Model-based Numerical Control (MNC) for the automation of casting processes

铸造是生产金属制品的基本成型工艺，重力铸造是最常见的铸造形式。目前，只有在使用特殊控制系统的情况下，才能实现铸造过程的完全自动化。在(部分)自动化系统中，通过示教工艺对工艺序列进行编程。然而，这种编程需要工人的专业知识，并与危险区域的铸造过程直接互动，这是由于处理液态金属造成的。这种类型的编程不能被参数化，因此，没有给出可伸缩性，并且运动序列必须在每次改变时被重新编程。然而，已经探索了铸造过程的数学和物理模型，这些模型适合于计算符合相关工艺目标的运动，例如被铸造物质的流速和目标点。但这种特殊的控制系统缺乏必要的灵活性，使得铸造过程可以简单且与机器无关地编程。NC系统具有很高的灵活性和易于对工艺进行参数化的潜力。这些好处将通过将NC与工艺模型相结合而转移到铸造工艺。该项目的目标是开发一种基于过程模型的NC体系结构，将任何批量的重力铸造转变为完全自动化的过程。

Casting is an elementary molding process for producing metallic products with gravity casting being the most common form of casting. Presently, a full automation of casting processes only takes place for large quantities using special control systems. In (partially) automated systems, the process sequence is programmed by means of teach-in processes. This programming requires, however, expertise by the worker and a direct interaction with the casting process in the danger zone, which results from handling liquid metal. This type of programming cannot be parameterized, therefore, scalability is not given and the motion sequences must be reprogrammed with every change. However, mathematical and physical models for the casting process, which are suitable for calculating the motions in compliance with the relevant process targets such as flow rate and target point of the substance to be cast, are already explored. But this special control system lack the necessary flexibility, so that the casting process can be simple and machine-independent programmed. NC systems have a high flexibility and the potential of easily parameterizing the process. These benefits are to be transferred to the casting process by combining an NC with process models. The objective of the project is the development of an NC architecture that, based on process models, turns gravity casting for any lot sizes into a fully automated process.