Molding system and molding method

Abstract

The invention provides a molding system and a molding method. The degree of freedom of layout in casting equipment related to snap flask molding is improved. A molding system is provided with: a flaskless molding machine for molding upper and lower molds and pushing out the upper and lower molds to a flat pallet located at a mold pushing-out position among a plurality of conveyed flat pallets; and the box cover covering device covers the box cover on the upper casting mold and the lower casting mold on the flat trolley at the casting mold push-out position.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a molding system and a molding method. BACKGROUND

[0002] Patent Literature 1 discloses a casting apparatus. The casting apparatus has a pouring line and a cooling line arranged in parallel with the pouring line. In the pouring line and the cooling line, flat pallets are conveyed at intervals. A mold is molded by a flaskless molding machine. The mold is placed on a flat pallet at a carrying-in position among the flat pallets conveyed in the pouring line. The flat pallet on which the mold is loaded is conveyed at intervals, and reaches a transfer device arranged downstream of the carrying-in position. The transfer device is arranged across the pouring line and the cooling line. The transfer device peels a jacket and a weight from the mold in the cooling line, and transfers the peeled jacket and weight to the mold in the pouring line.

[0003] Patent Literature 1: International Publication No. 2019 / 044257

[0004] The casting apparatus described in Patent Literature 1 can not be introduced into a plant in which the space is limited. For example, in a case where the pouring line and the cooling line cannot be arranged in parallel, it is difficult to arrange the transfer device of the jacket and the weight. The present disclosure provides a technique for increasing the degree of freedom of layout in a casting apparatus related to flaskless molding. SUMMARY

[0005] The molding system according to one aspect of the present disclosure includes a flaskless molding machine that molds an upper and lower mold and pushes the upper and lower mold out to a flat pallet at a mold pushing-out position among a plurality of flat pallets conveyed, and a jacket capping device that caps a jacket on the upper and lower mold on the flat pallet at the mold pushing-out position.

[0006] The molding method according to another aspect of the present disclosure includes a step of molding an upper and lower mold and pushing the upper and lower mold out to a flat pallet at a mold pushing-out position among a plurality of flat pallets conveyed, and a step of capping a jacket on the upper and lower mold on the flat pallet at the mold pushing-out position.

[0007] According to the present disclosure, a technique for increasing the degree of freedom of layout in a casting apparatus related to flaskless molding is provided. BRIEF DESCRIPTION OF DRAWINGS

[0008] Figure 1 is a plan view schematically showing one example of a structure of a casting apparatus included in a molding system according to one embodiment.

[0009] Figure 2 is a plan view schematically showing one example of a structure of a casting apparatus included in a molding system according to one embodiment. Figure 1 is a front view schematically showing one example of a structure of the casting apparatus shown in

[0010] Figure 3 (A) to (D) of FIG. 1 are views for explaining the operation of the first flask lifter at the casting ejection position. Figure 3 (D) of FIG. 1 is a view for explaining the operation of the first flask lifter at the casting ejection position.

[0011] Figure 4 (A) to (D) of FIG. 1 are views for explaining the operation of the first flask lifter at the casting ejection position. Figure 4 (F) of FIG. 1 are views for explaining the operation of the second flask lifter and the weight lifter at the disassembly position. DETAILED DESCRIPTION

[0012] Hereinafter, an embodiment of the present disclosure will be explained in detail with reference to the drawings. The same reference numerals are attached to the same elements in the explanation of the drawings, and the repeated explanation will be omitted. The dimensional ratio of the drawings is not necessarily consistent with the content of the explanation. The terms of "upper", "lower", "left", and "right" are based on the illustrated state, and are for convenience. The X direction and the Y direction in the drawing are horizontal directions, and the Z direction is a vertical direction.

[0013] Figure 1 is a plan view schematically showing one example of the structure of a casting apparatus included in a molding system according to one embodiment. Figure 2 is a front view schematically showing one example of the structure of the casting apparatus shown in Figure 1 Figure 1 Figure 2 The casting apparatus 100 shown in

[0014] As shown in Figure 1 Figure 2 The molding system 1 includes a molding machine 10. The molding machine 10 is a flaskless molding machine that molds a mold by compacting molding sand. The molding machine 10 is communicably connected to a control section 11. The molding machine 10 starts molding in accordance with a molding start signal received from the control section 11. The molding machine 10 pours molding sand into a sand flask in which a pattern is arranged, and pressurizes the sand in the sand flask to solidify it. The molding machine 10 obtains a mold by taking out the pattern from the solidified sand. The molding machine 10 molds an upper mold and a lower mold, and molds the upper mold and the lower mold to form an upper-and-lower mold M. The molding machine 10 ejects the upper-and-lower mold M by a working cylinder or the like, and hands it over to a conveyance line. The molding machine 10 transmits a signal indicating that the upper-and-lower mold M is handed over to the control section 11.

[0015] ​​​The transport line is a device that transports the mold M upward and downward. The transport line receives the mold M upward and downward from the molding machine 10 and transports the mold M upward and downward toward the casting machine 2 downstream in the transport direction. The transport line has, for example, a guide rail and a plurality of flat cars B that run on the guide rail. The transport line transports the mold M upward and downward by placing the mold M upward and downward on the plurality of flat cars B, respectively. The mold M upward and downward is pushed out to a flat car B located at a mold push-out position among the plurality of flat cars B. The mold push-out position is a position at which the molding machine 10 hands over the mold M upward and downward to the transport line, and is, for example, a position P0 opposite to the molding machine 10.

[0016] The molding system 1 is provided with a first flask jacket lifter 12 (an example of a flask cover device). The first flask jacket lifter 12 covers the mold M upward and downward with a flask jacket J. The flask jacket J is a frame having an inner surface. The inner surface of the flask jacket J has the same inclination as that of the side surface of the mold M upward and downward and is in close contact with the side surface of the mold M upward and downward. Thus, displacement of the upper mold and the lower mold due to impact or the like when the mold M upward and downward is transported can be suppressed. In addition, collapse or floating of the upper mold at the time of casting can be suppressed.

[0017] The first flask jacket lifter 12 is a device that moves the flask jacket J upward and downward. The first flask jacket lifter 12 has, for example, a lifting mechanism and a plurality of arms. The lifting mechanism is a driving mechanism such as a cylinder or an electric motor that moves the plurality of arms upward and downward. The plurality of arms have a clamping mechanism for holding the flask jacket J. The first flask jacket lifter 12 covers the mold M upward and downward with the flask jacket J on the flat car B located at the mold push-out position. The first flask jacket lifter 12 is disposed, for example, above the position P0, stands by with the flask jacket J lifted before the mold M upward and downward is pushed out, lowers the flask jacket J in accordance with the mold M upward and downward being pushed out onto the flat car B, and covers the mold M upward and downward with the flask jacket J.

[0018] The first flask jacket lifter 12 can also move a weight W upward and downward together with the flask jacket J. The weight W is a heavy object placed on the mold upward and downward. By using the weight W, floating of the upper mold at the time of casting can be suppressed. The first flask jacket lifter 12 moves the flask jacket J upward and downward in a state in which the weight W overlaps the flask jacket J, whereby the flask jacket J can be covered to the mold M upward and downward and the weight W can be placed on the mold M upward and downward. Depending on the quality of the cast product required, the weight W can not be used. Details of the operation of the first flask jacket lifter 12 will be described later. Hereinafter, the flat car on which the mold M upward and downward before casting is placed and on which the flask jacket J and the weight W are disposed in a state in which the mold M upward and downward is covered with the flask jacket J and the weight W is placed on the mold M upward and downward is referred to as a flat car in state T1.

[0019] A plurality of pallets B are arranged, for example, at equal intervals on a guide rail. The plurality of pallets B are conveyed by intermittent driving by a prescribed number of sand boxes at a time. The prescribed number of sand boxes can be one sand box or a plurality of sand boxes. The pallets are conveyed in the X direction by a first conveyance device 13 (one example of a conveyance device) and a second conveyance device 14 (one example of a conveyance device), respectively. The first conveyance device 13 is a pushing device or the like provided at one end of the guide rail, and the second conveyance device 14 is a buffer device or the like provided at the other end of the guide rail. A conveyance line is communicably connected to the control section 11. The conveyance line conveys the plurality of pallets B by a prescribed number of sand boxes at a time in accordance with a sand box conveyance signal received from the control section 11. When conveyance of the prescribed number of sand boxes is completed, the conveyance line sends a sand box conveyance completion signal to the control section 11.

[0020] The pallet in state T1 reaches a pouring area in which the pouring machine 2 is arranged by the conveyance line. The pouring machine 2 is a device that pours molten metal into the upper and lower molds M, for example, and has a nozzle for pouring molten metal into the upper and lower molds M. The pouring machine 2 is communicably connected to the control section 11. The pouring machine 2 pours molten metal into the upper and lower molds M of the pallet in state T1 in accordance with a pouring signal received from the control section 11. Hereinafter, the pallet in a state in which the poured upper and lower molds M are placed and the box sleeve J and the weight W are arranged in the upper and lower molds M will be referred to as a pallet in state T2.

[0021] The pallet in state T2 is moved to a cooling lane for cooling of the molten metal. The cooling lane is provided below a casting lane in which the molding, pouring, and box separation processes are performed. The casting lane and the cooling lane are not only arranged in a vertical direction but also can be arranged in an XY plane. The pallet in state T2 is moved to the cooling lane on the lower level (first floor) by the first elevator 15 (one example of a conveyance device). In the cooling lane, the pallet in state T2 is conveyed in the Y direction by a third conveyance device 16 (one example of a conveyance device) and a fourth conveyance device 17 (one example of a conveyance device), respectively. The third conveyance device 16 is a pushing device or the like provided at one end of the guide rail, and the fourth conveyance device 17 is a buffer device or the like provided at the other end of the guide rail. The pallet in state T2 is moved to the casting lane on the upper level (second floor) by the second elevator 18 (one example of a conveyance device). Thus, the pallet in state T2 is moved to the upstream of the molding machine 10 in the casting lane.

[0022] The platform car in state T2 is conveyed by the conveyance line to a knockout area where a knockout device 24 is arranged. The knockout device 24 is a device that takes out the cast product from the upper and lower molds M. The knockout device 24 is communicably connected to the control section 11. The knockout device 24 starts the knockout in accordance with the reception of a knockout start signal from the control section 11. If the platform car in state T2 reaches a position P39, the weight W on the platform car is lifted by a weight lifter 19. The weight lifter 19 is a device that moves the weight W up and down. The weight lifter 19 has, for example, a lifting mechanism and a plurality of arms. The lifting mechanism is a driving mechanism such as a hydraulic cylinder or an electric motor that moves the plurality of arms up and down. The plurality of arms have a clamping mechanism for holding the weight W. Details of the operation of the weight lifter 19 will be described later.

[0023] The weight W lifted by the weight lifter 19 is cleaned by a weight cleaning device 20. The weight cleaning device 20 is a device that cleans the upper surface or the lower surface of the weight W, and has, for example, a doctor blade and / or a brush. The doctor blade has a blade edge for removing sand or foreign matter adhering to the upper surface or the lower surface of the weight W, and the brush has bristles for removing fine sand. The weight cleaning device 20 can also have a blowing device.

[0024] Next, the platform car is moved in the Y direction by a transfer table or the like conveyance device 21. Thus, the upper and lower molds M from which the weight W is detached are conveyed to a position where a second flask lifting device 22 is arranged. The second flask lifting device 22 detaches the flask J from the upper and lower molds M on the platform car. The second flask lifting device 22 has, for example, a lifting mechanism and a plurality of arms. The lifting mechanism is a driving mechanism such as a hydraulic cylinder or an electric motor that moves the plurality of arms up and down. The plurality of arms have a clamping mechanism for holding the flask J. Details of the operation of the second flask lifting device 22 will be described later.

[0025] The flask J lifted by the second flask lifting device 22 is cleaned by a flask cleaning device 23. The flask cleaning device 23 is a device that cleans the inner surface or the outer surface of the flask J, and has, for example, a doctor blade and / or a brush. The flask cleaning device 23 can also have a blowing device.

[0026] The upper and lower molds M from which the flask jackets J and the weights W have been removed are handed over from the flatbed car to the flask separating device 24. The flask jackets J and the weights W are returned to the empty flatbed car. Hereinafter, the flatbed car in the state in which the flask jackets J and the weights W are arranged will be referred to as a flatbed car in a state T3. If the flatbed car in the state T3 reaches the mold pushing-out position, i.e., the position P0, the flask jackets J and the weights W are lifted by the first flask jacket lifter 12. Thereby, the flatbed car becomes in a state in which the upper and lower molds M can be placed. By the above-described structure and operation, the pair of the flatbed car, the flask jacket J, and the weight W is not changed. By the pair of the flatbed car, the flask jacket J, and the weight W not being changed, the tracing of the manufacturing history becomes easy, and the quality management and traceability are improved. In addition, by the efficient maintenance and the stabilization of the production process, the manufacturing cost can be reduced and the product quality can be stabilized.

[0027] The control section 11 is a device that comprehensively manages the casting process of the casting apparatus 100. The control section 11 is configured as, for example, a PLC (Programmable Logic Controller). The control section 11 can also be configured as a computer system including a processor such as a CPU (Central Processing Unit), a memory such as a RAM (Random Access Memory) and a ROM (Read Only Memory), an input / output device such as a touch panel, a mouse, a keyboard, a display, and a communication device such as a network card.

[0028] The control section 11 associates information related to molding as shift data with the upper and lower molds M (for example, an identifier of the mold). The shift data is associated with the position information in the mold row, and is shifted in correspondence with the movement each time the mold is moved (transported). The shift is to disassociate the association with the position information in the mold row. For example, in a case where the upper and lower molds M1 are manufactured and pushed out, the upper and lower molds M1 are stored in association with the position P0. Next, in a case where the upper and lower molds M2 are manufactured and pushed out, the upper and lower molds M2 are stored in association with the position P0, and the position is shifted for the upper and lower molds M1 to be stored in association with the position P1. In this way, the control section 11 can manage the upper and lower molds M in association with the positions on the data.

[0029] The control section 11 can also manage the teaming of the pallet table, the box sleeve J, and the weight W using the shift data. For example, in the case where the pallet table is provided with an RFID (Radio Frequency Identification) tag, the control section 11 associates the information on the teaming read from the RFID tag by the reader with the shift data and stores them in the storage device of the control section 11. The RFID tag can also be provided to either of the box sleeve J or the weight W. The RFID tag can also be a two-dimensional code. Alternatively, the control section 11 can also associate the information on the teaming read from the RFID tag by the reader with the shift data and write them to the RFID tag. Alternatively, the control section 11 can also virtually assign a number to the pallet table in advance, grasp the number of the pallet table on which the upper and lower molds M are received on the data every time a sand box is conveyed, and associate the grasped number with the shift data. The control section 11 can also associate only one pallet table with the shift data and determine the other pallet table based on the number of the sand boxes conveyed.

[0030] Figure 3 (A) of FIG. 10, Figure 3 (D) of FIG. 10 is a view that explains the operation of the first box sleeve lifter at the mold push-out position. As shown in Figure 3 (A) of FIG. 10, the pallet table Bl in the state T3 is conveyed to the position P0 below the first box sleeve lifter 12, that is, the position P0 as the mold push-out position. The box sleeve Jl and the weight Wl are placed on the pallet table Bl. Next, as shown in Figure 3 (B) of FIG. 10, the box sleeve Jl and the weight Wl are lifted from the pallet table Bl by the first box sleeve lifter 12. Thereby, the pallet table Bl becomes empty. Next, as shown in Figure 3 (C) of FIG. 10, the upper and lower molds Ml are pushed out onto the pallet table Bl by the molding machine 10. Next, as shown in Figure 3 (D) of FIG. 10, the upper and lower molds Ml cover the box sleeve Jl on the pallet table Bl and load the weight Wl. As such, the box sleeve J is covered and the weight W is loaded on the upper and lower molds M before the pallet table Bl starts to move, and thus, it is possible to avoid the displacement of the upper and lower molds due to the impact of the conveyance.

[0031] Figure 4 (A) of FIG. 10, Figure 4 (F) of FIG. 10 is a view that explains the operation of the second box sleeve lifter and the weight lifter at the disassembly position. The disassembly position includes both the position below the second box sleeve lifter 22 and the position P39 below the weight lifter 19 (see Figure 2 ). As shown in Figure 4 (A) of FIG. 10, the pallet table Bl in the state T2 is conveyed to the position P39 below the weight lifter 19. The upper and lower molds Ml, the box sleeve Jl, and the weight Wl are placed on the pallet table Bl. Next, as shown inFigure 4 The heavy block W1 is lifted from the upper and lower molds M1 by the heavy block lifter 19 as shown in (B). Then, the upper surface and / or the lower surface of the heavy block W1 is cleaned by the heavy block cleaning device 20. Next, as shown in (C), the platform car B1 is transported in the Y direction, and is disposed below the second flask lifting device 22. Then, the flask J1 is detached from the upper and lower molds M1 by the second flask lifting device 22. Then, the inner surface and / or the outer surface of the flask J1 is cleaned by the flask cleaning device 23. Next, as shown in (D), the upper and lower molds M1 are handed over from the platform car B1 to the flasking device 24. Thus, the platform car B1 becomes empty. Next, as shown in (E), the flask J1 is loaded on the platform car B1. Next, as shown in (F), the heavy block W1 is loaded on the flask J1. In this way, the flask J1 and the heavy block W1 are cleaned on the upstream side of the molding machine 10, and thus the quality of the cast product can be improved. Figure 4 Figure 4 Figure 4 Figure 4

[0032] [Summary of Embodiments]

[0033] In the molding system 1, the flask J is capped on the platform car at the mold ejection position, i.e., the position P0. Therefore, it is not necessary to dispose the capping device of the flask J in a manner of straddling the passage. Thus, the molding system 1 can improve the degree of freedom of layout in the casting facility 100 related to the flasking. In addition, after the flask J is capped, the movement of the platform car is started. Thus, the molding system 1 can avoid the displacement of the upper mold and the lower mold due to the impact of transportation. Also, in the case where the capping device of the flask J is disposed in a manner of straddling the passage, not only the centering of the molding machine 10 and the transportation line, but also the centering of the capping device of the flask J and the transportation line is necessary. In contrast, the molding system 1 caps the flask J at the ejection position of the molding machine 10, and thus the centering of the molding machine 10 and the transportation line is sufficient, and the number of times of centering is once. Thus, the molding system 1 can realize the efficiency of the production of the cast product.

[0034] [Modified Example]

[0035] The above-described various example embodiments have been described, but are not limited to the above-described example embodiments, and various omissions, substitutions, and changes can be made. For example, the first flask lifting device 12 does not need to be integrated with the molding machine 10. That is, the first flask lifting device 12 can have a dedicated frame, and be supported by the dedicated frame.

[0036] [Summary of Embodiments of the Present Disclosure]

[0037] The present disclosure includes the following modes. ​​​​

[0038] (Entry 1)

[0039] The styling system includes:

[0040] A casking molding machine shapes the upper and lower molds and pushes them out onto a flatbed trolley located at the mold ejection position among multiple conveying flatbed trolleys; and

[0041] The mold cover device consists of upper and lower mold cover boxes on a flatbed trolley located at the mold ejection position.

[0042] In this molding system, upper and lower mold cover sleeves are mounted on a flatbed trolley located at the mold ejection position. Therefore, there is no need for a device to configure the cover sleeves J across the channel. This increases the flexibility of layout in casting equipment related to mold ejection. Furthermore, the flatbed trolley begins moving after the cover sleeves are installed. This prevents misalignment of the upper and lower molds due to transport impacts.

[0043] (Item 2)

[0044] Based on the molding system described in Item 1, the box cover device can also cover the upper and lower molds with a box cover and place a weight on the upper and lower molds. In this case, the box cover and the weight can be applied to the upper and lower molds simultaneously.

[0045] (Item 3)

[0046] The molding system described in item 1 or 2 may also include a weight removal device, which is positioned upstream of the stencil casting machine in the transport direction of the multiple flatbed trolleys to remove weights. In this case, the molding system can apply the removed weights to the upper and lower molds immediately following molding.

[0047] (Item 4)

[0048] The molding system described in any of items 1 to 3 may also include a cassette cleaning device, which is positioned upstream of the cassette demolding machine in the conveying direction of the multiple flatbed trolleys, to clean the inner surface of the cassette. In this case, the molding system can apply the cleaned cassette to the upper and lower molds immediately after molding.

[0049] (Item 5)

[0050] The molding system according to any one of items 1 to 4 can further include a conveyance device that conveys a plurality of pallets, and a control unit that is connected to the conveyance device and the flaskless molding machine, generates shift data in which a conveyance position and information related to the mold are associated with each other, and associates at least one of the pallet, the flask, and the weight with the shift data. In this case, at least one of the pallet, the flask, and the weight is easily determined, and thus the molding system 1 can quickly provide information that is effective for countermeasures against defects.

[0051] (ITEM 6)

[0052] Another aspect of the present disclosure relates to a molding method including a step of molding an upper and lower mold and pushing the upper and lower mold out to a pallet located at a mold pushing position among a plurality of pallets conveyed, and a step of covering a flask on the upper and lower mold on the pallet located at the mold pushing position. The molding method has the same effects as the molding system described above.

Claims

1. A modeling system, characterized in that, have: The cassette molding machine shapes the upper and lower molds and pushes the upper and lower molds out to the mold ejection position of one of the multiple flatbed trolleys being transported. and A cover device for the upper and lower mold cover boxes located on the flatbed trolley at the mold ejection position.

2. The modeling system according to claim 1, characterized in that, The box cover device covers the box cover on the upper and lower molds and places the weight on the upper and lower molds.

3. The modeling system according to claim 2, characterized in that, It also has: A heavy block cleaning device is arranged on the upstream side of the unpacking molding machine in the conveying direction of the plurality of flatbed trolleys to clean the heavy blocks.

4. The modeling system according to any one of claims 1 to 3, characterized in that, It also has: A box cleaning device is positioned upstream of the box-forming machine in the conveying direction of the plurality of flatbed trolleys to clean the inner surface of the box.

5. The shaping system according to claim 2 or 3, characterized in that, It also has: A conveying device for conveying the plurality of flatbed trolleys; and The control unit is connected to the conveying device and the unpacking molding machine. The control unit generates displacement data that associates the conveying position with information related to the mold, and associates at least one of the data of the flatbed trolley, the box sleeve, and the weight with the displacement data.

6. A modeling method, characterized in that, have: The process of molding upper and lower molds and ejecting the upper and lower molds into a flatbed trolley located at the mold ejection position among multiple conveying flatbed trolleys; and The process of installing the upper and lower mold cover boxes on the flatbed trolley located at the mold ejection position.

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