Casting apparatus for casting metal casting material and method for casting metal casting material
By introducing a adjustment station with induction elements into the casting equipment, the casting material is converted into a thixotropic state by using electromagnetic stirring technology, and transported to the casting device through a quantitative feeding container, the problem of low operating performance of the existing casting equipment is solved, and an efficient casting process and excellent finished product quality is achieved.
Patent Information
- Application Number
- CN202380064164.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2022-09-12
- Filing Date
- 2023-08-24
- Publication Date
- 2025-04-15
AI Technical Summary
When casting metal casting materials, existing casting equipment has low operating performance and is difficult to effectively convert casting materials from liquid to thixotropic state, resulting in poor production efficiency and finished product quality.
Using a adjustment station with an induction element, the dosing container is moved to the adjustment station, the casting material is stirred in electromagnetic manner using the induction element, converted into a thixotropic state, and the material is conveyed to the casting device through the dosing container.
The operational performance of casting equipment is improved, the efficient conversion of casting materials into thixotropic state is achieved, the oxidation effect and material loss is reduced, and the production efficiency and finished product quality is improved.
Smart Images
Figure CN119836329A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a casting device for casting metal casting materials, wherein the casting device comprises: a molten pool container, which is used to provide liquid casting material; a casting device, which is used to press the casting material into a casting mold of the casting device; and a quantitative feeding container, which can be moved from the molten pool container to the casting device and is especially used as a quantitative feeding pipette, so as to use the quantitative feeding container to pick up a quantitative amount of casting material from the molten pool container into a receiving space of the quantitative feeding container and convey the casting material to the casting device, wherein the quantitative feeding container is connected to a vacuum device of the casting device, so as to use the vacuum device to evacuate the receiving space to form a negative pressure in the receiving space, thereby receiving a quantitative amount of casting material into the receiving space.
[0002] The present invention also relates to a method for casting metal casting materials, wherein a quantitative feeding container, in particular a quantitative feeding pipette, is used to pick up a quantitative casting material from a molten pool container into a receiving space of the quantitative feeding container, wherein liquid casting material or solid casting material is conveyed into the receiving space, after which the quantitative feeding container is moved from the molten pool container to a casting device, and the casting material from the receiving space is conveyed to the casting device so that the casting material conveyed to the casting device can be pressed into a casting mold of the casting device using the casting device, wherein during the process of picking up the liquid casting material using the quantitative feeding container, the receiving space is evacuated using a vacuum device so as to form a negative pressure in the receiving space, thereby receiving a quantitative casting material into the receiving space. Background Art
[0003] A casting device for casting liquid metal casting material is known, wherein a dosing pipette, which can usually be moved by a robot arm, is used to remove a fixed amount of casting material from a crucible, while emptying the dosing pipette, after which the dosing pipette is moved to a die casting device using the robot arm, and the casting material from the dosing pipette is supplied to a casting chamber of the die casting device, wherein the die casting device is configured to inject the casting material supplied to the casting chamber into a casting mold of the die casting device so as to produce a part by cooling the casting material in the casting mold. The function of the crucible is usually to provide a molten pool of liquid casting material. The purpose of the dosing pipette is usually to transfer a fixed amount of liquid casting material from the crucible to the die casting device to reduce oxidation effects and casting material losses, and to transport the casting material to the casting chamber. In this way, a fixed amount of liquid casting material can be effectively supplied to the die casting device, and parts can be produced by the die casting device by injecting the liquid casting material into the casting mold.
[0004] Casting equipment for performing thixotropic casting, also known as semi-solid casting, is referred to as another type of casting equipment. Here, it is generally envisaged that the liquid casting material is scooped from the crucible into the conditioning crucible using a spoon, and then the casting material in the conditioning crucible is conditioned so as to convert the liquid state of the casting material into a thixotropic state. Typically, conditioning includes cooling and stirring the casting material in the conditioning crucible, typically involving the use of stirring tools, so as to achieve a thixotropic phase or solid-liquid phase of the casting material while generally shearing the casting material. Typically, the casting material thus forms a slurry-like casting material body in the conditioning crucible. The thixotropic casting material is then typically poured from the crucible into a casting chamber of a die casting device, wherein the die casting device is typically designed to press the thixotropic casting material into a casting mold without generating turbulence. Using casting equipment designed specifically for thixotropic casting, near-net-shaped parts with high precision can generally be produced. Compared with casting equipment with liquid die casting, casting equipment for thixotropic die casting generally requires complex process routes and space-intensive settings. Summary of the invention
[0005] The present invention solves this problem.The object of the present invention is to specify a casting plant of the type named at the outset which has improved operating properties.
[0006] Furthermore, the object of the invention is to specify a method for casting a metallic casting material of the type named at the outset, which method has improved operating properties.
[0007] According to the invention, this object is achieved by means of a casting device of the type named at the outset, which comprises a conditioning station with an induction element, wherein, in particular, as an option, before the casting material is fed to the casting device using a dosing container, the dosing container can be moved to the conditioning station in order to stir the casting material electromagnetically using the induction element and thereby convert the casting material into a thixotropic state.
[0008] The basis of the present invention is the idea of using an embodiment of a casting device for liquid casting, which is based on a dosing container that can be moved from a molten pool container to a casting device, wherein the dosing container is configured to pick up a quantitative amount of casting material from the molten pool container into a evacuable receiving space of the dosing container to achieve thixocasting, especially thixomolding. In this way, a casting device for liquid casting, especially as an option for thixocasting, can be used at reduced costs. This can be achieved if the dosing container is used to adjust the casting material. Adjustment usually means that the casting material is treated so that the casting material is converted into a thixotropic phase, especially starting from the liquid phase of the casting material. It has been shown that the thixotropic phase of the casting material can be achieved by electromagnetically stirring the casting material, especially the liquid casting material, in the receiving space. The dosing container is preferably a dosing pipette. If the casting device includes a regulating station with an induction element, so as to use the induction element to electromagnetically stir the casting material in the receiving space, the thixotropic state of the casting material can be achieved in the receiving space. Typically, the dosing container can be moved relative to the inductive element into an adjustment position in which the casting material in the receiving space can be electromagnetically stirred using the inductive element. In this way, it is possible to pick up casting material into the dosing container, in particular the receiving space, using the dosing container, while reducing the interaction with the ambient atmosphere, in particular reducing oxidation effects, and then convert the casting material into a thixotropic state and to convey the casting material to the casting device using the dosing container. As a result, a high operating performance of the casting device can be achieved.
[0009] The molten pool container, which can be a crucible, is usually configured to contain liquid casting material, especially as a molten pool, or to provide casting material for removal using a dosing container. Usually, after picking up a quantitative amount of casting material, especially a quantitative amount of casting material, from the molten pool container using the dosing container, especially after stirring the casting material in the receiving space electromagnetically using the induction element, the dosing container can be moved to the casting device so as to transport the casting material from the receiving space to the casting device. The molten pool container and the casting device are usually separate objects and / or arranged to be spaced apart from each other. The induction element is usually controlled, especially closed-loop controlled, so that the temperature and / or solid content of the casting material in the receiving space can be adjusted using the induction element. It has been shown that it is beneficial that the solid content is less than 20%, especially between 0.1% and 20%, preferably between 1% and 15%, and particularly preferably between 3% and 10%. With this type of solid content, a particularly interference-free handling of the thixotropic material can be achieved, especially in terms of handling using the dosing container when the thixotropic material is located in the receiving space.
[0010] Advantageously, the casting device comprises an electronic control device for controlling, in particular closed-loop controlling the casting device. For this purpose, the electronic control device usually comprises a microcontroller. The electronic control device can be designed to control, in particular closed-loop controlling the casting device, preferably in an automatic manner, in particular depending on the casting material composition.
[0011] The casting device generally comprises a moving device, with which the dosing container can be moved, in particular in a controlled manner, preferably with closed-loop control. In particular, the dosing container can be moved from the molten pool container to the regulating station and / or the casting device by means of the moving device. The moving device can be designed to move the dosing container along a movement axis or a plurality of movement axes, in particular oriented orthogonally to one another. The moving device can be, for example, a swivel arm or a gantry robot. The dosing container is generally mechanically connected to the moving device, in particular can be detached from the moving device. The moving device can be controlled, in particular closed-loop controlled, by an electronic control device and in particular can be connected accordingly to the electronic control device.
[0012] The dosing container usually comprises a receiving space which can be evacuated so that a negative pressure is formed in the receiving space by evacuating the receiving space using a vacuum device. Usually, in order to receive the casting material, the casting material is sucked into the receiving space by evacuating the receiving space. The dosing container, in particular the receiving space, is usually configured so that in order to receive the casting material into the receiving space, the casting material can be supplied to the receiving space from the bottom of the dosing container, in particular from the bottom of the receiving space, and / or in order to convey the casting material from the receiving space, the casting material can be discharged from the receiving space through the bottom of the casting container, in particular from the bottom of the receiving space. Usually, the casting material can be supplied to the receiving space and / or discharged from the receiving space in a lower area, in particular the lowest area of the receiving space. The dosing container is usually configured so that in a state where the receiving space is partially filled with casting material, there is an atmospheric volume sealed from the environment of the dosing container above the casting material. Usually, the vacuum device is connected to the atmospheric volume in a gas-conducting manner so as to discharge gas from the atmosphere. It is beneficial that the vacuum device is connected to the receiving space at the top of the receiving space, in particular the highest area of the receiving space, in a gas-conducting manner. The receiving space usually forms a cavity, which can be closed using a closing device of the dosing container. The receiving space is usually formed with a receiving space wall, which preferably substantially completely surrounds the receiving space. Usually, the receiving space wall of the dosing container is at least partially, preferably substantially completely, formed of a ceramic material. The dosing container can be configured to pick up a quantitative amount of liquid casting material, especially a quantitative amount of liquid casting material, into the receiving space by at least partially immersing the dosing container in a liquid casting material or a molten pool contained by the molten pool container. The molten pool is usually formed by liquid casting material. Advantageously, the dosing container includes an outer wall that is at least partially configured to be inert. The parts of the outer wall that are configured to be inert can be immersed in the molten pool, especially substantially no chemical reaction occurs between these parts and the molten pool, so that the casting material can be picked up from the molten pool using the dosing container. Usually, the outer wall of the dosing container is at least partially, preferably substantially completely, formed of a ceramic material. The dosing container is usually configured to pick up liquid casting material into a receiving space, in particular from a molten pool container. The dosing container is usually configured to convey free-flowing thixotropic casting material from the receiving space to a casting device, in particular a casting chamber of the casting device.
[0013] The dosing container generally comprises a casting material opening, which is used to receive the casting material in the dosing container, especially in the receiving space, and / or is used to convey the casting material from the dosing container, especially in the receiving space, through the casting material opening. Conveniently, the dosing container can be configured to supply the casting material to the receiving space through the casting material opening and / or convey the casting material from the receiving space through the casting material inlet. The casting material opening is generally connected to the receiving space in a casting material conduction manner. The dosing container may include a controllable, especially closed-loop controllable closing device to close and / or open the casting material opening. The closing device can be controlled by a control device, especially closed-loop control, and can be connected to an electronic control device accordingly. When the casting material opening is opened, the casting material can be supplied to the receiving space through the casting material opening, or conveyed from the receiving space through the casting material outlet. In particular, when the casting material opening is closed, the closing device can substantially prevent the casting material from passing through the casting material opening. The closing device is preferably a closing plug. Therefore, it is beneficial that the dosing container comprises a casting material opening. The casting material opening can be closed using a controllable closing device, in particular a closing plug that can be moved in a controlled manner, so that when the casting material opening is opened, the casting material is supplied to the receiving space via the casting material opening. Conveniently, the dosing container may include a plurality of casting material openings. In particular, the dosing container may include a first casting material opening and a second casting material opening, the first casting material outlet being used to receive the liquid casting material in the receiving space via the first casting material inlet, and the second cast metal opening being used to convey the free-flowing casting material via the second casting material opening. The first casting material opening and / or the second casting material opening may be implemented in the manner described with respect to the casting material opening. The first casting material opening and the second casting material opening may be opened and closed separately from each other, in particular in a controllable manner, preferably using closed-loop control, typically using one or more closing devices, which may be implemented in the manner described herein. In particular, a separate closing device may be associated with the first casting material opening and the second casting material opening, respectively, so as to open and close the corresponding casting material opening using a closing device. The dosing container can be designed for metered intake of casting material into the dosing container, in particular the receiving space, and / or for metered delivery of casting material from the dosing container, in particular from the receiving space.
[0014] In order to take out the liquid casting material from the molten pool container using the dosing container, the casting material opening is preferably immersed in the liquid casting material or the molten pool provided by the molten pool container, so that the casting material can be sucked into the receiving space through the casting material opening, especially below the molten pool surface of the molten pool. The dosing container is usually implemented accordingly. In this way, the oxidation effect can be effectively reduced, especially the oxidation effect can be prevented. It is beneficial that the casting material opening of the dosing container is arranged in the base area of the dosing container, preferably arranged in a downward direction. As a result, by immersing the base area, especially the casting material opening in the liquid casting material or the molten pool, the casting material can be effectively picked up into the receiving space. It is advantageous that the dosing container is constructed so that when the casting material opening is opened, the free-flowing casting material can automatically flow out of the receiving space. The dosing container can be controlled, especially closed-loop controlled, with an electronic control device, and can especially be connected to the electronic control device accordingly.
[0015] The vacuum pump usually includes a vacuum pump to evacuate the receiving space, especially to generate a negative pressure in the receiving space. Usually, when the casting material opening is immersed in the molten pool, the casting material can be supplied to the receiving space via the casting material opening, especially sucked into the receiving space, and the receiving space is evacuated at the same time, especially to form a negative pressure in the receiving space. The vacuum pump, especially the vacuum pump, is usually connected to the receiving space in a gas conduction manner, especially through a vacuum line. Through the vacuum line, the gas can be guided out of the receiving space, especially sucked out using the vacuum pump. The vacuum line is preferably connected to the receiving space at the top of the receiving space. The vacuum pump can be part of a dosing container. The vacuum pump can be configured to variably control, especially closed-loop control, the negative pressure in the receiving space, especially when the casting material is received in the receiving space. In this way, the suction force acting on the casting material in the receiving space can be controlled, especially in a closed loop, especially in order to pick up the casting material to the receiving space and / or transport the casting material from the receiving space respectively. The vacuum pump can be controlled, especially closed-loop controlled, with an electronic control device, and can be connected to the electronic control device accordingly.
[0016] Advantageously, the casting device comprises a gas supply device so that the receiving space is supplied with gas, in particular an inert gas, such as argon, using the gas supply device. Thus, the gas supply can be carried out in a controlled manner, in particular by closed-loop control. The gas supply device can be connected to the dosing container, in particular the receiving space, in a gas-conducting manner via a gas supply line. The gas supply device can be controlled, in particular closed-loop controlled, by an electronic control device and can in particular be connected to the electronic control device accordingly, in particular for transmitting control signals.
[0017] Advantageously, the dosing container comprises a filling level measuring device for determining the filling level, in particular the filling volume, of the receiving space with the casting material. The filling level measuring device can be designed to measure the weight and / or the filling height of the casting material in the receiving space. The filling level measuring device can be implemented with one or more measuring sensors. Based on the determination of the filling level of the receiving space using the filling level measuring device, the dosing container can be immersed in the molten pool located in the molten pool container in order to pick up the casting material from the molten pool into the dosing container, in particular into the receiving space. Based on the determination of the filling level of the receiving space using the filling level measuring device, the casting material can be removed and / or conveyed from the dosing container, in particular the receiving space.
[0018] It is feasible that the receiving space comprises a first receiving space section whose cross-sectional area narrows in the casting material conveying direction of the receiving space. The casting material opening is usually arranged downstream of the first receiving space section along the casting material conveying direction of the receiving space. Conveniently, the first receiving space section can lead to the casting material opening or a casting material channel forming the casting material opening. The casting material conveying direction of the receiving space usually means the flow direction of the casting material in the receiving space when the casting material is discharged from the receiving space to convey the casting material through the casting material opening. The first receiving space section can be arranged downstream of the second receiving space section in the casting material conveying direction of the receiving space, wherein the second receiving interval section has substantially a constant cross-sectional area. For example, the second receiving space section can be formed with a wall section in the shape of a cylindrical sleeve, and / or the first receiving section can be formed with a wall section in the shape of a conical sleeve, in particular a truncated conical sleeve. The wall section is usually a part of the receiving space wall of the receiving space. Usually, the dosing container, in particular the outer surface of the receiving space wall and / or the dosing container, preferably the sleeve surface, is mainly, in particular substantially formed so that it comprises a ceramic material or consists of a ceramic material.
[0019] It is feasible that the casting material opening is formed by a casting material channel. The casting material channel is connected to the receiving space in a casting material conducting manner. Via the casting material channel, the casting material can be supplied to the receiving space and / or discharged from the receiving space. The casting material channel usually has an average cross-sectional area through which the casting material can flow, which is smaller than the average cross-sectional area of the receiving space, especially the receiving space segment. The cross section of the receiving space, especially the receiving space segment, is usually orthogonal to the casting material conveying direction of the receiving space. The casting material channel is usually connected to the receiving space in a casting material conducting manner at the bottom of the receiving space. The casting material channel and / or the casting material opening can be formed by a tubular neck of the dosing container, which protrudes away from the base of the dosing container, especially protrudes downward. The receiving space is usually mainly located, preferably basically located in the base of the dosing container. It is beneficial that the outer diameter of the neck narrows in the protruding direction of the neck. The protruding direction usually refers to the direction in which the neck protrudes outward from the base. Usually, the longitudinal extension direction of the neck is parallel to the protruding direction. The protruding direction is preferably oriented downward. Downwards generally refers to a direction in which the dosing container is at least partially immersed in the liquid casting material or the melt pool so that the casting material is picked up using the dosing container.
[0020] Advantageously, the dosing container is designed for conveying a free-flowing, thixotropic casting material, in particular to a casting device. Advantageously, the dosing container is designed for conveying a free-flowing, metallic casting material, in particular a thixotropic casting material, having a solid content of more than 0.1%, in particular 0.1% to 20%, preferably 1% to 15%, particularly preferably 3% to 10%, usually from the receiving space to the casting device via the casting material opening. Thus, the thixotropic casting material with such a solid content can be conveyed from the dosing container to the casting device with virtually no interference. In particular, a corresponding embodiment of the casting material opening, in particular the casting material channel, is necessary for conveying a casting material with such a solid content from the receiving space. This is particularly important, since otherwise a blockage of the thixotropic casting material may occur in the dosing container, in particular in the region of the casting material opening.
[0021] Advantageously, the casting material opening can be opened in a controlled manner, in particular by closed-loop control, so that free-flowing metallic casting material with a solid content of more than 3%, preferably between 3% and 20%, particularly preferably between 3% and 15%, can be conveyed from the receiving space via the casting material opening to the casting device. The casting material opening can be controlled, in particular by closed-loop control, using an electronic control device.
[0022] Advantageously, the ratio of the average diameter of the receiving space to the diameter of the casting material opening is 2 to 15, in particular 3 to 12, preferably 5 to 10, particularly preferably 5 to 8. As a result, low-interference operation of the dosing container for thixotropic materials can be achieved in the dosing container while reducing oxidation effects. The diameter of the receiving space is usually measured perpendicularly to the casting material conveying direction of the receiving space. The diameter of the casting material opening is usually measured perpendicularly to the casting material conveying direction at the casting material opening, in which direction the casting material flows through the casting material opening when the casting material is discharged from the receiving space for conveying the casting material through the casting material opening.
[0023] The casting material conveying direction of the receiving space generally denotes the flow direction of the casting material in the receiving space when the casting material is discharged from the receiving space for conveying the casting material via the casting material opening.
[0024] Typically, the induction element defines a processing container, into which the dosing container can be at least partially inserted, in order to electromagnetically stir the casting material in the receiving space, so that the dosing container is at least partially surrounded by the induction element. Advantageously, the processing container and the dosing container are configured such that their shapes correspond to each other. The processing container typically defines the adjustment position of the dosing container. The dosing container can typically be inserted in a contactless manner into the receiving space of the adjustment station, in particular the induction element. Typically, the dosing container is inserted into the processing container using a moving device.
[0025] Preferably, the induction element is formed with one or more inductors, in particular one or more induction coils. The inductors generally define the processing container. Each inductor can be an induction coil comprising a plurality of coil windings. The electromagnetic induction field is generally generated by a current flowing through the coil windings. The area covered by the coil windings generally defines the processing container. The coil windings are generally arranged on the envelope surface of a rotating body, such as a cylinder or a cone. For example, the induction element can be formed by a cylindrical induction coil comprising a plurality of coil windings, wherein the area covered, in particular surrounded, by the coil windings is the processing container. The inductor is generally configured to generate an electromagnetic induction field so as to electromagnetically stir the casting material in the receiving space in the adjustment position of the dosing container. It is generally envisaged that shearing of the casting material is generated by stirring the casting material so as to achieve a thixotropic state of the casting material, in particular with a defined solid content. It is advantageous that the induction element is configured so that the dosing container in the adjustment position is surrounded by the induction element in all directions orthogonal to the insertion direction of the dosing container into the processing container.
[0026] Advantageously, the dosing container can be inserted into the treatment container such that at least 20%, in particular at least 50%, preferably at least 65% of the volume of the receiving space is located inside the treatment container. As a result, a defined solid content of the casting material in the receiving space can be effectively adjusted. It is therefore particularly advantageous if at least 75%, in particular at least 85%, preferably at least 90% of the volume of the receiving space is located inside the treatment container. In particular, substantially the entire receiving space can be located inside the treatment container. In this way, the transformation of the casting material into the thixotropic state can be controlled with high precision, in particular in a closed loop.
[0027] It is preferred that the dosing container can be inserted into the treatment container, in particular in a controlled manner, preferably in a closed-loop control, so that at least 20%, in particular at least 50%, preferably at least 65% of the filling volume of the receiving space is located in the interior of the treatment container. As a result, a defined solid content of the casting material in the receiving space can be effectively adjusted. Therefore, it is particularly advantageous that at least 75%, in particular at least 85%, preferably at least 90% of the filling volume of the receiving space is located in the interior of the treatment container. In particular, substantially the entire filling volume of the receiving space of the casting material can be located in the interior of the treatment container. The filling volume of the receiving space represents the volume of the receiving space in the receiving space that is occupied by the casting material. The filling volume can be conveniently determined using a filling level measuring device. In this way, the conversion of the casting material into the thixotropic state can be controlled with particularly high precision, in particular in a closed loop. The insertion of the treatment container can be carried out in a controlled manner, in particular in a closed-loop control, usually depending on the filling volume of the receiving space. This can be achieved by using an electronic control device.
[0028] Typically, the temperature and / or the solid content in the casting material of the receiving space can be adjusted in the adjustment position of the dosing container by control, in particular closed-loop control, of the regulating station, in particular of the sensing element. Typically, in the adjustment position of the dosing container, cooling and / or active cooling of the casting material in the receiving space is allowed to achieve a thixotropic state of the casting material, in particular while electromagnetically stirring the casting material. The regulating station, in particular of the sensing element, can be controlled, in particular closed-loop controlled, by an electronic control device and can in particular be connected to the electronic control device accordingly via an electronic control line.
[0029] Advantageously, the regulating station comprises a cooling device. With the aid of the cooling device, the casting material in the receiving space can be cooled in the case of a dosing container that has been guided to the regulating station or in the regulating position of the dosing container, in particular while the casting material is stirred electromagnetically using an induction element. As a result, a thixotropic state of the casting material can be achieved particularly effectively. The cooling of the cooling device can usually be carried out in a controlled manner, in particular in a closed-loop control, using an electronic control device. The cooling device can be formed with one or more cooling elements, through which a cooling fluid can flow, the cooling elements being preferably arranged and constructed so that the elements can at least partially surround the dosing container in the position of the dosing container that has been guided to the regulating station or in the regulating position of the dosing container. The cooling element can be a cooling channel, which can in particular be constructed as part of a cooling circuit.
[0030] Advantageously, the sensing element can be configured to be movable so that the sensing element can be moved in conjunction with the dosing container to a certain extent. As a result, during the movement of the dosing container, the casting material in the receiving space can be adjusted, in particular electromagnetically stirred. Therefore, when the dosing container is at least partially inserted into the processing container, a series movement can occur. Therefore, a high efficiency can be achieved. The sensing element can be moved together with the moving device of the casting device, in particular in a controlled manner, preferably using closed-loop control. The moving device can be implemented by a mobile device. Alternatively, it may be advantageous that the sensing element can be passively moved in series with the dosing container, for example a mechanical connection between the dosing container and the regulating station, in particular the sensing element, can be achieved. It is feasible to activate or deactivate the mechanical connection in a controlled manner, in particular by closed-loop control.
[0031] The casting device usually comprises a casting chamber in which the casting material can be cast. The casting mold of the casting device is usually arranged downstream of the casting chamber, so that the casting material can be pressed from the casting chamber into the casting mold using a pressing element of the casting device, especially a plunger. The casting device is usually a die casting device and / or a forming device, especially a die forging device. The casting device can be controlled by an electronic control device, especially a closed-loop control, and can especially be connected to the electronic control device accordingly.
[0032] The control, in particular the closed-loop control, of the dosing container, the mobile device, the regulating station and / or the casting device can each be carried out by means of, in particular, a separate electronic control device, which is in particular part of the casting device. The dosing container, the mobile device, the regulating station and / or the casting device can accordingly be connected, usually in each case via an electrical control line, to the electronic control device for transmitting control signals.
[0033] According to the invention, the object of the invention is achieved by means of a method for casting a metal casting material of the type named at the outset, in particular as an option, the method moves a dosing container to a regulating station with an induction element before conveying the casting material to a casting device, after which the casting material in the receiving space is electromagnetically stirred using the induction element to convert the casting material into a thixotropic state. The method can be implemented by a casting device described herein. By using a dosing container for regulation, wherein in particular as an option, the casting material in the receiving space of the dosing container is converted into a thixotropic state, the casting of thixotropic casting materials can be effectively achieved. In this way, high operating performance can be achieved. Usually, after the casting material in the receiving space is converted into a thixotropic state, the casting material is conveyed to the casting device by the dosing container, after which the casting material in the thixotropic state is pressed into the casting mold of the casting device. Pressing usually occurs without any turbulence. The dosing container is usually a dosing pipette, which is configured to suck liquid casting material into the dosing pipette or its receiving space, thereby forming a negative pressure.
[0034] For the dosing container, liquid casting material, in particular the metered amount of liquid casting material, is preferably sucked from the molten pool container into the receiving space of the dosing container. Alternatively, mainly in the case of small amounts of casting material and / or cost-intensive conditions, it may be beneficial to feed solid casting material, usually a single item, into the receiving space of the dosing container, usually together with the metered amount of casting material. Usually, during or in the case of sucking up liquid casting material using the dosing container and / or in the case of or in the process of picking up solid casting material using the dosing container, the receiving space is evacuated using a vacuum device, thereby forming a negative pressure in the receiving space, in order to receive the in particular metered amount of casting material into the receiving space.
[0035] It is advantageous that, in particular, as an option, in a first method sequence, the casting material in the receiving space is converted into a thixotropic state by means of a regulating station and the thixotropic casting material is delivered to the casting device using a dosing container; or, as an option, in a second method sequence, the casting material in the receiving space is not converted into a thixotropic state by means of a regulating station, but the casting material is delivered in a liquid state from a casting container to a casting device. Typically, the casting material delivered to the casting device is injected into a casting mold using a casting device. In the first method sequence, the casting material in the thixotropic state is typically pressed into the casting mold by the casting device. In the second method sequence, the casting material in the liquid state is typically pressed into the casting mold by the casting device. The first method sequence and the second method sequence can be implemented in the manner described herein, respectively. The casting device can be configured accordingly for carrying out the first method sequence and / or the second method sequence. The first method sequence and the second method sequence can be carried out successively. In the first method sequence, in particular, in contrast to the second method sequence, the dosing container is typically not moved to a regulating station or a regulating position in order to electromagnetically stir the casting material in the receiving space. The first method sequence and the second method sequence can be carried out using different casting molds of the casting device. The first process sequence and the second process sequence can have the same or different casting material compositions. It is expedient for the casting installation to comprise a plurality of molten pool containers, wherein the dosing container can be moved into different molten pool containers in order to pick up casting material from the respective molten pool containers. It is advantageous for casting materials with different casting material compositions, in particular different molten pool compositions, to be accommodated or provided in the various molten pool containers, usually in each case in the liquid state or in a molten pool.
[0036] The method for casting a metallic casting material can be configured within the scope of a casting plant according to the features and effects described above in particular in this text. The method is also applicable to a casting plant.
[0037] It is advantageous if the solid content of the casting material in the receiving space is adjusted by means of the adjusting station to between 0.1% and 20%, in particular between 1% and 20%, preferably between 3% and 15%. With such a solid content, a particularly non-disruptive handling of the thixotropic material can be achieved, in particular with regard to the handling using a dosing container when the thixotropic material is in the receiving space.
[0038] It is advantageous to actively cool the casting material in the receiving space simultaneously with the electromagnetic stirring in order to convert the casting material into a thixotropic state. As a result, the thixotropic state of the casting material in the receiving space can be achieved particularly effectively. This can be achieved by means of a cooling device of the conditioning station.
[0039] It is advantageous to control the casting device in an automatic manner, in particular in a closed-loop control. This can be achieved by an electronic control device designed for this purpose. Control, in particular in a closed-loop control, can be performed depending on the amount of casting material and / or the casting material composition of the casting material. It is particularly advantageous to control the regulating station, in particular in a closed-loop control, in particular in a sensing element, in an automatic manner, in particular in a closed-loop control, in order to adjust the thixotropic state of the casting material, in particular of the casting material with a predetermined solid content, depending on the material composition of the casting material, in particular the alloy composition. The electronic control device can be designed for this purpose. This can be achieved effectively because a high degree of reproducibility can be achieved by using a dosing container for the regulation. In particular, oxidation effects can usually be ignored and / or the receiving space, which is usually isolated from the environment to the greatest extent possible, can accurately control the conversion of the casting material in the receiving space to the thixotropic state.
[0040] The casting material is usually a metal alloy, in particular a light metal alloy. Preferably, the casting material is a magnesium-based alloy, an aluminum-based alloy or a copper-based alloy.
[0041] Liquid casting material generally refers to casting material at a temperature above the liquidus temperature of the casting material. Thixotropic casting material generally refers to casting material in a semi-solid state or at a temperature between the liquidus temperature and the solidus temperature of the casting material. Typically, the molten pool container, the regulating station, the casting device and the dosing container are separate objects and / or are arranged to be spaced apart from each other. BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Additional features, advantages and effects of the present invention are derived from the following description of exemplary embodiments. In the drawings referenced herewith:
[0043] Figure 1 shows a schematic diagram of a casting apparatus;
[0044] Figure 2 and Figure 3 Microscopic images of the material structure of a part produced using a casting apparatus with and without a conditioning station of the casting apparatus are shown. DETAILED DESCRIPTION
[0045] exist Figure 1 In FIG. 1 , a casting plant 1 and a method sequence for casting a metallic casting material are schematically shown. The casting plant 1 comprises a molten pool container 2, a regulating station 3, a casting device 4, and a dosing container 5 which can be moved using a moving device 6. Figure 1, the interaction states of the dosing container 5 with the molten pool container 2, the regulating station 3 and the casting device 4 are respectively shown. The molten pool container 2 is configured to contain or be used to provide liquid casting material. In particular, as an option, the dosing container 5 can be moved from the molten pool container 2 to the regulating station 3 and to the casting device 4 using a moving device 6. The moving device 6 can be, for example, a rotating arm. In the case of the dosing container 5, a quantitative amount of liquid casting material can be picked up from the molten pool container 2 into the receiving space 8 of the dosing container, after which, in particular as an option, the dosing container is moved to the regulating station 3 using the moving device 6 so as to electromagnetically stir the casting material in the receiving space 8 using the induction element 7 of the regulating station 3 to transform the casting material from the liquid state to the thixotropic state. The electromagnetic stirring usually occurs during the cooling of the casting material in the receiving space 8. Then, the dosing container 5 can be moved to the casting device 4 using the moving device 6 so as to transport the thixotropic casting material from the receiving space 8 to the casting device 4, usually the casting chamber 9 of the casting device 4. The casting material delivered to the casting chamber 9 can then be pressed into the casting mold in the casting device 4 using a pressing element 10, in particular a plunger, of the casting device 4 in order to produce a part by cooling the casting material in the casting mold. The dosing container 5 is connected to an evacuation device 11, with which the receiving space 8 can be evacuated, so that a negative pressure can be achieved in the receiving space 8, in order to receive, in particular to suck the casting material into the receiving space 8. The evacuation device 11 is usually connected to the receiving space 8 in a gas-conducting manner via an evacuation line 12, in order to evacuate the receiving space 8 via the evacuation line 12. The dosing container 5 usually comprises a casting material opening 13 connected to the receiving space 8 in a casting material-conducting manner, in order to receive the casting material into the receiving space via the casting material opening 13 and / or to convey the casting material from the receiving space 8 via the casting material opening 13. In general, it is envisaged that the casting material opening 13 is immersed in the liquid casting material located in the molten pool container 2, in order to suck the casting material into the receiving space 8 via the casting material opening 13. In this way, a metered amount of casting material can be picked up with a reduced oxidation effect using the dosing container 5 , which can then, in particular, alternatively be used to cast liquid casting material with the casting device 4 or to cast thixotropic casting material with the casting device 4 .
[0046] The induction element 7 is usually formed by an induction coil comprising a plurality of coil windings. The induction coil forms a process container into which the dosing container 5 can be at least partially inserted in order to electromagnetically stir the casting material in the receiving space 8. It is practical to insert the dosing container 5 into the process container such that at least 20% of the volume of the receiving space 8, preferably at least 20% of the volume of the receiving space 8 filled with casting material, is located inside the process space. In this way, a specific, in particular predetermined, solid content in the casting material in the thixotropic state can be set.
[0047] In order to convey the thixotropic casting material in the receiving space 8 to the casting device 4, the thixotropic casting material is conveyed to the casting device 4, in particular to the casting chamber 9 of the casting device 4, via the casting material opening 13. For this purpose, it is advantageous if the ratio of the average diameter of the receiving space 8 to the diameter of the casting material 13 is 2 to 15. Alternatively, it is advantageous, preferably cumulatively, to convey the thixotropic casting material having a solid content of more than 3%, in particular 3% to 20%, from the receiving space 8 to the casting device 4 via the casting material opening 13. In this way, a low-interference operation of the handling, in particular the conveying, of the thixotropic casting material can be achieved using the dosing container 5.
[0048] Figure 2 and Figure 3 Shows the use of Figure 1 Microscopic images of the material structure of a part produced by the casting device 1 in FIG. 1 with and without the conditioning station 3 of the casting device 1 . The microscopic images show by way of example the material structure of a part produced by the casting device 1 with an AlSi7 alloy as casting material. Figure 2 The material structure of a part is shown which is produced without the use of a conditioning station 3 , namely by injecting liquid casting material into a casting mold using a casting device 4 . Figure 3 The material structure of the part produced using the conditioning station 3 is shown, i.e., by using the conditioning station 3, the casting material in the receiving space 8 is converted into a thixotropic state, wherein a solid content of 5% is achieved, and the thixotropic casting material is subsequently pressed into the casting mold using the casting device 4. Figure 2 In the microscopic image of , a dendritic grain structure can be seen. Figure 3 Spherical corn structures can be seen in the image.
[0049] It is possible that, by means of the dosing container 5, the liquid casting material can be introduced into the drainable receiving space 8 of the dosing container 5, after which the receiving space can be electromagnetically stirred in the receiving space 8 by means of the induction element 7 of the regulating station 3 in order to transform the casting material from the liquid state into the thixotropic state, and the thixotropic casting material is subsequently conveyed to the casting device 4 in order to introduce the casting material into the casting mold, so that thixotropic casting or parts produced by thixotropic casting can be realized in a cost-effective manner and with reduced oxidation effects. In particular, the casting device 1 can be used, in particular as an option, for casting with liquid casting material and / or for casting with thixotropic casting material. As a result, a casting device 1 with high operating performance can be realized.
Claims
1. A casting device (1) for casting a metal casting material, wherein the casting device (1) comprises: A molten pool container (2) for providing liquid casting material; A casting device (4) for pressing casting material into a casting mold of the casting device (4); and a dosing container (5) which can be moved from the molten pool container (2) to the casting device (4) and is particularly used as a dosing pipette, so as to use the dosing container (5) to pick up a certain amount of casting material from the molten pool container (2) into the receiving space (8) of the dosing container (5), and to transport the casting material to the casting device (4), wherein the dosing container (5) is connected to the vacuum device (11) of the casting equipment (1) so as to utilize the vacuum device (11) to press the casting material into the casting mold of the casting device (4); and a dosing container (5) which can be moved from the molten pool container (2) to the casting device (4) and is particularly used as a dosing pipette, so as to use the dosing container (5) to pick up a certain amount of casting material from the molten pool container (2) into the receiving space (8) of the dosing container (5), and to transport the casting material to the casting device (4). The vacuum device (11) evacuates the receiving space (8) to form a negative pressure in the receiving space (8), thereby receiving a certain amount of casting material into the receiving space (8), characterized in that the casting equipment (1) includes an adjustment station (3) with an induction element (7), wherein, in particular, as an option, before using the quantitative feeding container (5) to transport the casting material to the casting device (4), the quantitative feeding container (5) can be moved to the adjustment station (3) so as to use the induction element (7) to electromagnetically stir the casting material, thereby converting the casting material into a thixotropic state.
2. The casting device (1) according to claim 1, characterized in that The dosing container (5) comprises a casting material opening (13) which can be closed using a controllable closing device, in particular a closing plug, so that casting material can be supplied to the receiving space (8) via the casting material opening (13) when the casting material opening (13) is open.
3. The casting device (1) according to claim 2, characterized in that The casting material opening (13) of the dosing container (5) is arranged in a base region in the dosing container (5).
4. The casting device (1) according to claim 2 or 3, characterized in that The casting material opening (13) is formed by a tubular neck of the dosing container (5), which protrudes away from the base body of the dosing container (5).
5. The casting device (1) according to one of claims 1 to 4, characterized in that The dosing container (5) is designed to convey free-flowing metal casting material having a solid content of more than 0.1%, in particular 0.1% to 20%, preferably 1% to 15%, in particular preferably 3% to 10%, from the receiving space (8) to the casting device (4).
6. Casting device (1) according to one of claims 1 to 5, characterized in that The inductive element (7) defines a processing container into which the dosing container (5) can be at least partially inserted in order to electromagnetically stir the casting material in the receiving space (8) so that the dosing container (5) is at least partially surrounded by the inductive element (7).
7. The casting device (1) according to claim 6, characterized in that The induction element (7) is formed with one or more inductors, in particular one or more induction coils, wherein the inductors define the processing container.
8. The casting device (1) according to claim 6 or 7, characterized in that The dosing container (5) can be inserted into the treatment container such that at least 20%, in particular at least 50%, of the volume of the receiving space (8) is located inside the treatment container.
9. The casting device (1) according to one of claims 1 to 8, characterized in that The conditioning station comprises a cooling device by means of which the casting material in the receiving space (8) can be cooled, in particular while the casting material is electromagnetically stirred using the induction element (7), when a dosing container (5) has been introduced into the conditioning station.
10. Casting installation (1) according to one of claims 1 to 9, characterized in that The cooling device can be formed with one or more cooling elements through which a cooling fluid can flow, the cooling elements being preferably arranged and constructed such that they can at least partially surround the dosing container (5) at the location of the dosing container (5) which is guided to the regulating station.
11. Casting device (1) according to one of claims 1 to 10, characterized in that The sensing element (7) is configured to be movable, so that the sensing element (7) can be moved in series with the dosing container (5) to a certain extent.
12. A method for casting metal casting material, wherein a quantitative feeding container (5), in particular a quantitative feeding pipette, is used to pick up a quantitative casting material from a molten pool container (2) into a receiving space (8) of the quantitative feeding container (5), wherein liquid casting material or solid casting material is conveyed into the receiving space (8), after which the quantitative feeding container (5) is moved from the molten pool container (2) to a casting device (4), and the casting material from the receiving space (8) is conveyed to the casting device (4), so that the casting material conveyed to the casting device (4) is pressed into a casting mold of the casting device (4) by the casting device (4), wherein when the liquid casting material is picked up by the quantitative feeding container (5), a vacuum device (11) is used to evacuate the receiving space (8) so as to form a negative pressure in the receiving space (8) so as to receive the quantitative casting material into the receiving space (8), characterized in that Before the casting material is conveyed to the casting device (4), the dosing container (5) is moved into a regulating station (3) having an induction element (7), after which the casting material in the receiving space (8) is electromagnetically stirred by the induction element (7) in order to convert the casting material into a thixotropic state.
13. The method according to claim 12, characterized in that The solid content of the casting material in the receiving space (8) is adjusted between 0.1% and 20% by means of the adjusting station (3).
14. The method according to claim 12 or 13, characterized in that While the casting material in the receiving space (8) is electromagnetically stirred, the casting material in the receiving space (8) is actively cooled so as to convert the casting material into a thixotropic state.
15. The method according to one of claims 12 to 14, characterized in that The regulating station (3), in particular the sensing element (7), is controlled automatically, in particular in a closed loop, depending on the material composition of the casting material in order to regulate the thixotropic state of the casting material, in particular a casting material having a predetermined solid content.