of casting equipment are changed, the system changes the color label of the machine into yellow and pushes the color label to related personnel for alarm pushing, and when the process change adjustment operation exceeds 4 times in the casting process adjustment process, the system changes the color standard of the machine into red and pushes the color label to higher-level related management personnel for follow-up. And after the casting equipment process change adjustment operation is continuously stabilized for 1 hour, the system gathers all records of the casting process change to form a casting equipment process change history record.
The related manager needs to combine the casting process change record information, write the reason and reason analysis of the corresponding process adjustment, carry out closed-loop management on the casting process change record after checking and confirming by the higher-level manager of the system flow, and change the machine color label to be green again after checking and confirming the corresponding adjustment reason and reason analysis in the system.
In some embodiments, the method comprises the steps of: the system collects quality inspection result information, monitors information such as aluminum liquid temperature, filling pressure, filling time, mold cooling water flow, cooling air flow, cooling opening time, cooling duration and the like on the machine table in real time, pushes alarm information to relevant personnel at the first time when quality inspection result problems, machine table alarms and technological parameters exceed set values and the like, processes the alarm information by matching with site operators or technicians, and automatically associates the alarm information with a technological change record to form a casting technology adjustment history after the operators or technicians perform technology adjustment according to the alarms.
In some embodiments, the method comprises the steps of: after the complete record of the primary casting change process adjustment is carried out in the system, the system marks the historical record of the primary casting change process as an unprocessed state in the historical record and the system to be done until relevant management staff writes the reason and the reason analysis of the primary casting change process and completes the verification, and then the system changes the historical record of the primary casting change process into a completed state.
When the system starts to monitor the change of the casting process parameters, the system automatically forms a casting process change record under the machine, the state of the record is incomplete, and when the system monitors that no process parameters are changed for one hour continuously after the field operator or technician finishes the last process change, the system forms a historical record, and changes the state of the historical record into unprocessed state so as to facilitate relevant management personnel to write corresponding reasons and reason analysis.
In some embodiments, the method comprises the steps of: when relevant management personnel process the casting process change history record, the system can be matched with collected equipment abnormal states or alarm information to carry out filling of reason analysis, so that on-site operators can conveniently and rapidly locate problems.
The system background is linked with the intelligent casting machine adjusting system, and the intelligent casting machine adjusting system can automatically adjust the casting production process according to the set machine adjusting logic and the acquired quality inspection result. The system automatically records the process change history of the intelligent casting machine adjusting system, automatically adjusts the labeling state of the machine in the system according to the adjustment of the intelligent casting machine adjusting system to the casting process, and automatically records the reason of the process change as the intelligent casting machine after the process change adjustment is finished so as to be distinguished from the manual adjustment, and meanwhile, the system can be directly related to the intelligent casting machine adjusting system to check the specific reason of the process machine adjusting.
In some embodiments, the method comprises the steps of: the system is associated with the mold management system, the corresponding mold can be queried according to the casting process change history record, meanwhile, the mold account information is called, and the related casting process adjustment record is queried by taking the casting mold as a dimension in the system and is matched with related management personnel to analyze the process adjustment reason.
In some embodiments, the method comprises the steps of: the system is used for developing a mobile terminal function, supporting function release of an apple system and an android system, ensuring safety of data transmission based on field industrial network segment application, realizing access of an external network of a mobile phone terminal of the system through port mapping, and simultaneously realizing an alarm pushing function, a reason analysis function and an approval confirmation function through the mobile terminal.
The second aspect is that the information acquisition module is used for acquiring real-time information of casting equipment and quality inspection equipment in real time, knowing the production condition of the current cast product, the model of the mould, the technological parameter information, monitoring the product with abnormal quality inspection result and real-time monitoring of casting technological change, and simultaneously communicating the intelligent casting machine adjusting system and the mould management system to adjust relevant process parameters.
The processing module records the change record of each casting process and summarizes key information such as the adjustment result, the process parameters and the reason analysis of each casting process according to the on-site processing condition.
The analysis module is used for recording each process parameter change adjustment record, accumulating a process parameter adjustment process, analyzing reasons and adjusting machine experience to form a knowledge base, and improving accumulated reliability data for the later casting process.
In a third aspect, embodiments of the present application further provide a storage medium storing non-transitory computer readable logic that when executed performs any of the above logic.
In a fourth aspect, an embodiment of the present application further provides an intelligent monitoring system for a casting process, including:
A memory;
a processor;
one or more computer system modules stored in the memory and configured to be executed by the processor, the one or more computer system modules including logic for implementing any of the methods described above, while recording each operational record for system post analysis to enhance the overall casting production process.
Compared with the prior art, the invention has the beneficial effects that:
the intelligent monitoring method, the intelligent monitoring system and the intelligent monitoring storage medium for the casting process can replace manual work according to product, mold and production process information of each casting device acquired in real time, and form process point inspection records of each casting device in each shift according to the set point inspection time in the system, so that a great deal of time is saved, and meanwhile, the accuracy of data is ensured. The system forms a multidimensional management mode for casting process parameters by recording the casting process change and combining quality inspection results and mold account information, so that the process parameter change process data is more comprehensive and accurate, and meanwhile, the change reasons of the casting production process can be analyzed by combining quality inspection results, mold account information and other angles, thereby accumulating a solid foundation for the integral improvement of the later casting process.
The following description of the embodiments of the present application will be made clearly and fully with reference to the accompanying drawings, in which it is evident that the embodiments described are some, but not all, of the embodiments of the present application. All other embodiments, which can be made by one of ordinary skill in the art based on the embodiments herein without making any inventive effort, are intended to be within the scope of the present application.
Example 1:
as shown in fig. 1, in embodiment 1, there is provided an intelligent monitoring system for a casting process, comprising: the system comprises an information acquisition module, a processing module and an analysis module.
The information acquisition module is used for acquiring real-time information of the casting equipment and the quality inspection equipment in real time, knowing the production condition of the current cast product, the model of the mould, the technological parameter information, monitoring the product with abnormal quality inspection results and real-time monitoring of casting technological change, and simultaneously communicating the intelligent casting machine adjusting system and the mould management system to adjust relevant process parameters.
The processing module records the change record of each casting process and summarizes key information such as the adjustment result, the process parameters and the reason analysis of each casting process according to the on-site processing condition.
The analysis module is used for recording each process parameter change adjustment record, accumulating a process parameter adjustment process, analyzing reasons and adjusting machine experience to form a knowledge base, and improving accumulated reliability data for the later casting process.
As shown in fig. 2, a flow chart of a method for intelligent monitoring of a casting process is given: a casting process intelligent monitoring system method comprises the following steps:
s01: the method comprises the steps of collecting detailed parameter information of casting equipment in the production process of producing products, such as product information, mould information, casting process parameters, aluminum liquid temperature and the like, collecting quality inspection result information of quality inspection equipment such as an X-ray machine, appearance inspection and the like, and realizing automatic association and data interaction with a mould management system and a casting intelligent machine adjusting system;
s02: setting casting process change monitoring logic in the system, setting continuous stable time, setting alarm pushing personnel and authority, setting corresponding technicians or related management personnel of cast products or machines, and setting auditing flow and node logic.
S03: the system monitors the production process information of each casting device in real time, and when the system monitors that the production process parameters of the casting device machine are changed, the system starts to comprehensively monitor and summarize the secondary production process change process to form a history record;
Wherein, step S03 includes the steps of: when the system monitors that the process of the casting equipment machine is changed, the system changes the originally marked green state of the casting equipment machine in the system into yellow, alarms and pushes the green state to corresponding managers, when the system monitors that the process of the process is changed for more than 4 times, the system changes the yellow state of the casting equipment machine into red and pushes the red state of the casting equipment machine to higher-layer managers to follow up attention until a field operator or a technician finishes the process change, the process change operation is not carried out for 1 hour continuously, and the records of the whole process change process are summarized to form a process change history record of the casting equipment machine, and the red state of the casting equipment in the system is not changed at the moment.
Wherein, step S03 includes the steps of: and the relevant management personnel of the casting process call up the historical record information of the machine in the yellow state or red state in the system, analyze the reason of the process change according to the on-site process call-up result, fill in the reason and analysis result, wait for the high-level management personnel to check and confirm, the system will finish the management closed loop of the casting process change at this time, and change the red state of the casting machine back to green.
Wherein, step S03 includes the steps of: the system marks the state of the casting machine table which is being subjected to process adjustment as not being finished, after the process adjustment is finished, the system is stabilized for 1 hour without any process change operation, the whole process record of the process change is formed, meanwhile, the casting machine table is changed to be untreated, relevant personnel of the casting process fill in the reason and result analysis, and after the high-level manager waits for checking and confirming, the casting machine table is changed to be finished.
S04: the system summarizes and summarizes the parameter changes of each casting process machine-switching monitoring process according to the setting logic, so as to form a process machine-switching history record, and provide solid data accumulation for the integral improvement of the later casting process.
As shown in fig. 3, a detailed flow chart of a casting process intelligent monitoring system of example 1 is provided.
1) When the quality problems are found in the quality inspection links such as X-ray machine, appearance detection and machine adjustment detection of the output product flow of the casting equipment, on-site personnel adjust the process parameters according to the quality problems, and the system monitors that the process changes and starts recording and changes the color state.
For example, the system monitors the operation process of each casting device in real time, when the quality problem is found in the field quality inspection link, the field personnel changes the process of the product producing machine according to the quality problem, the system monitors the process parameter of the casting machine to change, and starts to monitor the process change process of the casting machine, at the moment, the system changes the casting machine from an initial green state to yellow, at the moment, the state of the casting machine in the system is not finished, and the current condition alarm is pushed to the relevant manager, so that the current field personnel can perform process adjustment, when the field personnel changes the process of the casting machine more than 4 times, the system changes the state of the casting machine from yellow to red and pushes the casting machine to the relevant manager of a higher layer, and after the process adjustment of the field personnel is completed, the system continuously stabilizes for one hour, and judges that the process adjustment is finished. The system can carry out statistics and summarization on all process parameter change histories in the process from the first process parameter change to the process dispatching completion to form a process change history record, meanwhile, the system changes the state of the casting machine to be processed, on-site operators or technicians wait for searching specific process dispatching reasons according to the process dispatching content and information such as quality inspection information or mold machine account and the like and write the specific process dispatching reasons into the system, and after high-level related managers verify the process dispatching reasons, the system changes the state of the casting machine to be finished and restores to green.
2) When the system monitors that the process dispatching is automatically regulated by the intelligent dispatching system for casting, the system can regulate the state of a casting machine table in the system according to the real-time feedback result of the casting dispatching, and meanwhile, the system can automatically change the process dispatching reason into the intelligent dispatching.
For example, in the casting intelligent dispatching system, the process parameter adjustment logic corresponding to the quality inspection problem detected by part of quality inspection links in the casting production links is set, when the casting intelligent dispatching system receives the quality inspection problem fed back by the quality inspection links, if a corresponding solution is judged in the system, the process parameters of the corresponding machine of the product are automatically adjusted according to the solution logic set in the system, at the moment, the system changes and executes the system state conversion logic according to the monitored process parameters, meanwhile, the system performs data interaction with the casting intelligent dispatching system, the current process dispatching behavior is known to be executed by the intelligent dispatching system, finally, after the casting intelligent dispatching system finishes process adjustment, the system automatically fills out the process dispatching reason without manual operation, and meanwhile, the history record is related to the casting intelligent dispatching system, so that history data query and post analysis are convenient.
Example 2:
a storage medium storing non-transitory computer-readable logic that when executed performs any of the above is provided in embodiment 2. By using the storage medium, for example, in an intelligent casting process monitoring system, when stored non-transitory computer readable logic is executed by a computer, production product information, mold information, production process information, aluminum liquid temperature and the like on a casting equipment machine are acquired in real time to form a process change adjustment record, so that later calling and checking are facilitated to form a knowledge base.
The storage medium may include various forms of computer-readable storage media, such as volatile memory and/or nonvolatile memory. Volatile memory can include, for example, random Access Memory (RAM) and/or cache memory (cache) and the like. The nonvolatile memory may include, for example, read Only Memory (ROM), hard disk, erasable Programmable Read Only Memory (EPROM), portable compact disc read only memory (CD-ROM), USB memory, flash memory, and the like. One or more computer program modules may be stored on the computer readable storage medium and executed by the processor to implement casting process change monitoring logic for multiple types or multiple casting manufacturers. Various applications and various data, as well as various data used and/or generated by the applications, etc., may also be stored in the computer readable storage medium. In some embodiments, the memory medium may be disposed on a server side (or cloud), for example, the non-transitory computer readable logic may be stored on the cloud or cloud disk, and meanwhile, the process information of all the casting equipment production processes and process change overall is effectively stored.
Example 3:
as shown in fig. 4, in an embodiment of the present application, there is further provided an intelligent casting process monitoring system including a memory, a processor, a communication interface, and one or more computer system modules. The one or more computer system modules are stored in the memory and configured to be executed by the processor, the one or more computer system modules comprising logic to implement one of the methods described in any of the embodiments above. The processor signals connect the memory and the communication interface, which may be interconnected by a bus system and/or other form of connection mechanism (not shown).
The processor is configured to execute non-transitory computer readable logic that, when executed by the processor, may perform one or more steps of a method as described in any of the embodiments above. For example, the processor may be a Central Processing Unit (CPU), a Digital Signal Processor (DSP), or other form of processing unit having data processing and/or program execution capabilities, such as a Field Programmable Gate Array (FPGA), or the like, e.g., the Central Processing Unit (CPU) may be an X86 or ARM architecture, or the like. The processor can be a general-purpose processor or a special-purpose processor, and can track and record the casting machine with the process change in real time by combining the variation of the current process parameters through all the collected process parameters.
The memory is used to store non-transitory computer readable logic (one or more computer program modules). For example, the memory may comprise any combination of one or more computer system products, which may include various forms of computer-readable storage media, such as volatile memory and/or non-volatile memory. Volatile memory can include, for example, random Access Memory (RAM) and/or cache memory (cache) and the like. The nonvolatile memory may include, for example, read Only Memory (ROM), hard disk, erasable Programmable Read Only Memory (EPROM), portable compact disc read only memory (CD-ROM), USB memory, flash memory, and the like. One or more computer system modules may be stored on the computer readable storage medium and a processor may run the one or more computer system modules to implement process change logic for a variety of foundry manufacturers or a variety of production systems. Various systems and various data, as well as various data used and/or generated by applications, etc., may also be stored in the computer readable storage medium.
In some embodiments, the memory and the processor may also be provided on the server side (or cloud), for example, one or more computer program modules may be stored on the cloud or cloud disk.
The communication interface is connected with the system, the die management system, the casting intelligent machine adjusting system and all on-site casting equipment to receive and send information. In some embodiments, the whole flow monitoring of the process change of the casting equipment can be realized by the communication interface (such as a wired local area network, a wireless local area network, a 3G/4G/5G communication network, bluetooth and the like) based on the corresponding communication protocol and the real acquisition of the production product information, the mold information, the production process information, the aluminum liquid temperature and the like on the casting equipment machine. For example, the communication protocol may be any suitable communication protocol, such as bluetooth communication protocol, ethernet, serial interface communication protocol, parallel interface communication protocol, etc., as embodiments of the present disclosure are not limited in this regard.
The foregoing has outlined rather broadly the more detailed description of embodiments of the present application, wherein specific examples are provided herein to illustrate the principles and embodiments of the present application, the above examples being provided solely to assist in the understanding of the methods of the present application and the core ideas thereof; meanwhile, as those skilled in the art will have modifications in the specific embodiments and application scope in accordance with the ideas of the present application, the present description should not be construed as limiting the present application in view of the above.
Claims (7)
1. An intelligent monitoring method for a casting process is used for an intelligent monitoring system for the casting process and is characterized by comprising the following steps:
receiving production process parameters, production product information and mold information of the casting equipment in real time, and adjusting the production process parameters of the on-site casting equipment by on-site operators or technicians according to X-ray detection, appearance detection or machine adjustment detection quality inspection results;
when the system monitors that the production process parameters on the casting equipment are changed, the system starts to track and record the process change;
when the last production process parameter adjustment is completed for one hour, no process parameter change exists, the system gathers and records the process parameter adjustment history, a complete process parameter adjustment result in the system is formed, later-stage related management staff selects or inputs a process change reason in the system according to the whole process record of the process adjustment result in the system, corresponding reason analysis is written, and reliability data accumulation of casting equipment process change adjustment is formed; in the process of casting production process adjustment, accuracy of the adjusted process parameters is determined by quality inspection results of a plurality of links, and on-site operators or technicians continuously perfects the casting process parameters according to the quality inspection results until the quality of casting production products is stable;
In a complete casting process adjustment operation record, one or more process change adjustment operations exist, green color mark injection is carried out on a machine which is not subjected to process adjustment in the system, when the system monitors that the process parameters of casting equipment are changed, the system changes the color mark of the machine into yellow and pushes the machine to related personnel for alarm pushing, and when the process change adjustment operation exceeds 4 times in the casting process adjustment process, the system changes the color standard of the machine into red and pushes the machine to higher-level related management personnel for follow-up; after the continuous stable operation of the casting equipment process change adjustment is carried out for 1 hour, the system gathers all records of the casting process change to form a casting equipment process change history record;
the relevant manager combines the casting process change record information, writes the reason and reason analysis of the corresponding process adjustment, carries out closed-loop management on the casting process change record after checking and confirming by the higher-level manager of the system flow, and changes the machine color label into green again after checking and confirming the corresponding adjustment reason and reason analysis in the system;
when relevant management personnel process the casting process change history record, the intelligent casting process monitoring system performs cause analysis filling according to the collected abnormal state of equipment or alarm information, so that on-site operators can conveniently and quickly locate the problem;
The system background of the intelligent casting process monitoring system is linked with the intelligent casting machine adjusting system, and the intelligent casting machine adjusting system automatically adjusts the casting production process according to the set machine adjusting logic and the acquired quality inspection result; the intelligent casting process monitoring system automatically records the process change history of the intelligent casting machine adjusting system, automatically adjusts the labeling state of the machine in the intelligent casting process monitoring system according to the adjustment of the intelligent casting process by the intelligent machine adjusting system, and automatically records the reason of the process change as an intelligent machine after the process change adjustment is finished so as to be distinguished from manual adjustment, and meanwhile, the intelligent casting process monitoring system can be directly related to the intelligent casting machine adjusting system to check the specific reason of the process machine;
the intelligent casting process monitoring system is associated with a mold management system, corresponding molds are queried according to the change history record of the casting process, mold account information is simultaneously retrieved, the related casting process adjustment record is queried by taking the casting mold as a dimension in the intelligent casting process monitoring system, and related management personnel are matched for analyzing the process adjustment reason,
In the intelligent casting machine adjusting system, process parameter adjusting logic corresponding to quality inspection problems detected by part of quality inspection links in the casting production links is set, when the intelligent casting machine adjusting system receives the quality inspection problems fed back by the quality inspection links, if a corresponding solution is judged in the intelligent casting process monitoring system, the process parameters corresponding to the machine platform of the product are automatically adjusted automatically according to the solution logic set in the intelligent casting process monitoring system, at the moment, the intelligent casting process monitoring system changes and executes system state conversion logic according to the monitored process parameters, meanwhile, the intelligent casting process monitoring system carries out data interaction with the intelligent casting machine adjusting system, the intelligent casting process monitoring system knows that the current process machine adjusting behavior is executed by the intelligent casting machine adjusting system, finally, the intelligent casting process monitoring system automatically fills out the process machine adjusting reason after the intelligent casting machine adjusting system completes process adjustment, and meanwhile, the history record is related to the intelligent casting machine adjusting system.
2. The intelligent monitoring method for casting process according to claim 1, comprising the steps of:
the intelligent casting process monitoring system collects quality inspection result information, monitors the temperature of aluminum liquid, the mold filling pressure, the mold filling time, the mold cooling water flow, the cooling air flow, the cooling opening time and the cooling duration time information on a machine table in real time, pushes alarm information to related personnel at the first time when quality inspection result problems occur, machine table alarms and process parameters exceed set values, processes the alarm information by matching with site operators or technicians, and automatically associates the alarm information with process change records to form casting process adjustment histories after the operators or technicians perform process adjustment according to the alarms.
3. The intelligent monitoring method for casting process according to claim 1, comprising the steps of:
after the complete record of the primary casting change process adjustment is carried out in the intelligent casting process monitoring system, marking the historical record of the primary casting change process as an unprocessed state in the historical record and the system to be done by the intelligent casting process monitoring system until relevant management staff writes the reasons and the reason analysis of the change adjustment result and completes the verification confirmation, and then the intelligent casting process monitoring system changes the historical record of the primary casting change process into a completed state;
when the intelligent casting process monitoring system starts to monitor the change of the casting process parameters, the intelligent casting process monitoring system automatically forms a casting process change record under the machine, the state of the record is incomplete, and when the system monitors that no process parameters are changed for one hour continuously after the on-site operator or technician finishes the last process change, the intelligent casting process monitoring system forms a historical record, and changes the state of the historical record into unprocessed state so as to facilitate the related manager to write corresponding reasons and reason analysis.
4. The intelligent monitoring method for casting process according to claim 1, comprising the steps of:
the intelligent casting process monitoring system supports function release of an apple system and an android system, ensures safety of data transmission based on field industrial network segment application, realizes access of an external network of a mobile phone end of the system through port mapping, and simultaneously can realize an alarm pushing function, a cause analysis function and an approval confirmation function through the mobile end.
5. An intelligent monitoring system for a casting process for implementing the method of any one of claims 1-4, comprising the steps of:
the information acquisition module is used for acquiring real-time information of the casting equipment and the quality inspection equipment in real time, knowing the production condition, the mould model and the technological parameter information of the current casting product, monitoring the product with abnormal quality inspection result and monitoring the change of the casting technology in real time, and simultaneously communicating the intelligent casting machine adjusting system and the mould management system to adjust relevant process parameters;
The processing module records the change record of each casting process and summarizes the adjustment result, the process parameters and the cause analysis key information of each casting process according to the on-site processing condition;
the analysis module is used for recording each process parameter change adjustment record, accumulating a process parameter adjustment process, analyzing reasons and adjusting machine experience to form a knowledge base, and improving accumulated reliability data for the later casting process.
6. A storage medium storing non-transitory computer readable logic that when executed is capable of performing a method embodying any one of claims 1-4.
7. An intelligent monitoring system for a casting process, comprising:
a memory;
a processor;
one or more computer system modules stored in the memory and configured to be executed by the processor, the one or more computer system modules comprising means for implementing the method of any of claims 1-4 while recording each operational record for system post analysis to enhance the overall casting production process.
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