A casting line for pouring multiple groups of series castings horizontally stacked in combination sand molds at one time

Abstract

The present invention discloses a casting line for pouring multiple groups of series castings horizontally stacked in combination sand molds at one time, and relates to the field of casting technology. The casting line includes an annular guide rail, a molding machine, a combination sand mold transport vehicle, and a pressurized and accelerated fully enclosed pouring system. A plurality of the combination sand mold transport vehicles are installed on the annular guide rail, and the molding machine and the pressurized and accelerated fully enclosed pouring system are installed on the outer side of the annular guide rail. The plurality of sand molds made by the molding machine are stacked horizontally one by one on the combination sand mold transport vehicle in a rectangular array of multiple rows and columns, and then transported by the combination sand mold transport vehicle to the casting and solidification area of ​​the combination sand mold, and poured at one time by the pressurized and accelerated fully enclosed pouring system. The casting line integrates sand mold making, sand mold transfer, sand mold transportation, and sand mold pouring, has a high degree of mechanization, can save manpower, and has high efficiency in making castings.

Description

Technical Field

[0001] The invention relates to the technical field of casting, and in particular to a casting line for casting multiple groups of series-connected castings in a single pouring process with horizontally stacked combined sand molds. Background Art

[0002] In the existing casting process, casting equipment, and casting assembly line, most of them are made of horizontal molding machines and vertical molding machines and their supporting auxiliary equipment. These two molding processes have their own advantages and disadvantages. The horizontal molding casting cavity requires two sand molds to be made at the same time, which are merged to form a cavity, horizontal molding, horizontal placement, horizontal pouring, and a group of sand molds are placed separately. It has good air permeability and a high rate of finished castings. However, the horizontal molding machine has more actions, slow molding speed, and high production cost, use cost, and maintenance cost; the sand mold made by the vertical molding machine adopts concave on both sides. Convex molds and sand molds are placed vertically and combined in sequence to form casting cavities. They have the characteristics of fast molding speed and high efficiency. One sand mold can form one or more casting cavities, but its molten iron utilization rate is low, the sand mold is large and has poor air permeability, and the casting yield rate is relatively low. Their common feature is that they can only cast one or several casting products at a time. So how to integrate these two types of molding machines, take their strengths and avoid their weaknesses, and turn a sand mold that can only cast one or several pieces at a time, or a single group in series, into a combination sand mold that can cast dozens or hundreds of pieces at a time, or multiple groups in series, is a direction worthy of research and invention. Summary of the invention

[0003] To this end, the present invention provides a casting line for casting multiple groups of series-connected castings in a horizontally stacked combined sand mold at one time, which perfectly combines the horizontal series mode of the cross runner system and the vertical series mode of the mold cavities of multiple groups of combined sand molds to solve the problems of poor sand mold permeability, large amount of molding sand, low molten iron utilization, low casting yield, low casting efficiency, etc. in the existing sand mold casting method.

[0004] In order to achieve the above object, the present invention provides the following technical solutions:

[0005] According to a first aspect of the present invention, a casting line for casting multiple groups of horizontally stacked combined sand molds in series at one time, the casting line includes an annular guide rail, a molding machine, a combined sand mold transport vehicle and a pressurized and accelerated fully enclosed pouring system, a plurality of the combined sand mold transport vehicles are installed on the annular guide rail, the molding machine and the pressurized and accelerated fully enclosed pouring system are installed on the outer side of the annular guide rail, a plurality of sand molds made by the molding machine are stacked horizontally one by one on the combined sand mold transport vehicle in a rectangular array of multiple rows and columns, and then transported by the combined sand mold transport vehicle to the casting and solidification area of ​​the combined sand mold for one-time pouring by the pressurized and accelerated fully enclosed pouring system.

[0006] Furthermore, a runner system is installed on the crossbeam of the combined sand mold transport vehicle;

[0007] The runner system includes a runner, a cover plate, a first ingode, a second ingode, a first valve and a runner inlet. The runner system is prefabricated with a high temperature resistant and erosion resistant material and is bonded to a metal trapezoidal groove on the crossbeam of the combined sand mold transport vehicle. A cover plate is installed on the runner, and a plurality of first ingodes and a plurality of second ingodes connected to the runner are vertically installed on the cover plate. A runner inlet is provided on the outermost side of the cover plate, and a first valve is provided between the runner inlet and the runner near the runner inlet.

[0008] The longitudinal section of the horizontal runner is a trapezoid; the horizontal runner includes a connected arc runner, two mutually parallel first straight runners and a plurality of mutually parallel second straight runners, one end of the arc runner is connected to one of the first straight runners, and the other end is connected to another of the first straight runners, and the first straight runners intersect the second straight runners perpendicularly;

[0009] The runner inlet is provided at a position of the cover plate corresponding to the vertex of the arc-shaped runner.

[0010] Furthermore, the first ingrate and the second ingrate are both prefabricated with high temperature resistant and erosion resistant materials, and are both provided with molten iron channels therein;

[0011] The first ingrate and the second ingrate are each provided with a molten iron outlet on the top and a first conical mounting portion on the bottom; and the cover plate is provided with a conical connecting groove matched with the first conical mounting portion.

[0012] Furthermore, the sand mold has a concave surface and a convex surface; the concave surface is recessed inward to form a plurality of casting cavities; the convex surface is provided with a plurality of bosses matching the casting cavities; the sand mold is provided with a plurality of vertical air permeable channels penetrating along the thickness direction; the inner diameter of the vertical air permeable channels gradually increases from the convex surface to the concave surface.

[0013] Furthermore, the sand mold is provided with a plurality of first vertical thin runners cooperating with the first ingates and a plurality of second vertical thin runners cooperating with the second ingates; the first vertical thin runners and the second vertical thin runners both include a connected straight portion and a tapered portion, the straight portion is used for the installation of the ingates, and the inner diameter of the tapered portion gradually increases from the convex surface to the concave surface.

[0014] Furthermore, a plurality of shrinkage-feeding points are evenly arranged around the casting cavity; the shrinkage-feeding points are connected to the casting cavity through a square groove; a plurality of inverted conical cavities are arranged at the corners of the convex surface and the concave surface;

[0015] The convex surface and the concave surface are both provided with a plurality of trapezoidal grooves; when a plurality of the sand molds are stacked together, the trapezoidal grooves of the upper sand mold and the trapezoidal grooves of the lower sand mold cooperate to form a trapezoidal air permeable channel;

[0016] The convex surface and the concave surface are provided with air guiding slopes; when a plurality of the sand molds are stacked together, the air guiding slopes of the upper sand mold and the air guiding slopes of the lower sand mold cooperate together to form a transverse oblique exhaust passage.

[0017] Further, the annular guide rail includes a first guide rail and a second guide rail, the first guide rail is located on the ground, and the second guide rail is located underground; the first guide rail is provided with a runner installation area, a sand mold combination area and a combined sand mold cooling area;

[0018] The combined sand mold casting and solidification area is arranged on the second guide rail, and a lifting device, a track-type spare iron ladle, a spare iron ladle lifting platform and steps leading to the ground are also arranged in the combined sand mold casting and solidification area.

[0019] Furthermore, the pressurized and accelerated fully enclosed pouring system comprises a pouring ladle, a second conical mounting portion and a second valve, the second valve is mounted at the lower portion of the pouring ladle, and the second conical mounting portion matching the pouring channel inlet is disposed at the bottom end of the pouring ladle;

[0020] The pouring iron ladle is prefabricated with high temperature resistant and erosion resistant materials; the pouring iron ladle is an inverted cone whose inner diameter decreases from top to bottom by connecting a plurality of prefabricated parts through plug-in, joint sealing and metal surrounding fixing; the pouring iron ladle is moved up and down by a vertical hydraulic lifting device.

[0021] Furthermore, the casting line also includes a robot, and the robot is installed on the outside of the first guide rail.

[0022] According to a second aspect of the present invention, a casting process for pouring multiple groups of series castings in a horizontally stacked composite sand mold at one time, the casting process uses the above-mentioned casting line, and the casting process comprises the following steps:

[0023] Install the combined sand mold transport vehicle on the annular guide rail, and install the runner system in the runner installation area of ​​the first guide rail;

[0024] In the sand mold combination area of ​​the first guide rail, a sand mold is first made by a molding machine, and then multiple sand molds are stacked horizontally one by one on a combination sand mold transport vehicle in a rectangular array of multiple rows, columns and groups by a manipulator to form a horizontally stacked combination sand mold consisting of multiple groups of independent sand molds; wherein the first ingrate is aligned with the first vertical fine runner of the bottom layer of the sand mold, the second ingrate is aligned with the second vertical fine runner of the bottom layer of the sand mold and inserted, the first vertical fine runners of the upper and lower sand molds are connected, and the second vertical fine runners of the upper and lower sand molds are connected;

[0025] The combined sand mold transport vehicle carrying the combined sand mold is moved to the combined sand mold casting and solidification area, and the pressurized speed-increasing fully enclosed pouring system is lowered through the vertical hydraulic lifting device, so that the second conical mounting portion under the pouring ladle is matched and closed with the pouring channel inlet on the cover plate, and the second valve is opened to start the pressurized speed-increasing fully enclosed pouring system, and the molten iron in the pouring ladle is introduced into the horizontal runner through the pouring channel inlet;

[0026] The molten iron flowing through the horizontal runner first passes through the molten iron outlets of the first ingating channel and the second ingating channel, and then enters the casting cavities of each vertically stacked sand mold through the first vertical fine runner and the second vertical fine runner of the sand mold in turn for overall one-time and synchronous pouring from bottom to top; observing the runner outer outlet at the top of the combined sand mold on the ground, it is observed that molten iron appears on the upper part of the combined sand mold, indicating that the molten iron has completely filled each cavity, and the second valve is immediately closed to stop the continued supply of molten iron, and the first valve is immediately closed to prevent the molten iron in the combined sand mold from flowing back, and the pressurized and accelerated fully enclosed pouring system is raised through the vertical hydraulic device to completely separate the pouring ladle from the runner inlet on the cover plate to complete a single pouring Note: During the casting process of molten iron, the air in each cavity of the combined sand mold enters the casting cavity of the sand mold from the bottom to the top along with the molten iron, and the air in the casting cavity is quickly discharged upward step by step until the vertical fine runner of the sand mold at the upper part of the combined sand mold is discharged out of the casting cavity. This exhaust process belongs to fast exhaust, which discharges the air in the cavity; the hot air generated by each casting in the sand mold during the solidification and cooling process is discharged out of the combined sand mold through the vertical ventilation channel, trapezoidal ventilation channel and transverse oblique exhaust channel in the sand mold. This process belongs to slow exhaust, which discharges the hot air generated by the casting out of the combined sand mold through each channel of the sand mold. The slow exhaust process can also play a role in cooling;

[0027] The combined sand mold after one-time pouring is lifted to the ground by the lifting device and transferred to the first guide rail, and then transported to the combined sand mold cooling area for cooling; then transported to the separation area, the combined sand mold and the casting are separated from the combined sand mold transport vehicle by the manipulator, and then the combined sand mold and the casting are transported to the casting and molding sand separation area to separate the casting from the molding sand;

[0028] Unload the cover plates and other damaged parts in the used runner system, and the intact parts in the runner system will continue to be recycled with the combined sand mold transport vehicle;

[0029] The separated castings are sent to the next process, and the separated molding sand is transported to the molding sand storage area for next use;

[0030] The stored molding sand enters the sand mixer for mixing, and the mixed molding sand is conveyed to the molding machine for secondary use.

[0031] The present invention has the following advantages:

[0032] The present invention discloses a casting line for pouring multiple groups of series castings in a single pouring process, which integrates the combination sand mold and the accelerated pouring process. The horizontal molding process is adopted, and the sand mold produced is a sand mold with concave and convex surfaces on both sides of a vertical molding machine, and then it is horizontally stacked and combined into one or more groups, and the process of pouring one, several or a single group at a time is changed to a casting process of pouring dozens or hundreds of pieces or multiple groups at a time, which can effectively improve work efficiency, reduce labor intensity, and at the same time improve the casting yield rate, improve the utilization rate of molten iron, so as to reduce labor and casting costs; the pressurized accelerated fully enclosed pouring system in the casting line of the present invention utilizes the pressure generated by the height difference between the pouring iron ladle and the combined sand mold to increase the flow rate of molten iron and reduce the pouring time; each casting in the mold cavity needs to be completely separated and isolated during solidification. The first vertical fine runner and the second vertical fine runner in the combined sand mold are used to combine and connect all the mold cavities in the combined sand mold during the pouring process. The castings in each mold cavity can also be completely disconnected during the solidification of each casting. Because the cross-sectional area of ​​the vertical fine runner is small, when the pouring of molten iron is stopped, it solidifies first. After solidification, each casting in the sand mold can become an independent unit body, and it plays the role of runner, straight exhaust channel and gate at the same time; when shrinkage occurs in the castings in each mold cavity during the solidification process, multiple shrinkage compensation points in the mold cavity can compensate for the shrinkage of the castings at multiple points at a close distance at the same time. The castings cast by the casting line of the present invention have a high finished product rate, good casting quality, high efficiency, high molten iron utilization rate, and low casting cost.

[0033] The present invention discloses a casting process for pouring multiple groups of series castings in one time and stacking sand molds in a horizontal manner. Each step is closely connected, the operation is convenient, and the degree of mechanization is high. The casting process can be made into a fully automatic or semi-automatic casting line according to the needs of customers. The casting process belongs to a double series mode and integrates horizontal modeling and vertical modeling. The casting products of this casting line are wide, high in quality, high in efficiency, and low in cost. The problems of material waste, high casting cost, low working efficiency, and low yield rate in the existing casting process can be fundamentally and thoroughly solved. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] In order to more clearly illustrate the implementation methods of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for the implementation methods or the description of the prior art. Obviously, the drawings in the following description are only exemplary, and for ordinary technicians in this field, other implementation drawings can be derived from the provided drawings without creative work.

[0035] The structures, proportions, sizes, etc. illustrated in this specification are only used to match the contents disclosed in the specification so as to facilitate understanding and reading by persons familiar with the technology. They are not used to limit the conditions under which the present invention can be implemented, and therefore have no substantial technical significance. Any structural modification, change in proportion or adjustment of size shall still fall within the scope of the technical contents disclosed in the present invention without affecting the effects and purposes that can be achieved by the present invention.

[0036] Figure 1 A schematic diagram of the overall structure of a casting line provided in Example 1 of the present invention;

[0037] Figure 2 A schematic diagram of the installation of the runner provided in Example 1 of the present invention on a combined sand mold transport vehicle;

[0038] Figure 3 A schematic diagram of the installation of the runner system provided in Example 1 of the present invention on a combined sand mold transport vehicle;

[0039] Figure 4 A schematic longitudinal section diagram of a runner provided in Example 1 of the present invention;

[0040] Figure 5 A schematic structural diagram of a conical connecting groove on a cover plate provided in Example 1 of the present invention;

[0041] Figure 6 A schematic diagram of the structure of a first ingates provided in Example 1 of the present invention;

[0042] Figure 7 A schematic diagram of the convex surface of the sand mold provided in Example 1 of the present invention;

[0043] Figure 8 A schematic diagram of the concave surface of the sand mold provided in Example 1 of the present invention;

[0044] Fig. 9 A schematic diagram of the internal structure of the first vertical thin runner provided in Example 1 of the present invention;

[0045] Fig.10 A schematic diagram of installing the combined sand mold provided in Example 1 of the present invention on a combined sand mold transport vehicle;

[0046] Fig.11A schematic diagram of the installation of a device for the combined sand casting solidification area provided in Example 1 of the present invention;

[0047] Fig.12 The flow diagram of molten iron in the process of forming a casting by pouring molten iron into a combined sand mold provided in Example 2 of the present invention. DETAILED DESCRIPTION

[0048] The following is a description of the implementation of the present invention by specific embodiments. People familiar with the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0049] Example 1

[0050] like Figure 1 The casting line shown in the figure for casting multiple groups of horizontally stacked combined sand molds in series at one time includes a circular guide rail 1, a molding machine 2, a combined sand mold transport vehicle 3, a manipulator 27 and a pressurized and accelerated fully enclosed pouring system 4. A plurality of the combined sand mold transport vehicles 3 are installed on the circular guide rail 1. The combined sand mold transport vehicle 3 is a rectangular sand mold vehicle made of finely welded steel parts, and eight sets of wheels are installed on the bottom to facilitate driving on the circular guide rail 1. The driving mode can be hydraulic jacking type, self-propelled, etc. The molding machine 2, the manipulator 27 and the pressurized and accelerated fully enclosed pouring system 4 are installed on the outer side of the circular guide rail 1. The multiple sand molds produced by the molding machine 2 are horizontally stacked one by one on the combined sand mold transport vehicle 3 in a rectangular array of multiple rows, columns and groups through the manipulator 27, and then transported by the combined sand mold transport vehicle 3 to the combined sand mold casting and solidification area 1021 for one-time pouring by the pressurized and accelerated fully enclosed pouring system 4.

[0051] The casting line integrates sand mold making, sand mold transfer, sand mold transportation and sand mold pouring, has a high degree of mechanization, can save manpower, and has high efficiency in making castings. In addition, the casting line adopts a one-time pouring of a horizontally stacked composite sand mold composed of multiple groups of independent sand molds, changing the existing technology that can only complete the pouring of one, several or a single group of casting blanks at a time into a pouring method that can complete dozens, hundreds or multiple groups of casting sand molds at a time, which can effectively improve work efficiency, reduce labor intensity, and at the same time improve the casting yield rate and the utilization rate of molten iron to reduce labor and casting costs.

[0052] The annular guide rail 1 includes a first guide rail 101 and a second guide rail 102, wherein the first guide rail 101 is located on the ground, and the second guide rail 102 is located two meters underground; the first guide rail 101 is provided with a runner installation area 1011, a sand mold combination area 1012 and a combined sand mold cooling area 1013; the combined sand mold casting and solidification area 1021 is provided on the second guide rail 102.

[0053] like Figure 2-3 As shown, a runner system is installed on the crossbeam of the combined sand mold transport vehicle 3; the runner system includes a runner 5, a cover plate 6, a first ingredient 12, a second ingredient 13, a first valve 11 and a runner inlet 10, the runner 5, the cover plate 6, the first ingredient 12, the second ingredient 13 and the first valve 11 of the runner system are all prefabricated with high temperature resistant and erosion resistant materials, which are bonded to the metal trapezoidal groove on the crossbeam of the combined sand mold transport vehicle 3, the runner 5 is installed with a cover plate 6, and a plurality of first ingredients 12 and a plurality of second ingredients 13 connected to the runner 5 are vertically installed on the cover plate 6; the runner system is prefabricated with high temperature resistant and erosion resistant materials, and can withstand the fast-flowing molten iron flowing out of the pressurized and accelerated fully enclosed pouring system 4, so that the molten iron maintains a uniform and fast flow speed after entering the sand mold.

[0054] The longitudinal section of the cross runner 5 is trapezoidal; the cross runner 5 includes a connected arc runner 51, two mutually parallel first straight runners 52 and a plurality of mutually parallel second straight runners 53, one end of the arc runner 51 is connected to one of the first straight runners 52, and the other end is connected to another first straight runner 52, and the first straight runner 52 intersects the second straight runner 53 vertically. The design of the arc runner 51 can reduce the impact of molten iron and reduce the generation of bubbles during the pouring process. The multiple first ingates 12 and the multiple second ingates 13 in the cross runner system form a series combination, which can simultaneously cast multiple horizontal sand molds.

[0055] A runner inlet 10 is provided at a position of the cover plate 6 corresponding to the vertex of the arc runner 51; a first valve 11 is provided between the runner inlet 10 and the cross runner near the runner inlet; the runner inlet 10 can be connected to the pressurized and accelerated fully enclosed pouring system 4 to introduce molten iron into the cross runner 5. The first valve 11 is a cylindrical gate device that vertically penetrates the cross runner 5. The cylindrical gate device is made of a high temperature resistant and erosion resistant material. When the cylindrical gate device is raised, it is close to the runner inlet and higher than the top wall of the runner. When it falls, it is away from the runner inlet, penetrates the runner and completely contacts the bottom wall of the runner. After the molten iron fills the combined sand mold, the second valve of the pressurized and accelerated fully enclosed pouring system 4 is closed, and then the first valve 11 is closed. The first valve 11 is in an open state during the combined installation.

[0056] like Figure 4-6 As shown, the first ingrate 12 and the second ingrate 13 are both prefabricated with high temperature resistant and erosion resistant materials, and are both provided with molten iron channels 14 inside; the first ingrate 12 and the second ingrate 13 are both provided with molten iron outlets on the top, and are both provided with first conical mounting portions 16 on the bottom; the cover plate 6 is provided with a conical connecting groove 9 that matches the first conical mounting portion 16. The molten iron entering the runner 5 is ejected in a vertical direction by the design of the first ingrate 12 and the second ingrate 13. The first ingrate 12 and the second ingrate 13 are both prefabricated with high temperature resistant and erosion resistant materials, and can effectively play the role of high temperature resistance and erosion resistance.

[0057] like Figure 7-8 As shown, the sand mold 17 has a concave surface 171 and a convex surface 172; the concave surface 171 is recessed inward to form a plurality of casting cavities 170; the convex surface 172 is provided with a plurality of bosses 177 that match the casting cavities 170; the sand mold 17 is provided with a plurality of vertical air permeable channels 174 that penetrate along the thickness direction; the inner diameter of the vertical air permeable channels 174 gradually increases from the convex surface 172 to the concave surface 171.

[0058] The sand mold 17 is provided with a plurality of first vertical fine runners 175 matched with the first ingates 12 and a plurality of second vertical fine runners 176 matched with the second ingates 13; Fig. 9 As shown, the first vertical sprue 175 and the second vertical sprue 176 both include a connected straight portion 18 and a tapered portion 19, wherein the straight portion 18 is used for installing the ingrate, and the inner diameter of the tapered portion 19 gradually increases from the convex surface to the concave surface. The cross-sectional area of ​​the first vertical thin runner 175 and the second vertical thin runner 176 is smaller than the cross-sectional area of ​​the casting. The design of the first vertical thin runner 175 and the second vertical thin runner 176 can, on the one hand, play a role in quick exhaust in the casting cavity (the vertical thin runner is the channel for molten iron to flow in the fully enclosed pouring process of the entire combined sand mold under pressure and speed increase. During the pouring process, the molten iron enters each cavity from bottom to top at a uniform speed and simultaneously, while the air in the cavity is directly discharged from the upper part of the combined sand mold out of the combined sand mold smoothly and quickly, which is called quick exhaust). On the other hand, it plays a role in closing the valve. The molten iron at the first vertical thin runner 175 and the second vertical thin runner 176 between the casting cavities of the sand mold solidifies first, and the casting cavities are completely disconnected before the casting solidifies. The castings in each casting cavity become independent units, which are independently cooled and formed in the independent units to ensure the yield of the castings.

[0059] A plurality of feeding points 20 are evenly arranged around the casting cavity 170; the feeding points 20 are connected to the casting cavity 170 via a square groove 21; a plurality of inverted conical cavities 22 are arranged at the corners of the convex surface 172 and the concave surface 171; the cross-sectional area of ​​the connection point between the feeding point 20 and the casting is larger than the cross-sectional area of ​​the casting. Through the design of the feeding point 20, the past one-point long-distance large riser feeding is changed to short-distance multi-point small riser direct feeding, which can effectively solve the shrinkage problem of the casting, and can also increase the utilization rate of molten iron and reduce the casting cost. The design of the inverted conical cavity 22 allows the corresponding pins to be configured during the horizontal stacking and combination of the sand molds to keep the combined sand mold vertical.

[0060] The convex surface 172 and the concave surface 173 are provided with a plurality of trapezoidal grooves 23; when a plurality of the sand molds 17 are stacked together, Fig.10 As shown, the trapezoidal groove 23 of the upper sand mold and the trapezoidal groove 23 of the lower sand mold cooperate together to form a trapezoidal air permeable channel 34; the trapezoidal groove 23 can connect the vertical air permeable channels 174 of each sand mold together.

[0061] The convex surface 172 and the concave surface 173 are provided with an air guiding inclined surface 32; Fig.10 As shown, when a plurality of the sand molds 17 are stacked together, the air guiding slope 32 of the upper sand mold and the air guiding slope 32 of the lower sand mold cooperate to form a transverse oblique exhaust channel 33. The trapezoidal air permeable channel 34 and the transverse oblique exhaust channel 33 can play the role of slow exhaust and cooling of the castings in each cavity during and after the pouring process. In this way, through the combined effect of the first vertical fine runner 175 and the second vertical fine runner 176, the trapezoidal air permeable channel 34 and the transverse oblique exhaust channel 33, the gas generated in the cavity during the pouring process can be effectively discharged, the occurrence of air trapping can be prevented, the air permeability of the sand mold can be increased, the amount of sand used in the sand mold can be reduced, and the strength of the sand mold can be enhanced.

[0062] The pressurized speed-increasing fully enclosed pouring system 4 comprises a pouring ladle 41, a second conical mounting portion 42 and a second valve 43. The second valve 43 is mounted at the lower portion of the pouring ladle 41, and the second conical mounting portion 42 matching the pouring channel inlet 10 is disposed at the bottom of the pouring ladle 41. The pouring ladle 41 is prefabricated with a high temperature resistant and erosion resistant material; the pouring ladle 41 is formed by a plurality of prefabricated parts connected into one body by plugging, and is an inverted cone whose inner diameter decreases from top to bottom in sequence; the pouring ladle 41 is moved up and down by a vertical hydraulic lifting device. The second valve 43. The design of the second conical mounting portion 42 enables the pouring ladle 41 to be matched with the pouring channel inlet 10.

[0063] The pouring ladle 41 is stably and sealedly connected to the pouring channel inlet 10 through the second conical mounting portion 42, and the molten iron supply can be closed and the molten iron flow rate can be adjusted through the second valve 43. The combined sand mold casting and solidification area is several millimeters below the ground (calculated according to the height of the combined sand mold). A step 29 leading to the ground is set away from the pouring place to lead to the ground for operators to go up and down. A sinking area is also set in this area. The inner wall is poured with cement (now) and then the four sides and the bottom are built with refractory bricks 30. Two ground rails are installed at the bottom and then the refractory bricks 30 are built. A transportable spare iron ladle 28 is set on the ground rail to receive the waste iron from the pouring ladle 41 vertically above. The spare iron ladle 28 can be transported to the ground through the spare iron ladle lifting platform 31. The second valve 43 is opened to control the flow rate of molten iron to pour the combined sand mold. When molten iron is found on the upper surface of the combined sand mold, it proves that each casting unit in the combined sand mold is fully filled with molten iron. Then the second valve 4343 is closed first, and then the first valve is closed, the pouring molten iron ladle 41 is raised, and the power system pushes the combined sand mold car, pushes out the combined sand mold transport car that has been poured, and at the same time, pours the combined sand molds on the next group of combined sand mold transport cars.

[0064] like Fig.11 As shown, the combined sand mold casting and solidification area is also provided with a lifting device 24, a track-type spare iron ladle 28, a spare iron ladle lifting platform 31 and steps 29 leading to the ground. Through the above technical solution, the sand mold making, sand mold transfer and sand mold transportation processes are carried out on the first guide rail 101, the sand mold casting is carried out below the ground, and the combined sand mold is transported underground, forming a clear height difference with the pressurized and accelerated fully enclosed pouring system 4 located on the ground, so that the molten iron can enter from the bottom of the combined sand mold under the action of the hydraulic pressure difference and then quickly move upward to efficiently complete the pouring process of multiple groups of sand molds.

[0065] Example 2

[0066] A casting process for casting multiple groups of series-connected castings in a horizontally stacked composite sand mold at one time, the casting process using the casting line described in Example 1, the casting process comprising the following steps:

[0067] The combined sand mold transport vehicle 3 is installed in the runner installation area 1011 of the first guide rail 101 of the annular guide rail 1, and then the runner system is installed on the combined sand mold transport vehicle 3;

[0068] In the sand mold assembly area 1012 of the first guide rail 101, a sand mold 17 is firstly made by a molding machine 2, and the made sand mold 17 is horizontally transferred to the assembled sand mold transport vehicle 3 by a manipulator 27, and multiple sand molds 17 are stacked horizontally one by one on the assembled sand mold transport vehicle in a rectangular array of multiple rows, columns and groups to form an assembled sand mold; wherein the first ingrate 12 is aligned with the first vertical fine runner 175 of the bottom layer of the sand mold 17, and the second ingrate 13 is aligned with the second vertical fine runner 176 of the bottom layer of the sand mold 17 and inserted, and the first vertical fine runners 175 of the upper and lower sand molds are connected, and the second vertical fine runners 176 of the upper and lower sand molds are connected;

[0069] The combined sand mold transport vehicle 3 carrying the combined sand mold is moved to the combined sand mold casting and solidification area 1021, lowered by the lifting device 24 and transferred to the second guide rail 102; the pressurized speed-increasing fully enclosed pouring system 4 is lowered by the vertical hydraulic lifting device, so that the pouring ladle 41 is matched and closed with the pouring channel inlet 10 on the cover plate 6, the second valve 43 is opened, the pressurized speed-increasing fully enclosed pouring system 4 is opened, and the molten iron in the pouring ladle 41 is introduced into the horizontal runner 5 through the pouring channel inlet 10;

[0070] The molten iron flowing through the horizontal runner 5 first passes through the molten iron outlets of the first ingrate 12 and the second ingrate 13, and then enters the casting cavities of each vertically stacked sand mold through the first vertical fine runner 175 and the second vertical fine runner 176 of the sand mold in sequence for overall one-time simultaneous pouring from bottom to top (the flow diagram of the molten iron in the process of pouring the combined sand mold to form a casting is shown in FIG. Fig.12 Observe the pouring channel outlet at the top of the combined sand mold on the ground, and observe that molten iron appears on the upper part of the combined sand mold, indicating that the molten iron has completely filled each cavity. Immediately close the second valve 43 to stop the continued supply of molten iron, and then close the first valve 11 to prevent the molten iron in the combined sand mold from flowing back. Raise the pressurized and accelerated fully enclosed pouring system 4 through the vertical hydraulic device to completely separate the pouring ladle 41 from the pouring channel inlet 10 on the cover plate to complete a single pouring. During the process of pouring molten iron, the air in each cavity of the combined sand mold enters from the bottom to the top along with the molten iron. While the sand mold is being filled with air, the air in the casting cavity is quickly and gradually discharged upward until it is discharged out of the casting cavity through the vertical fine runner of the sand mold at the upper part of the combined sand mold. This exhaust process belongs to fast exhaust, which discharges the air in the cavity; the hot air generated by each casting in the sand mold during the solidification and cooling process is discharged out of the combined sand mold through the vertical ventilation channel, trapezoidal ventilation channel and transverse oblique exhaust channel in the sand mold. This process belongs to slow exhaust, which discharges the hot air generated by the casting out of the combined sand mold through each channel of the sand mold. This slow exhaust process can also play a role in cooling down.

[0071] The combined sand mold after one-time pouring is lifted to the ground by the lifting device 24 and transferred to the first guide rail 101, and then transported to the combined sand mold cooling area 1013 for cooling; then transported to the separation area, the combined sand mold and the casting are separated from the combined sand mold transport vehicle 3 by the manipulator, and then the combined sand mold and the casting are transported to the casting and molding sand separation area to separate the casting from the molding sand;

[0072] The cover plates and other damaged parts in the used runner system are unloaded from the combined sand mold transport vehicle 3, and the intact parts in the runner system are continuously recycled with the combined sand mold transport vehicle 3;

[0073] The separated castings are sent to the next process, and the separated molding sand is transported to the molding sand storage area for next use;

[0074] The stored molding sand enters the sand mixer for mixing, and the mixed molding sand is conveyed to the molding machine for secondary use.

[0075] Although the present invention has been described in detail above by general description and specific embodiments, it is obvious to those skilled in the art that some modifications or improvements can be made to the present invention. Therefore, these modifications or improvements made without departing from the spirit of the present invention all belong to the scope of protection claimed by the present invention.

Claims

1. A casting line for casting multiple groups of horizontally stacked sand molds in series at one time, characterized in that: The casting line comprises an annular guide rail, a molding machine, a combined sand mold transport vehicle and a pressurized and accelerated fully enclosed pouring system. A plurality of the combined sand mold transport vehicles are installed on the annular guide rail, and the molding machine and the pressurized and accelerated fully enclosed pouring system are installed on the outer side of the annular guide rail. The plurality of sand molds made by the molding machine are stacked horizontally one by one on the combined sand mold transport vehicle in a rectangular array of multiple rows and columns, and then transported by the combined sand mold transport vehicle to the casting and solidification area of ​​the combined sand mold for one-time pouring by the pressurized and accelerated fully enclosed pouring system. A horizontal runner system is installed on the crossbeam of the combined sand mold transport vehicle; The runner system includes a runner, a cover plate, a first ingode, a second ingode, a first valve and a runner inlet. The runner system is prefabricated with a high temperature resistant and erosion resistant material and is bonded to a metal trapezoidal groove on the crossbeam of the combined sand mold transport vehicle. A cover plate is installed on the runner, and a plurality of first ingodes and a plurality of second ingodes connected to the runner are vertically installed on the cover plate. A runner inlet is provided on the outermost side of the cover plate, and a first valve is provided between the runner inlet and the runner near the runner inlet. The longitudinal section of the horizontal runner is a trapezoid; the horizontal runner includes a connected arc runner, two mutually parallel first straight runners and a plurality of mutually parallel second straight runners, one end of the arc runner is connected to one of the first straight runners, and the other end is connected to another of the first straight runners, and the first straight runners intersect the second straight runners perpendicularly; The runner inlet is provided at a position of the cover plate corresponding to the vertex of the arc-shaped runner.

2. The casting line according to claim 1, characterized in that The first ingrate and the second ingrate are both prefabricated with high temperature resistant and erosion resistant materials, and are both provided with molten iron channels; The first ingrate and the second ingrate are each provided with a molten iron outlet on the top and a first conical mounting portion on the bottom; and the cover plate is provided with a conical connecting groove matched with the first conical mounting portion.

3. The casting line according to claim 2, characterized in that The sand mold has a concave surface and a convex surface; the concave surface is recessed inward to form a plurality of casting cavities; the convex surface is provided with a plurality of bosses matching the casting cavities; the sand mold is provided with a plurality of vertical air permeable channels penetrating along the thickness direction; the inner diameter of the vertical air permeable channels gradually increases from the convex surface to the concave surface.

4. The casting line according to claim 3, characterized in that The sand mold is provided with a plurality of first vertical fine runners cooperating with the first ingates and a plurality of second vertical fine runners cooperating with the second ingates; the first vertical fine runners and the second vertical fine runners both include a connected straight portion and a tapered portion, the straight portion is used for the installation of the ingates, and the inner diameter of the tapered portion gradually increases from the convex surface to the concave surface.

5. The casting line according to claim 3, characterized in that A plurality of shrinkage-feeding points are evenly arranged around the casting cavity; the shrinkage-feeding points are connected to the casting cavity through a square groove; a plurality of inverted conical cavities are arranged at the corners of the convex surface and the concave surface; The convex surface and the concave surface are both provided with a plurality of trapezoidal grooves; when a plurality of the sand molds are stacked together, the trapezoidal grooves of the upper sand mold and the trapezoidal grooves of the lower sand mold cooperate to form a trapezoidal air permeable channel; The convex surface and the concave surface are provided with air guiding slopes; when a plurality of the sand molds are stacked together, the air guiding slopes of the upper sand mold and the air guiding slopes of the lower sand mold cooperate together to form a transverse oblique exhaust passage.

6. The casting line according to claim 1, characterized in that The annular guide rail comprises a first guide rail and a second guide rail, wherein the first guide rail is located on the ground and the second guide rail is located underground; the first guide rail is provided with a runner installation area, a sand mold combination area and a combined sand mold cooling area; The combined sand mold casting and solidification area is arranged on the second guide rail, and a lifting device, a track-type spare iron ladle, a spare iron ladle lifting platform and steps leading to the ground are also arranged in the combined sand mold casting and solidification area.

7. The casting line according to claim 2, characterized in that The pressurized and accelerated fully enclosed pouring system comprises a pouring ladle, a second conical mounting portion and a second valve, the second valve being mounted at the lower portion of the pouring ladle, and the second conical mounting portion cooperating with the pouring channel inlet being disposed at the bottom end of the pouring ladle; The pouring iron ladle is prefabricated with high temperature resistant and erosion resistant materials; the pouring iron ladle is an inverted cone whose inner diameter decreases from top to bottom by connecting a plurality of prefabricated parts through plug-in, joint sealing and metal surrounding fixing; the pouring iron ladle is moved up and down by a vertical hydraulic lifting device.

8. The casting line according to claim 6, characterized in that The casting line further comprises a robot, which is mounted outside the first guide rail.

9. A casting process for pouring multiple groups of series castings in horizontally stacked sand molds at one time, characterized in that: The casting process uses the casting line according to any one of claims 1 to 8, and the casting process comprises the following steps: Install the combined sand mold transport vehicle on the annular guide rail, and install the runner system in the runner installation area of ​​the first guide rail; In the sand mold combination area of ​​the first guide rail, a sand mold is first made by a molding machine, and then multiple sand molds are stacked horizontally one by one on a combination sand mold transport vehicle in a rectangular array of multiple rows, columns and groups by a manipulator to form a horizontally stacked combination sand mold consisting of multiple groups of independent sand molds; wherein the first ingrate is aligned with the first vertical fine runner of the bottom layer of the sand mold, the second ingrate is aligned with the second vertical fine runner of the bottom layer of the sand mold and inserted, the first vertical fine runners of the upper and lower sand molds are connected, and the second vertical fine runners of the upper and lower sand molds are connected; The combined sand mold transport vehicle carrying the combined sand mold is moved to the combined sand mold casting and solidification area, and the pressurized speed-increasing fully enclosed pouring system is lowered through the vertical hydraulic lifting device, so that the second conical mounting portion under the pouring ladle is matched and closed with the pouring channel inlet on the cover plate, and the second valve is opened to start the pressurized speed-increasing fully enclosed pouring system, and the molten iron in the pouring ladle is introduced into the horizontal runner through the pouring channel inlet; The molten iron flowing through the horizontal runner first passes through the molten iron outlets of the first ingating channel and the second ingating channel, and then enters the casting cavities of each vertically stacked sand mold through the first vertical fine runner and the second vertical fine runner of the sand mold in turn for overall one-time and synchronous pouring from bottom to top; observing the runner outer outlet at the top of the combined sand mold on the ground, it is observed that molten iron appears on the upper part of the combined sand mold, indicating that the molten iron has completely filled each cavity, and the second valve is immediately closed to stop the continued supply of molten iron, and the first valve is immediately closed to prevent the molten iron in the combined sand mold from flowing back, and the pressurized and accelerated fully enclosed pouring system is raised through the vertical hydraulic device to completely separate the pouring ladle from the runner inlet on the cover plate to complete a single pouring Note: During the casting process of molten iron, the air in each cavity of the combined sand mold enters the casting cavity of the sand mold from the bottom to the top along with the molten iron, and the air in the casting cavity is quickly discharged upward step by step until the vertical fine runner of the sand mold at the upper part of the combined sand mold is discharged out of the casting cavity. This exhaust process belongs to fast exhaust, which discharges the air in the cavity; the hot air generated by each casting in the sand mold during the solidification and cooling process is discharged out of the combined sand mold through the vertical ventilation channel, trapezoidal ventilation channel and transverse oblique exhaust channel in the sand mold. This process belongs to slow exhaust, which discharges the hot air generated by the casting out of the combined sand mold through each channel of the sand mold. The slow exhaust process can also play a role in cooling; The combined sand mold after one-time pouring is lifted to the ground by the lifting device and transferred to the first guide rail, and then transported to the combined sand mold cooling area for cooling; then transported to the separation area, the combined sand mold and the casting are separated from the combined sand mold transport vehicle by the manipulator, and then the combined sand mold and the casting are transported to the casting and molding sand separation area to separate the casting from the molding sand; Unload the cover plates and other damaged parts in the used runner system, and the intact parts in the runner system will continue to be recycled with the combined sand mold transport vehicle; The separated castings are sent to the next process, and the separated molding sand is transported to the molding sand storage area for next use; The stored molding sand enters the sand mixer for mixing, and the mixed molding sand is conveyed to the molding machine for secondary use.

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