THERMAL CONTROL UNIT FOR CASTING PROCESSES

BACKGROUND

Casting manufacturing, such as high-pressure die casting manufacturing, relates to processes in which liquefied material, such as molten metal, is poured or injected into the cavity (e.g., the shot sleeve) of a specially designed mold and allowed to harden. As applied to metal casting, the molds are generally referred to as “steel dies” or “dies” and can be made from non-ferrous metals, specifically zinc, copper, aluminum, magnesium, lead, pewter, and tin-based alloys. In high-pressure die casting, molten metal, such as aluminum is forced into the die/mold via high pressure into the mold cavity and held in place via compressive forces applied to the die. The specific amount of pressure and temperature of the molten metal being injected into the mold chamber can vary based on the characteristics (e.g., melting temperature) of the metal being injected in the mold. Casting methods can be utilized to form a variety of products for a wide range of applications, including automotive components, aerospace parts, etc.

SUMMARY

An aspect of this disclosure is directed to a casting system. The system includes a plurality of fluid sources, wherein individual fluid sources are configured to provide a fluid at specified operating parameters. The specified operating parameters include at least a specified temperature. The system further includes a plurality of casting circuits, wherein individual casting circuits include an input fluid having a specified temperature parameter for fluid utilized in a casting process, wherein the input fluid corresponds to a mixing of the plurality of fluid sources.

A variation of the aspect above, wherein the plurality of fluid sources include a central fluid reservoir supplying fluid corresponding to a first specified temperature and wherein the central fluid reservoirs provide fluid at least one additional fluid source of the plurality of fluid sources.

A variation of the aspect above, wherein the plurality of fluid sources comprise the first fluid source at a first specified temperature, a second fluid source at a second specified temperature, and a third fluid source at a third specified temperature.

A variation of the aspect above, wherein the plurality of fluid sources include a heat exchanger configured to generate fluid at the second specified temperature based on the first fluid source, wherein the second specified temperature is lower than the first specified temperature.

A variation of the aspect above, wherein the plurality of fluid sources include a heater configured to generate fluid at the third specified temperature based on the first fluid source, wherein the third specified temperature is higher than the first specified temperature.

A variation of the aspect above, wherein the plurality of casting circuits include one or more fluid source outlet valves configured to control a mixing ratio of the plurality of fluid sources.

A variation of the aspect above further includes a return line configured to direct used fluid from the plurality of casting circuits to the central fluid reservoir, and an outlet valve configured to control attributes of fluid in the return line.

A variation of the aspect above further includes a plurality of feedback sensors to monitor attributes of fluids in one or more of the plurality of fluid sources and/or the plurality of fluid lines and provide feedback signals.

Another aspect is directed to a thermal management system. The system includes a set of shared thermal infrastructure equipment for use in casting processing. The set of shared thermal infrastructure equipment includes a fluid reservoir providing fluid at a first specified temperature, a heat exchanger providing fluid at a second specified temperature, and a heater providing fluid at a third specified temperature. The system further includes a plurality of casting circuits, wherein individual fluid lines supply to a die casting circuit, and at least one of the plurality of casting circuits has a specified temperature. The plurality of casting circuits are associated with a combination of a plurality of fluid lines, wherein individual fluid lines receive three fluid inputs corresponding to the fluid at the first specified temperature, the fluid at the second specified temperature, and the fluid at the third specified temperature. The individual fluid lines generate an output fluid corresponding to a combination of the fluids based on individual control parameters. The system also includes a controller configured to specify the control parameters for the plurality of fluid lines.

A variation of the aspect above, wherein the controller executes the control parameters for the plurality of fluid lines by controlling one or more valves configured to mix and direct the three fluid inputs according to a mixing ratio.

A variation of the aspect above, wherein the controller determines the mixing ratio of the three fluid inputs based at least in part on input information corresponding to desirable operating parameters for the system.

A variation of the aspect above, wherein the controller monitors attributes of one or more of the three fluid inputs and the plurality of fluid lines, and makes adjustments to the control parameters based at least in part on the attributes.

Another aspect is directed to a controller for a thermal management system. The controller is configured to receive input information corresponding to one or more casting circuits, individual casting circuits corresponding to a fluid line, and individual fluid lines corresponding to a combination of a plurality of fluid sources. The controller is further configured to receive feedback signals for individual fluid sources and individual fluid lines. The controller is also configured to determine individual control parameters for the individual fluid lines based at least in part on the one or more inputs, the control parameters comprising at least a ratio of the plurality of fluid sources in the combination of the plurality of fluid sources.

A variation of the aspect above, wherein the input information comprises desirable operating temperatures for the one or more casting circuits, and wherein at least one of the plurality of casting circuits has a desired temperature different from that of the rest of the plurality of casting circuits.

A variation of the aspect above, wherein the feedback signals comprise temperature information for the individual fluid sources, and wherein the controller is configured to adjust temperatures of the individual fluid sources based at least in part on the temperature information for the fluid sources.

A variation of the aspect above, wherein the controller is configured to adjust temperatures of the individual fluid sources by controlling a pump, a heater, and/or a heat exchanger.

A variation of the aspect above, wherein the feedback signals comprise temperature information for the fluid lines, wherein the controller is configured to adjust temperatures of the individual fluid lines based at least in part on the temperature information for the fluid lines.

A variation of the aspect above, wherein the plurality of fluid sources are combined by one or more fluid source outlet valves, and wherein the controller is configured to adjust temperatures of the individual fluid lines by controlling one or more fluid source outlet valves to adjust the ratio of the plurality of fluid sources in the combination of the plurality of fluid sources.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is described with reference to the accompanying drawings, in which like reference characters reference like elements, and wherein:

FIG. 1 is a block diagram illustrating an exemplary embodiment of a thermal system for casting circuits according to this disclosure.

FIG. 2 is a block diagram illustrating a logical representation of an exemplary control system for use in the thermal system in FIG. 1.

FIG. 3 depicts one embodiment of a controller for a thermal system.

FIG. 4 is a flow chart illustrating an exemplary control process for use by a controller in accordance with a thermal system.

DETAILED DESCRIPTION

Generally described, the pressure and temperature of molten metal being injected into a mold chamber, and the pressure and temperature of the mold chamber can vary based on the characteristics (e.g., melting temperature) of the metal being injected in the mold or the size and/or shape of the part being casted. In one specific aspect, casting processes or methodologies can include or incorporate thermal systems that are configured to implement various types of thermal transfers during the casting process. For example, a thermal system may be configured to increase or maintain temperature experienced at the die during the casting process. In another example, a thermal system may be configured to extract heat or decrease temperature experienced at the die during the casting process. The casting processes can illustratively specify different thermal temperature ranges/inputs at different portions of the casting processes. Additionally, in more complex scenarios, a die may be characterized as having different portions in which individual portions of the die may be specified with different thermal temperature ranges/inputs during the casting process.

One approach to implementation of a thermal systems in a casting process corresponds to large-scale manufacturing equipment in which thermal energy is exchanged between the die and the thermal system via a fluid, such as oil-based fluids or fluid-based fluids. The thermal energy that is exchanged can be based on the temperature of the fluid, pressure of the fluid and/or the flow rate of the fluid through the individual fluid line. Additionally, in some approaches, the thermal system can be further configured to provide a set of individual thermal inputs, often referred to as circuits, in which the thermal system has individual fluid lines or circuits that can be applied to the die at specific locations. Illustratively, one or more of the individual fluid lines can have some adjustable parameters that can vary the amount of thermal exchange between the thermal system and the die.

One approach to implementation of such a multi-input thermal system corresponds to implementation of thermal control units for each circuit/fluid line. Traditional thermal control unit (TCU) systems are deployed in individual housings that are physically mounted in a manufacturing environment. Each individual TCU housing includes a fluid pump, control valve(s), heater, heat exchanger, water reservoir, and etc. that are configured to generate a pressurized fluid having a specified temperature. The components within an individual TCU are configured to work in concert according to the specified temperature and pressure parameters (e.g., the heater and heat exchanger must be configured in combination). The complexity of the component interaction can often result in lag or slow responsive time to make adjustments to the inputted temperature. Additionally, for thermal system incorporating multiples of TCUs (e.g., 20, 30, 40, 50, 100), the housings including the plurality of TCUs often require a very large footprint of manufacturing space. Additionally, maintenance and management of the individual components at scale may create further deficiencies. For example, various operational issues, including corrosion and scaling, cleaning, updates, extra downtime, and need of maintenance become more problematic in requiring individual access to the TCUs. There also remains a need to address these common operational issues to reduce costs and improve efficiency.

To address at least a portion of the deficiencies discussed above, at least in part, one or more aspects of the present disclosure relate to a thermal system. More specifically, the present application relates to a thermal system for casting processes that can be used to manufacture larger parts with lower costs and fewer operational issues. In certain embodiments, one or more aspects of the disclosure relates to a thermal system for high pressure die casting process and tooling. As will be described in detail below, the thermal system may be implemented in a manner such that a set of individual fluid lines, or circuits, may be implemented utilizing a common or shared set of input fluids or fluid sources, illustratively, three input sources of pressurized fluid at different temperatures. The individual circuits can be individually controlled by control processes that define how the three input fluids are blended or combined to form the fluid line provided to a die. Illustratively, a set of control valves corresponding to each fluid line can facilitate the blending/combination process. Additionally, a control valve on a return line corresponding to each individual fluid line can further control the flow rate of the pressurized, combined input fluid to individually control the flow rate on a per line basis.

Various aspects of this application disclose a system that can supply fluid of desired flow rate, temperature, and pressure (e.g., 15-22 bar) to over 100 individually controlled circuits. More specifically, the flow rate, temperature, and pressure of each circuit can be monitored in real time and actively adjusted instantly. Although one or more aspects of the present application will be described with regarding to exemplary numbers of fluid lines (e.g., circuits), temperature ranges, pressure ranges, and utilizations, one skilled in the relevant art will appreciate that the examples are illustrative in nature and should not be construed as limiting.

FIG. 1 is a block diagram illustrating a thermal system 1000 incorporating one or more aspects of the present application. As shown in FIG. 1, the thermal system 1000 can include a set of centralized infrastructure components that can be configured to provide common sources of input fluid to a set of fluid lines (or circuits). More specifically, the centralized infrastructure components can include centralized fluid system that comprises a central fluid reservoir 20, a heat exchanger 30, and a heater 33. As will be described in greater detail below, each of the centralized infrastructure components provide one of three input sources at banks of inputs sources 100A, 100B, 100C that correspond to individual circuits/fluid lines of a casting process. For example, if a casting system includes 10 distinct circuits/fluid lines, each respective circuit would include an input line from the central fluid reservoir 20 (at a first temperature), an input line from the heat exchanger 30 (at a second temperature), and an input line from the heater 33 (at a third temperature). As will be explained in greater detail below, a temperature of each individual circuit can be individually controlled according to defined parameters based on mixing or blending of the inputs from respective banks of circuit/fluid line inputs 100A, 100B, 100C.

For purposes of present application, the thermal system 1000 can include a number of components, such as filters, pumps, values, interconnects, and sensing components that are not illustrated in FIG. 1 for purposes of simplification. Generally described, in some embodiments, the central fluid reservoir 20 can be fed from a fluid supply 10 using a pump 11. In some embodiments, a drain line 12 can deliver surplus fluid from the central fluid reservoir back to the fluid supply 10 to recycle the fluid.

As previously described, the thermal system 1000 is configured to provide a plurality of fluid sources at different temperature ranges. In some embodiments, the central fluid reservoir 20 may supply to the entire system through a pump 22. In one aspect, the central fluid reservoir 20 can provide fluid that is maintained at a first specified temperature (e.g., “warm temperature”) and is directly provided as input to a first bank of input sources 100C. In some embodiments, the first water source 100 may be directly fed from the central fluid reservoir 20 and be maintained at or around the first specified temperature 104. The fluid reservoir 20 can further provide fluid to one or more of the other input sources.

In one aspect, the heat exchanger 30 can be configured to cool fluid from the central fluid reservoir 20 and generate a second fluid source at a second specified temperature (e.g., “lower temperature” or “cold temperature”). The fluid from the heat exchanger 30 can be provided as input to the second bank of input sources 100B.

In yet another aspect, the heater 33 can be configured to heat fluid from the central fluid reservoir 20 and generate a third fluid source at a third specified temperature (e.g., “higher temperature” or “hot temperature”). The fluid from the heater 33 can be provided as input to the third bank of input sources 100A. By having fluid at three different temperatures, the system can instantly supply water within a certain temperature range by mixing the three at a certain proportion to enable instant temperature adjustment in the system.

As previously described, the individual fluid lines of the thermal system can further include one or more fluid source outlet valves including, for example, a three-way-valve (not shown) to regulate fluid coming from inputs from respective lines from the three banks of input sources 100A, 100B, 100C. Thereby, the temperature of fluid supplied to each casting circuit in the system can be individually adjusted and controlled by each three-way-valve. For example, to provide water at a temperature higher than the desired temperature, the valves can be controlled to allow warm water (e.g., first specified temperature) and hot water (e.g., third specified temperature) to enter the circuit at a certain proportion predetermined or determined by a control process. The desired temperature of the central fluid reservoir can be a pre-determined temperature fit for the processes in the system. In some embodiments, a control process can be used to determine the desired temperature, which is a temperature that can be minimally and most efficiently adjusted to satisfy different needs of the circuits in the system. Additionally, a control system can determine and change the desired temperature in real time by the control process based on monitored temperature data of the circuits in the system. With a desired temperature that requires minimal adjustments with hot and cold water, the system can reduce power usage by the heat exchanger and the heater in order to increase efficiency. Still further, the use of combination of input fluids provides for increased response time or dynamic adjustment that may be beneficial in the casting process. For example, the fluid temperature can be immediately increased or decreased based on different blending processes without need to adjust the controls or the heater or heat exchanger.

FIG. 1 illustrates a logical organization of a thermal system 1000 having a single set of centralized infrastructure components, namely, the central fluid reservoir 20, the heat exchanger 30, and the heater 33. Additionally, FIG. 1 illustrates that the inputs from the centralized infrastructure components corresponds to banks of inputs sources 100A, 100B, 100C. In some embodiments, the thermal system 1000 can be organized such that multiple sets of centralized infrastructure components can be implemented to serve a plurality of casting circuits with different subsets of fluid lines. For example, the thermal system 1000 may include a plurality of central fluid reservoirs 20, heat exchangers 30, or heaters 33. Similarly, FIG. 1 illustrates that the banks of inputs sources 100A, 100B, 100C correspond to an organization of inputs lines for each circuit in the thermal system 1000. In some embodiments, the banks of inputs sources 100A, 100B, 100C may not be physically correlated to require grouping of all the inputs. In still other embodiments, the thermal system 100 can include some sub-groupings of input lines based on attributes/specifics of individual casts.

Illustratively, a control process or set of control processes may be implemented in a computing device that is configured to determine individual parameters or settings that generate a target temperature, pressure and flow rate for individual fluid lines. The temperature range and the proportion of fluids can be pre-determined or determined by the control process. Additionally, the control process may incorporate sensor or measurement data collected in real-time to allow for dynamic adjustment of the attributes or settings. Illustratively, a controller utilized to implement the control processes may include physical hardware components, one or more virtualized components, or a combination thereof. Additionally, the components of the controller or the functionality attributed by the controller may be implemented in a virtualized environment. Illustratively, the controller can include a processing unit, a network interface, a computer-readable medium drive, and an input/output device interface, all of which may communicate with one another by way of a communication bus. The components of the controller may be physical hardware components or implemented in a virtualized environment.

As described above with respect to FIG. 1, in other aspects, the individual fluid sources can also be configured to include valves that can adjust flow rate and pressure instantly and dynamically during a casting cycle. As described above, each casting circuit can include one or more individual valves so the casting circuit's flow rate and pressure can also be adjusted individually to fit its specific need. In some embodiments, since the fluid can be supplied to a casting circuit at three different temperatures, pressure differences between the three fluid sources connected to each three-way-valve can cause the fluid to back flow. It may be desirable to include one or more valves on each fluid source to control the flow and pressure of the fluid to create a proper pressure differential between the fluid sources to prevent backflow.

Additionally, as described above with respect to FIG. 1, the thermal system 1000 can include one or more valves on the return line 35 of the used fluid to regulate a flow and pressure of the fluid returning to the central fluid reservoir 20. The return fluid can be from the casting system 50 after utilization in the casting process. Additionally, the return fluid can be from excess or unused fluid provided at the banks of inputs sources 100A, 100B, 100C. Since fluid can be at various different temperatures and pressures after different casting processes at the casting circuits, it can be advantageous to adjust the flow and pressure of fluid before the fluid returns to the reservoir to make sure the fluid flows back to the fluid reservoir and mixes properly. Additionally, this system can supply fluid maintained at a high pressure to each circuit in its liquid form because of the capability of controlling and maintaining pressure. The return line 35 can further include additional filters or processing components to ensure that any potential contaminants can be removed prior to return to the central fluid reservoir 20.

In traditional thermal systems for casting, oil is commonly used as the casting fluid because it can be maintained in its liquid form at a desired high temperature that would exceed the typical boiling point of a water-based fluid. By supplying high-pressure fluid that does not boil at its normal boiling point (i.e., 212° F. or 100° C.), one or more aspects of the thermal system 1000 of the present application can the utilization of a variety of different fluids for the casting system, such as water, with a low boiling point to minimize fire hazards, be more environmentally friendly, and have better heat transfer. In this regard, the fluids can include various combinations or mixtures of fluids, such as water-based fluids that include additional mixing substances.

The thermal system 1000 can also include one or more feedback sensors 2 that can provide inputs to the system regarding the input flows for the banks of inputs sources 100A, 100B, 100C. Illustratively, the feedback sensors 2 can include, but are not limited, to one or more sensors configured for instant flow detection, pressure detection (inlet and outlet at casting circuit), temperature detection (inlet and outlet at casting circuit), leak detection and the like. By way of illustrative examples, each of the banks of inputs sources 100A, 100B, 100C can be associated with feedback sensors 2 that include a temperature transmitter (“TT”), pressure transmitter (“PT”), and flow transmitter (“FT”). Illustratively, each feedback sensor 2 can be implemented at various points of the thermal system 1000 to monitor temperature, pressure, and flow rate and provide feedback to the control system to better regulate temperature, pressure, and flow of the fluid.

In some embodiments, the feedback sensors 2 can also include one or more thermal cameras for each casting circuit to provide feedback to the system and better control the flow and temperature for each circuit. For example, one or more infrared cameras can be attached to each die cast machine. The control system can employ an process to determine various metrics that can most efficiently run the system and identify any defects and leaks in the system.

FIG. 2 illustrates a logic representation of an exemplary control system 2000 including a controller 40 configured to control the thermal system 1000 disclosed herein. In some embodiments, the controller 40 can receive one or more inputs corresponding to the desired operating parameters of a casting process. The one or more inputs can correspond to specific operating parameters for individual casting circuits or sets of casting circuits. In some embodiments, for example, the one or more inputs can include desirable operating temperatures for the one or more casting circuits. In other embodiments, the one or more inputs can also include desirable operating temperatures for each of the fluid sources 210, 212, 214 (e.g., the three fluid temperatures). The inputs may be provided via various interfaces, such as graphical user interfaces, application program interfaces (“APIs ”), etc. Additionally, in some embodiments, the inputs may be pre-configured or recall from profiles that have been previously provided to the controller 40.

Illustratively, the controller 40 can be configured to control pumps to deliver fluid to the casting system 50 (FIG. 1). Specifically, the controller 40 can provide control, or otherwise provide instructions, that cause the preparation and delivery of fluid from one or more of the banks of inputs sources 100A, 100B, 100C for individual circuits. For example, the controller 40 can be configured to cause the delivery of fluid from the central fluid reservoir 20 to a first bank of input sources 100C (FIG. 1). In some embodiments, the controller 40 can be configured to control the pump 22 to cause the delivery of fluid from the central fluid reservoir 20 to a first bank of input sources 100C. The controller 40 can be configured to control the heat exchanger 30 to cool and generate fluid at the second specified temperature and a second bank of input sources 100B (FIG. 1). Still further, the controller 40 can also be configured to control the heater 33 to heat and generate fluid at the third specified temperature and going to the third bank of input sources 100A (FIG. 1).

As shown in FIG. 2, fluid from the first, the second, and the third fluid sources are shown in individual lines 210, 212, and 214 and may be combined at the one or more fluid source outlet valves 7. The combined fluid then proceeds via fluid line 216 to the casting circuit 50 (FIG. 1). In some embodiments, the controller 40 can be configured to control the one or more fluid source outlet valves 7 to mix fluids from the first, the second, and the third fluid sources 210, 212, 214 in a desired proportion in order to supply fluid to the fluid line 216 at a desired temperature corresponding to a desirable operating temperature for the casting circuit 50. The controller 40 may determine operating parameters (e.g., a mixing ratio) for the one or more fluid source outlet valves 7 based at least in part on the one or more inputs parameters. Illustratively, the controller 40 can transmit control instructions or operating parameters to the valve (or an associated controller) via a control line 200. The control line 200 can correspond to both direct electrical control lines, wireless transmissions and the like.

In accordance with various embodiments, the controller 40 can also be configured to receive a first feedback signal 202 corresponding to the fluid being provided by the central fluid reservoir 20, a second feedback signal 204 corresponding to the fluid being provided by the heat exchanger 30, and a third feedback signal 206 corresponding to the fluid being provided by the heater 33. The first, second, and third feedback signals 202, 204, 206 may illustratively be provided from feedback sensors 2 (FIG. 1) positioned along the fluid sources (e.g., TT, PT, and FT). In other embodiments, the central fluid reservoir 20, a heat exchanger 30, and a heater 33 may be further configured with feedback sensors 2 to provide feedback alone or in combination with additional feedback sensors (such as sensors integrated in the input lines coming from the central fluid reservoir 20, a heat exchanger 30, and a heater 33.

The controller 40 can determine adjustments needed to a flow rate, temperature, and/or pressure of fluids from the first, the second, and the third fluid sources 210, 212, 214, based at least in part on the first, the second, and the third feedback signals 202, 204, and 206 (e.g., a temperature information). In some embodiment, the controller 40 can be configured to make the adjustments to the flow rate, temperature, and/or pressure of fluids from the first, the second, and the third fluid sources 210, 212, 214 by controlling the pump 22, heat exchanger 30, and heater 33 respectively. For example, if the controller 40 received a third feedback signal 206 indicating that the fluid from the third fluid source 214 is at a temperature lower than the desirable temperature included in the inputs, the controller 40 may control the heater 33 to heat up fluids going into the third fluid source 300.

Similarly, the controller 40 can also receive a fourth feedback signal 220 corresponding to fluid from the return line 208 as shown in FIG. 2. In some embodiments, for example, the fourth feedback signal 220 may include pressure information. In some embodiments, the controller 40 can be configured to determine adjustments needed to a flow rate, temperature, and/or pressure of fluids in the return line through one or more sensors (e.g., TT, PT, and FT). In some embodiments, the determined adjustments to be made may be based at least in part on the inputs including, for example, a desired pressure at the central fluid reservoir 20, where the return line may route to. Based at least in part on the determined adjustments to be made, the controller 40 can be configured to control an outlet valve to change the pressure of fluid in the return line 208

FIG. 3 depicts one embodiment of an architecture of an illustrative controller 40 for managing one or more controller parameters associated with the thermal system. The general architecture of the controller 40 depicted in FIG. 3 includes an arrangement of computer hardware and software components that may be used to implement aspects of the present disclosure. As illustrated, the controller 40 includes a processing unit 302, a network interface 304, a computer-readable medium drive 306, and an input/output device interface 308, all of which may communicate with one another by way of a communication bus. The controller 40 may be physical hardware components or implemented in a virtualized environment.

In some embodiments, the controller 40 can include a network interface 304 that may provide connectivity to one or more networks or computing systems or components of the thermal system 1000. The processing unit 302 may thus receive information and instructions from other computing systems or services via a network, such as configuration of the operating parameters of individual casting processes. The processing unit 302 may also communicate to and from memory 310 and further provide output information for an optional display via the input/output device interface 308. In some embodiments, the controller 40 may include more (or fewer) components than those shown in FIG. 3, such as if the controller 40 is implemented as an integrated component, such as programmable logic controller (“PLC”) that may have more limited interfaces.

The memory 310 may include computer program instructions that the processing unit 302 executes in order to implement one or more embodiments. The memory 310 generally includes RAM, ROM, or other persistent or non-transitory memory. The memory 310 may store an operating system 314 that provides computer program instructions for use by the processing unit 302 in the general administration and operation of the controller 40. The memory 310 may further include computer program instructions and other information for implementing aspects of the present disclosure. For example, in one embodiment, the memory 310 includes interface software 312 for receiving and transmitting data in accordance with various aspects of the present application.

Additionally, the memory 310 may include sensor interface component 316 for obtaining and processing inputs or configuring one or more feedback sensors 2 as described in accordance with various aspect. Illustratively, the thermal system 1000, in some embodiments, may include a plurality of feedback sensors 2 associated with each of the banks of inputs sources 100A, 100B, 100C or central fluid reservoir 20, heat exchanger 30, and heater 33. Additionally, the memory 310 may include an operating parameter component 318 for configuring the operating parameters for individual casting processes of the thermal system 1000. In some embodiments, the operating parameters can include operational parameters associated with the central fluid reservoir 20, heat exchanger 30, or heater 33. Such operational parameters include, but are not limited to, fluid temperature, fluid pressure, fluid composition, fluid section, and the like. In other embodiments, the operating parameters can include a determination of the mixing operational parameters implemented by one or more values 7 (FIG. 2). Such mixing operational parameters include, but are not limited to, mixing percentages, mixing times, volume thresholds, and the like. The memory 310 can further include an outlet valve interface component 320 and infrastructure interface component 322 for generating, selecting, configuration or transmitting control instructions to outlet valves 7 associated with individual circuits or the central fluid reservoir 20, heat exchanger 30, or heater 33 in accordance with determined parameters.

FIG. 4 illustrates an exemplary control process 400 for the thermal system 1000 disclosed herein. Process 400 may be illustratively implemented by a controller 40 or groups of controllers. Illustratively, at block 402, the controller 40 can be configured to first obtain input information associated with one or more casting processes in the thermal system 1000. As described above, the inputs may be provided via various interfaces, such as graphical user interfaces, application program interfaces (“APIs”), etc. Additionally, in some embodiments, the inputs may be pre-configured or recall from profiles that have been previously provided to the controller 40.

At block 404, the controller 40 can be configured to determine operational parameters for the components of the thermal system. As described above, in some embodiments, the operating parameters can include operational parameters associated with the central fluid reservoir 20, heat exchanger 30, or heater 33. Such operational parameters include, but are not limited to, fluid temperature, fluid pressure, fluid composition, fluid section, and the like. In other embodiments, the operating parameters can include a determination of the mixing operational parameters implemented by one or more values 7 (FIG. 2). Such mixing operational parameters include, but are not limited to, mixing percentages, mixing times, volume thresholds, and the like. The input information, as described above, can include, for example, a desirable temperature for the one or more casting circuits. a mixing ratio for the plurality of fluid sources and other operating parameters for the control system 2000. The operating parameters can include, for example, desirable temperatures for the plurality of fluid sources 100A, 100B, and 100C and/or operating parameters (e.g., desirable pressure) for the return line 400.

In some embodiments, as part of block 404, the controller 40 can be configured to control (or cause control) of one or more fluid valves 7 to supply fluids from the fluid sources respective banks of fluid sources 100A, 100B, 100C to the fluid line 216 according to the mixing ratio determined at block 504. Also at block 404, in some embodiments, the controller 40 can be configured to control the central fluid reservoir 20, the heat exchanger 30, and/or the heater 33 to control attributes of the fluid sources 100A, 100B, and 100C respectively as previously described. In some embodiments, the controller 40 can control the attributes of the fluid sources 100A, 100B, and 100C according to the operating parameters determined at block 402.

At block 406, the controller 40 can be configured to monitor attributes (e.g., temperature, flow rate, and/or pressure) of fluids in the 100A, 100B, 100C, and the resulting fluid mixes in the fluid line 216. In some embodiments, the controller 40 can monitor the attributes of fluids by receiving feedback signals from feedback sensors 2 associated with each respective input from the banks of inputs 100A, 100B, 100C.

At decision block 408, in some embodiments, the controller 40 may decide whether to make adjustments to one or more operational parameters or control instructions based on the feedback. For example, the controller 40 can be configured with various thresholds or processing logic that can be evaluated to determine whether one or more of the inputs sources associated with the 100A, 100B, 100C should be adjusted (e.g., temperature or pressure change) or if the mixing ratios associated with individual valve 7 (or groups of valves 7) should be adjusting. If the controller 40 decide not to make adjustment or after the adjustments are determined, the control process 400 may proceed to block 412 to control an outlet valve to maintain the used fluid in the return line 35 under desired conditions (e.g., a desirable pressure) based on the input information. Process 400 can then repeat until the casting process is terminated.

The utilization of centralized fluid supply and control circuit can allow this thermal system to occupy 50% less floor space than traditional thermal control unit (TCU) systems as less units of various components (e.g., pumps, control valves, heaters, fluid reservoirs, temperature transmitters, piping) are required. At the same time, this system can maintain the same amount of efficiency as the individually controlled TCU to conserve utilities. For example, the system's method of mixing fluid at different temperature and real time fluid refresh reduces the power needed to maintain temperature and pressure and the amount of downtime and maintenance required.

This system also addresses several operational issues, such as corrosion and scaling in the casting circuits. In a traditional TCU system, scaling is removed from fluid by draining and refilling all of the fluid inside each unit, which can take up to several hours and result in machine downtime. If fluid is not maintained and changed regularly and timely, fluid with impurities can cause corrosion in the casting circuits and less efficient heat transfer of the system. An aspect of this application includes using real time fluid refresh to reduce corrosion and scaling in the casting circuits in real time to maintain fluid quality in the process as shown in FIG. 1. Real time fluid refresh can be enabled by one or more filters placed in this centralized system. For example, one or more filters can be place at the return line of fluid and filter the fluid returning to the central fluid reservoir in real time to remove any impurities coming from the casting processes. Additionally, fresh soft fluid can be constantly supplied to the central fluid reservoir to minimize machine downtime as compared to a traditional TCU system. Also, real time fluid refresh can achieve an efficient system with maximum heat transfer because of reduced scaling and corrosion in the casting circuits. The amount of maintenance required is also reduced because of less scaling and corrosion in the system.

This system also allows more precise leak detection with point of use sensors, data tending, pattern recognition, utilization of special geometry tanks, and flow direction in and out of the tank to allow for precise level monitoring to detect leaks. Molten aluminum interacts explosively with fluid, and this system can help eliminate this risk. Additionally, the high-pressure system architecture allows replacement of all oil circuits in the system with fluid by supplying liquid fluid at a temperature above boiling point. Therefore, this system can minimize fire hazards, be more environmentally friendly, and provide better heat transfer of the system.

Another aspect of this application includes modularity and adaptability of the system. This system can be applied to all high pressure die casting machines of various sized due to its modular design. This size and capacity of this system can also be easily expanded or reduced to meet different needs of various processes. This system can include ability to operate with particulate in the fluid stream due robust component selection and due to particulate and corrosion removal capability of the system.

The overall footprint of the thermal system can be reduced relative to a footprint traditionally required for a thermal system incorporating a large number of TCUs for individual fluid lines. Such an overall geometry further facilitates additional modularization of the thermal system to increase or reduce capacity by the modification of the number of fluid lines incorporated in the thermal system. This provides additional benefit for large scale or more complex casting process. Various aspects of this application can be used in large and complex injection molding processes as well as extrusion processes, such as aluminum extrusion processes.

The present disclosure is not limited to the embodiments as disclosed above. Various alternative embodiments can be used in some aspects of the present disclosure. For example, in one alternative embodiment, a hybrid client-side secondary event data rendering system can insert the second content into the original content by utilizing both the client computing device and streaming service provider resources (i.e., network computing device resources such as CPUs, GPUs, or streaming servers). Illustratively, some tasks of the processing the original content by inserting the secondary event data can be performed by utilizing the streaming service provider's resources such as streaming servers, GPUs, and CPUs, and the other tasks of the channel branding can be performed by utilizing the client computing devices as disclosed herein. For example, one or more graphics may be inserted into the original content, and the original content with the graphic can be encoded into encoded content segments. In this example, the client may also receive manifest data, including the secondary event instruction for processing the original content by inserting the secondary event data. In addition, the client also may process the original content by utilizing personalized secondary event data and/or the secondary event instructions disclosed in one or more embodiments of the present disclosure.

It is to be understood that not necessarily all objects or advantages may be achieved in accordance with any particular embodiment described herein. Thus, for example, those skilled in the art will recognize that certain embodiments may be configured to operate in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

All of the processes described herein may be fully automated via software code modules, including one or more specific computer-executable instructions executed by a computing system. The computing system may include one or more computers or processors. The code modules may be stored in any type of non-transitory computer-readable medium or other computer storage device. Some or all the methods may be embodied in specialized computer hardware.

Many other variations than those described herein will be apparent from this disclosure. For example, depending on the embodiment, certain acts, events, or functions of any of the processes described herein can be performed in a different sequence, can be added, merged, or left out altogether (e.g., not all described acts or events are necessary for the practice of the processes). Moreover, in certain embodiments, acts or events can be performed concurrently, e.g., through multi-threaded processing, interrupt processing, or multiple processors or processor cores or on other parallel architectures, rather than sequentially. In addition, different tasks or processes can be performed by different machines and/or computing systems that can function together.

The various illustrative logical blocks and modules described in connection with the embodiments disclosed herein can be implemented or performed by a machine, such as a processing unit or processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A processor can be a microprocessor, but in the alternative, the processor can be a controller, microcontroller, or state machine, combinations of the same, or the like. A processor can include electrical circuitry configured to process computer-executable instructions. In another embodiment, a processor includes an FPGA or other programmable device that performs logic operations without processing computer-executable instructions. A processor can also be implemented as a combination of external computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. Although described herein primarily with respect to digital technology, a processor may also include primarily analog components. A computing environment can include any type of computer system, including, but not limited to, a computer system based on a microprocessor, a mainframe computer, a digital signal processor, a portable external computing device, a device controller, or a computational engine within an appliance, to be name a few.

Conditional language such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, are otherwise understood within the context as used in general to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular embodiment.

Disjunctive language such as the phrase “at least one of X, Y, or Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to present that an item, term, etc., may be either X, Y, or Z, or any combination thereof (e.g., X, Y, and/or Z). Thus, such disjunctive language is not generally intended to, and should not, imply that certain embodiments require at least one of X, at least one of Y, or at least one of Z to each be present.

Any process descriptions, elements or blocks in the flow diagrams described herein and/or depicted in the attached figures should be understood as potentially representing modules, segments, or portions of code that include one or more executable instructions for implementing specific logical functions or elements in the process. Alternate implementations are included within the scope of the embodiments described herein in which elements or functions may be deleted, executed out of order from that shown, or discussed, including substantially concurrently or in reverse order, depending on the functionality involved as would be understood by those skilled in the art.

Unless otherwise explicitly stated, articles such as “a” or “an” should generally be interpreted to include one or more described items. Accordingly, phrases such as “a device configured to” are intended to include one or more recited devices. Such one or more recited devices can also be collectively configured to carry out the stated recitations. For example, “a processor configured to carry out recitations A, B, and C” can include a first processor configured to carry out recitation A working in conjunction with a second processor configured to carry out recitations B and C.

THERMAL CONTROL UNIT FOR CASTING PROCESSES

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