Light-weight cabin shell casting equipment and casting process

Abstract

The invention relates to light-weight cabin shell casting equipment and a casting process, and relates to the technical field of casting equipment. The device comprises a casting tank, a defoaming tank fixed to the casting tank, a casting pipe arranged on the casting tank, a video sensor used for detecting the model of a mold, a distance sensor used for detecting the amount of molten metal in the casting tank, a heat preservation assembly used for conducting heat preservation on the molten metal in the casting tank and a casting assembly used for conducting quantitative casting on the molten metal. The casting assembly comprises three liquid outlet pipes communicating with the casting tank, three agent outlet pipes communicating with the defoaming tank, liquid outlet plates movably arranged on the three liquid outlet pipes correspondingly, and control valves fixed to the three agent outlet pipes correspondingly. The casting tank has the advantages that the molten metal is defoamed and optimized, the discharging speed of the molten metal and the defoaming agent can be controlled according to the model of the mold, the liquid discharging speed of the molten metal and the defoaming agent is prevented from being affected by the static pressure head as much as possible, and the casting effect of the casting tank on multiple molds of different models is guaranteed.

Description

Technical Field

[0001] This application relates to the technical field of casting equipment, and in particular to a lightweight compartment-type shell casting equipment and casting process. Background Technology

[0002] When producing lightweight cabin-type shells, casting equipment is usually required to cast molten aluminum alloy metal. During the casting process, different models of shells have huge differences in geometry, wall thickness distribution and solidification characteristics. A special gating system is usually matched to control parameters such as casting temperature and speed. Otherwise, defects such as poor filling in thin-walled areas and shrinkage porosity in thick-walled areas are very likely to occur.

[0003] Existing technology employs a typical serial single-piece production mode for multiple types of cabin shells, namely "one furnace, one model". The specific steps are as follows: first, a special mold is installed for model A and the gating system is debugged. Then, the alloy is melted and poured, pressure held and cooled. After the mold is opened and the part is removed, the machine must be stopped to disassemble the entire set of molds. Then, the special mold for model B is hoisted and re-aligned and installed. The process parameters are then debugged again before the production of the next model can begin. This process must be repeated when switching between different models.

[0004] Regarding the aforementioned technologies, the inventors believe that the following drawbacks exist: Firstly, the traditional method of equipping each model with a dedicated mold and casting system severely restricts the mass production efficiency of compartment-type shells. Each model change leads to a long production line downtime, resulting in low equipment utilization and an inability to meet the flexible manufacturing needs of multiple varieties and small batches. The difference in preparation time for each furnace leads to a discontinuous overall production process, with a significant amount of time spent on mold changes and restarts. Furthermore, to maintain continuous production of different models, multiple casting furnaces often need to be started in parallel, which not only significantly increases equipment investment and energy consumption but also affects the consistency of castings due to fluctuations in process parameters for each furnace. It also requires the maintenance of a large and ever-growing casting furnace, which greatly extends the production cycle. Therefore, improvements are proposed to address these issues. Summary of the Invention

[0005] To address the aforementioned problems, this application provides a lightweight cabin-type hull casting equipment and casting process.

[0006] The lightweight compartment-type hull casting equipment and casting process provided in this application adopt the following technical solution: A lightweight compartment-type shell casting equipment includes a casting tank, a defoaming tank fixed on the casting tank, a casting pipe disposed on the casting tank, a video sensor for detecting the mold model, a distance sensor for detecting the amount of molten metal in the casting tank, a heat preservation component for heat preservation of the molten metal in the casting tank, and a casting component for quantitative casting of the molten metal. The casting assembly includes three liquid outlet pipes connected to the casting tank, three agent outlet pipes connected to the defoaming tank, liquid outlet plates movably disposed on the three liquid outlet pipes, control valves fixed on the three agent outlet pipes, a moving component for adjusting the moving range of the liquid outlet plates, an adjusting component for adjusting the opening size of the control valves, a synchronizing component for synchronously driving the moving component and the adjusting component, and a switching component for switching the opening of the three liquid outlet pipes and the three agent outlet pipes. The synchronizing component is automatically driven by the switching component. The heat preservation assembly includes three heating plates fixed inside the casting tank, three adjusting blocks disposed on the casting tank, and a driving component for timed driving of the heating plates.

[0007] By adopting the above technical solutions, lightweight compartment shells are typically made of high-strength aluminum alloys. Their performance is extremely sensitive to internal microscopic defects. The refining agent, mainly composed of chloride / fluoride salts and covering agents, can dissolve and adsorb oxide inclusions, reduce their surface tension, and form a protective layer on the liquid surface to prevent secondary oxidation and gas absorption by the melt. The core function of the refining agent is purification and deterioration. Therefore, adding a refining agent to the molten metal can remove gases and inclusions and refine grains, improving the strength, plasticity, and toughness of the shell material, thus achieving the microscopic basis for lightweighting. Without adding a refining agent to the molten metal, the casting will develop dispersed pores, oxide inclusions, and coarse aggregates. The brittle phase results in tensile strength, elongation, and especially fatigue life that are far below design values. Under alternating loads, it is prone to low-stress brittle fracture, which completely fails to meet the reliability requirements of compartment-type shells. At the same time, when adding refining agents to molten metal, the amount of refining agent added needs to be precisely controlled because the degassing and impurity removal reactions have their own stoichiometric ratios. If the amount of refining agent added is insufficient, the molten metal will not be thoroughly purified and residual defects will remain. If the amount of refining agent added is excessive, it will lead to element burn-off and contamination, melt overheating and energy consumption, and the generation of new inclusions causing secondary pollution. Therefore, the amount of refining agent added needs to be controlled according to the casting volume of molten metal to avoid adding too much or too little. The casting tank, defoaming tank, casting pipe, and video sensor can move above multiple molds via a conveying mechanism, enabling the defoaming tank to cast molten metal into multiple molds one by one. The casting assembly pours the molten metal into the molds for casting. Defoamers can be added to the molten metal to defoam and optimize its properties, ensuring the quality of the cast shell. The outlet pipe can be opened at a specified height according to the amount of molten metal in the casting tank, minimizing the impact of static pressure on the flow rate during dispensing. This prevents the gradual loss of molten metal from affecting the dispensing speed when casting batches of molds, ensuring successful batch casting. The video sensor can detect the mold model to be cast below when it moves, and control the molten metal discharge rate according to the mold model. For casting thin-walled molds, the molten metal discharge rate can be increased, and for casting thick-walled molds, the molten metal discharge rate can be decreased, ensuring the casting effect of different mold models. The heat preservation component can keep the molten metal in the casting tank at the optimal temperature, avoiding heat loss when casting multiple molds. At the same time, the molten metal in different positions can be heat-preserved to prevent the molten metal from affecting the discharge rate due to temperature loss.

[0008] Optionally, the movable component includes three wedge-shaped blocks fixed to the three liquid outlet plates, three annular springs fixed to the three wedge-shaped blocks, the three annular springs being fixedly connected to the three liquid outlet pipes, each of the three liquid outlet pipes being provided with a receiving groove, and the three receiving grooves being slidably connected to the three liquid outlet plates.

[0009] By adopting the above technical solution, the speed at which molten metal flows out of the outlet pipe from the casting tank can be controlled by the moving component. The flow speed of the molten metal can be adjusted according to the size of the mold model. When the synchronizing component drives the moving component, it can control the movement of the designated wedge block, which can drive the outlet plate to move in the outlet pipe and keep the ring spring in a compressed state. The opening size of the outlet pipe can be controlled according to the movement range of the outlet plate in the receiving tank. The discharge speed of the molten metal in the casting tank can be controlled by the range of movement of the wedge block by the synchronizing component.

[0010] Optionally, the adjusting component includes movable gears fixed to three control valves and movable racks fixed to three wedge blocks respectively. The three movable gears are respectively engaged with the three movable racks, and the three dispensing pipes are respectively connected to the three liquid dispensing pipes.

[0011] By adopting the above technical solution, the speed at which the defoamer flows out of the defoamer tank from the outlet pipe can be controlled by the adjusting component. The outlet speed of the defoamer can be controlled according to the outlet speed of the molten metal. When the synchronizing component drives the moving component, it can control the movement of the designated wedge block, which can drive the moving rack to move and drive the moving gear to rotate. The number of rotations of the moving gear can control the opening size of the control valve, thereby controlling the outlet speed of the defoamer in the defoamer tank. The defoamer in the defoamer tank can flow through the opened outlet pipe to the designated outlet pipe to mix with the molten metal, thereby optimizing the defoaming treatment of the molten metal.

[0012] Optionally, the switching component includes a threaded rod rotatably mounted on the casting tank, a threaded block movably mounted on the casting tank, and a motor fixed on the casting tank. The threaded rod is fixedly connected to the output end of the motor, and the threaded rod is threadedly connected to the threaded block.

[0013] By adopting the above technical solution, the switching component can open a designated outlet pipe to discharge molten metal and a designated outlet pipe to discharge defoamer according to the amount of molten metal in the casting tank. The motor can drive the threaded rod to rotate, which in turn can drive the threaded block to move up and down in sequence. It can drive the synchronization component and the switching component. The distance sensor can detect the remaining amount of molten metal in the casting tank and control the drive rod to fit with the wedge block at a designated height, ensuring the casting effect of the casting tank on different types of molds and controlling the optimal casting speed for different types of molds when casting molten metal.

[0014] Optionally, the synchronizing element includes a drive rod fixed to the threaded block, the inclined surfaces of the three wedge blocks are all movably fitted with the drive rod, the video sensor is fixedly connected to the casting pipe, and both the distance sensor and the video sensor are electrically connected to the motor.

[0015] By adopting the above technical solution, the synchronizing component can synchronously drive the moving component and the adjusting component to ensure that the molten metal and the defoamer flow synchronously. At the same time, it can match the flow rate of the molten metal with the flow rate of the defoamer, ensuring the defoamer's optimized defoaming effect on the molten metal. When the switching component drives the synchronizing component, it can drive the driving rod to move up and down, allowing the driving rod to fit against the designated wedge block. It can also control the position of the driving rod on the designated wedge block, so that when the wedge block moves, it can synchronously drive the liquid outlet plate and the movable rack to move, thereby synchronously releasing the molten metal and the defoamer.

[0016] Optionally, the driving component includes three heating blocks fixed to the casting tank, three receiving cavities, three sensors, adjusting brackets respectively fixed to the three adjusting blocks, and telescopic springs respectively fixed to the three adjusting brackets. The three telescopic springs are all fixedly connected to the casting tank. The three heating blocks are respectively fixedly connected to the three adjusting blocks. The three sensors are respectively movably fitted with the three adjusting brackets. The three adjusting blocks expand and contract in the three receiving cavities. The three sensors are respectively electrically connected to the three heating plates.

[0017] By adopting the above technical solution, the driving component can maintain the temperature of molten metal at different positions in the casting tank, ensuring that the molten metal in the casting tank is always kept at the optimal casting temperature. After the molten metal is poured into the casting tank, three heating blocks will be heated, and the heating blocks will transfer heat to the regulating blocks. The three regulating blocks at different heights can then detect the heat of the molten metal at three different heights in the casting tank. When the heat of the molten metal is higher than the optimal casting temperature, the regulating block will expand due to the heat, which can drive the regulating frame to move, causing the telescopic spring to compress and separating the regulating frame from the sensor. This will close the heating plate and stop heating the molten metal, preventing the molten metal from exceeding the optimal casting temperature. When the heat of the molten metal is lower than the optimal casting temperature, the regulating block will gradually contract and return to its original shape. The telescopic spring can increase the speed of the regulating block's recovery, allowing the regulating frame to re-adhere to the sensor, opening the heating plate and reheating the molten metal, preventing the molten metal from falling below the optimal casting temperature. This ensures the effective heating and heat preservation of the molten metal at different positions.

[0018] Optionally, all three liquid outlet pipes are connected to the casting pipe, the three liquid outlet pipes are arranged at equal distances on the casting tank, and the three agent outlet pipes are arranged at equal distances on the defoaming tank.

[0019] By adopting the above technical solution, when the amount of molten metal in the casting tank is large, the molten metal flows from the top outlet pipe, and the defoamer flows out from the top outlet pipe. When the amount of molten metal in the casting tank is moderate, the molten metal flows from the middle outlet pipe, and the defoamer flows out from the middle outlet pipe. When the amount of molten metal in the casting tank is small, the molten metal flows from the bottom outlet pipe, and the defoamer flows out from the bottom outlet pipe. This minimizes the impact of static pressure head on the outflow rate of the molten metal and defoamer, ensuring the casting tank's effectiveness for casting different types of molds.

[0020] Optionally, the casting tank is provided with three heating chambers, which are arranged at equal distances on the casting tank. The three heating plates are located inside the three heating chambers respectively, and the three sensors are electrically connected to the distance sensor.

[0021] By adopting the above technical solution, a specified number of heating plates and sensors can be activated according to the amount of molten metal in the casting tank using a distance sensor. When the amount of molten metal in the casting tank is large, three heating plates and three sensors can be activated. When the amount of molten metal in the casting tank is moderate, the heating plates and sensors in the middle and bottom can be activated. When the amount of molten metal in the casting tank is small, the heating plate and sensor at the bottom can be activated. This allows the three heating plates and three adjusting blocks to heat and detect the molten metal at three different locations.

[0022] Optionally, a protective cover is fixedly connected to the inner side of the casting tank, and the distance sensor is fixedly connected to the protective cover, with the distance sensor located inside the protective cover.

[0023] By adopting the above technical solution, the remaining amount of molten metal in the casting tank can be detected by the distance sensor. Based on the detected amount, the distance sensor will drive the motor. The protective cover can protect the distance sensor and create a relatively stable local working environment for the sensor, thereby ensuring the long-term stability and reliability of the liquid level detection signal.

[0024] A lightweight compartment-type hull casting process includes the following steps: S1. The casting tank, defoaming tank and casting pipe can be moved above multiple molds by the conveying mechanism, so that the casting tank can cast molten metal into multiple molds one by one; S2. The electric motor can drive the threaded rod to rotate, which can drive the threaded block and the drive rod to move up and down to fit with the designated wedge block. The position of the drive rod on the designated wedge block can be adjusted, which can drive the wedge block and the liquid outlet plate to move, control the liquid outlet speed of the molten metal. When the wedge block moves, it will also drive the movable rack to move, so that the movable gear rotates to control the opening size of the control valve, control the liquid outlet speed of the defoamer, and enable the defoamer to defoam and optimize the molten metal. S3. When the video sensor moves, it can detect the model of the mold to be cast below. When it detects that the mold is casting a thin shell, it opens the liquid outlet pipe and control valve more open to increase the discharge speed of molten metal and defoamer. When it detects that the mold is casting a thick shell, it opens the liquid outlet pipe and control valve less open to reduce the discharge speed of molten metal and defoamer. S4. The distance sensor detects the remaining amount of molten metal in the casting tank and controls the opening and closing of different liquid outlet pipes and agent outlet pipes. When the liquid level is in different ranges of high, medium and low, the outlets of molten metal and defoamer are automatically switched to the corresponding liquid outlet pipe and agent outlet pipe at the corresponding height to ensure precise control of the casting speed of different mold types. S5. The distance sensor can activate a specified number of heating plates and sensors to heat and maintain the temperature of the molten metal according to the amount of molten metal in the casting tank and detect the temperature. When the temperature of the molten metal is higher than the optimal casting temperature, the adjusting block will expand due to the heat, which can drive the adjusting frame to move and separate from the sensor, so that the heating plate closes and stops heating the molten metal. When the temperature of the molten metal is lower than the optimal casting temperature, the adjusting block will gradually shrink and return to its original shape, so that the adjusting frame re-fits with the sensor, which can activate the heating plate and reheat the molten metal.

[0025] By adopting the above technical solution, at the start of casting, the liquid level is at its highest, and the uppermost liquid outlet pipe and flux outlet pipe are used. When the liquid level drops to near the pipe opening, the liquid outlet pipe and flux outlet pipe at the middle height are switched. At this time, the height difference between the liquid level and the new pipe opening is similar to the initial state. This process is repeated until the bottommost liquid outlet pipe and flux outlet pipe are used. In this way, the large and continuous drop in liquid level is transformed into several small step-like drops, thereby keeping the driving pressure head stable. There will be a certain temperature gradient in the molten metal in the casting tank. Usually, the temperature of the molten metal near the bottom of the casting tank is lower, while the temperature at the top is higher. Setting multiple heating plates can ensure that the different molten metals in the casting tank are kept consistent, maintain a constant pouring speed, ensure quality consistency, and reduce molten metal oxidation and gas absorption.

[0026] In summary, this application includes at least one of the following beneficial technical effects: 1. The casting tank, defoaming tank, casting pipe, and video sensor can move above multiple molds via a conveying mechanism, so that the casting pipe can sequentially connect with the casting ports of multiple molds. This allows the casting tank to pour molten metal into multiple molds one by one, enabling batch casting of compartment-type shells. The switching component, in conjunction with the synchronization component and the moving component, can control the discharge speed of the molten metal in the casting tank. The molten metal can flow into the casting pipe through the open discharge pipe, and then be poured into the current mold for shell casting. At the same time, the regulating component can control the discharge speed of the defoaming agent in the defoaming tank. The defoaming agent can flow into the connected discharge pipe through the open agent pipe and mix with the molten metal. Through the mixing of the defoaming agent and the molten metal, the molten metal can be defoamed and optimized to ensure the quality of the subsequent molten metal casting of the shell. 2. When the video sensor moves, it can detect the model of the mold to be cast below. Based on the detected mold model, it drives the switching mechanism to control the discharge speed of molten metal and defoamer. When it detects that the mold is casting a thin shell, it can increase the discharge speed of molten metal and defoamer to allow the molten metal to quickly fill the mold for casting. When it detects that the mold is casting a thick shell, it can decrease the discharge speed of molten metal and defoamer to allow the molten metal to fill the mold smoothly for casting, thus ensuring the casting quality of shells with different wall thicknesses. The distance sensor can detect the remaining amount of molten metal in the casting tank and drive the switching mechanism based on the detected amount. When the amount of molten metal in the casting tank is large, the molten metal flows out from the top outlet pipe, and the defoamer flows out from the top outlet pipe. When the amount of molten metal in the casting tank is moderate, the molten metal flows out from the middle outlet pipe, and the defoamer flows out from the middle outlet pipe. When the amount of molten metal in the casting tank is small, the molten metal flows out from the bottom outlet pipe, and the defoamer flows out from the bottom outlet pipe. This is to minimize the impact of static pressure head on the outflow rate of the molten metal and defoamer, ensuring the casting tank can effectively cast multiple molds of different models, and controlling the optimal casting speed for different mold models when casting molten metal. 3. The drive unit can heat and maintain the temperature of molten metal at different locations within the casting tank. Simultaneously, it can detect the heat of molten metal at three different heights within the casting tank. When the heat of the molten metal exceeds the optimal casting temperature, heating is stopped to prevent it from exceeding this temperature. When the heat of the molten metal falls below the optimal casting temperature, heating is restarted. A distance sensor can activate a specified number of heating plates and sensors based on the amount of molten metal in the casting tank, allowing for heating and monitoring of the molten metal at three different locations. This prevents the molten metal from falling below the optimal casting temperature, ensuring effective heating and maintenance at different locations. It minimizes differences in heat levels that could affect the casting process, prevents overheating, and avoids temperature drops that could affect the flow rate of the molten metal, ensuring optimal flow at the outlet. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the overall structure of an embodiment of this application; Figure 2 Cross-sectional view of the casting tank connection structure in the embodiments of this application; Figure 3 The appearance diagram of the casting tank connection structure in the embodiments of this application; Figure 4 The appearance diagram of the casting pipe connection structure in the embodiments of this application.

[0028] Reference numerals: 1. Casting tank; 2. Defoaming tank; 3. Casting pipe; 4. Discharge pipe; 5. Discharge tube; 6. Motor; 7. Threaded rod; 8. Threaded block; 9. Drive rod; 10. Wedge block; 11. Ring spring; 12. Discharge plate; 13. Control valve; 14. Movable gear; 15. Movable rack; 16. Video sensor; 17. Heating plate; 18. Heated block; 19. Adjusting block; 20. Adjusting frame; 21. Telescopic spring; 22. Sensor; 23. Protective cover; 24. Distance sensor; 25. Inlet pipe; 26. Sealing cap; 27. Intelligent controller; 28. Guide rod. Detailed Implementation

[0029] The following is in conjunction with the appendix Figure 1-4 This application will be described in further detail.

[0030] This application discloses a lightweight compartment-type shell casting equipment, referring to... Figure 1 and Figure 2 The system includes a casting tank 1, a defoaming tank 2 fixed to the casting tank 1, a casting pipe 3 set on the casting tank 1, a video sensor 16 for detecting the mold model, a distance sensor 24 for detecting the amount of molten metal in the casting tank 1, a heat preservation component for heat preservation of the molten metal in the casting tank 1, and a casting component for quantitative casting of the molten metal; the casting component includes three liquid outlet pipes 4 connected to the casting tank 1, three liquid outlet pipes 5 connected to the defoaming tank 2, liquid outlet plates 12 respectively movably set on the three liquid outlet pipes 4, and respectively fixed to the mold model. The three outlet pipes 5 include a control valve 13, a moving part for adjusting the moving range of the liquid outlet plate 12, an adjusting part for adjusting the opening size of the control valve 13, a synchronizing part for synchronously driving the moving part and the adjusting part, and a switching part for switching the opening of the three liquid outlet pipes 4 and the three outlet pipes 5. The synchronizing part is automatically driven by the switching part. The heat preservation assembly includes three heating plates 17 fixed inside the casting tank 1, three adjusting blocks 19 set on the casting tank 1, and a driving part for timed driving of the heating plates 17.

[0031] The movable component includes three wedge-shaped blocks 10 fixed on the three liquid outlet plates 12, three annular springs 11 fixed on the three wedge-shaped blocks 10, the three annular springs 11 being fixedly connected to the three liquid outlet pipes 4, each of the three liquid outlet pipes 4 having a receiving groove, the three receiving grooves being slidably connected to the three liquid outlet plates 12, each of the three liquid outlet pipes 4 having a connecting hole, and the three wedge-shaped blocks 10 being slidably connected to the three connecting holes.

[0032] The regulating component includes movable gears 14 fixed to three control valves 13 and movable racks 15 fixed to three wedge blocks 10. The three movable gears 14 are respectively engaged with the three movable racks 15. The three dispensing pipes 5 are respectively connected to the three liquid dispensing pipes 4. The three control valves 13 are all one-way valves, which can prevent the molten metal in the liquid dispensing pipe 4 from flowing into the defoaming tank 2 through the dispensing pipe 5.

[0033] The switching component includes a threaded rod 7 rotatably mounted on the casting tank 1, a threaded block 8 movably mounted on the casting tank 1, and a motor 6 fixed on the casting tank 1. The threaded rod 7 is fixedly connected to the output end of the motor 6, and the threaded rod 7 is threadedly connected to the threaded block 8. A guide rod 28 is fixedly connected to the casting tank 1, and a guide hole adapted to the diameter of the guide rod 28 is provided on the threaded block 8. The guide rod 28 is slidably connected to the guide hole. By setting the guide rod 28 and the guide hole, the circumferential rotation of the threaded block 8 can be restricted, while ensuring the stability of the up-and-down movement of the threaded block 8.

[0034] The synchronizing element includes a drive rod 9 fixed to the threaded block 8, and the inclined surfaces of the three wedge blocks 10 are all in contact with the drive rod 9. The video sensor 16 is fixedly connected to the casting pipe 3. The distance sensor 24 and the video sensor 16 are both electrically connected to the motor 6. The three wedge blocks 10 are double-sided inclined blocks. The top inclined surface allows the drive rod 9 to adjust the movement range of the wedge blocks 10, and the bottom inclined surface allows the drive rod 9 to move up and down smoothly on the three wedge blocks 10.

[0035] The driving component includes three heating blocks 18 fixed to the casting tank 1, three receiving cavities, three sensors 22, adjusting brackets 20 respectively fixed to three adjusting blocks 19, and telescopic springs 21 respectively fixed to the three adjusting brackets 20. The three telescopic springs 21 are all fixedly connected to the casting tank 1. The three heating blocks 18 are fixedly connected to the three adjusting blocks 19 respectively. The three sensors 22 are movably fitted to the three adjusting brackets 20 respectively. The casting tank 1 is provided with three sliding holes. The three adjusting brackets 20 are slidably connected to the three sliding holes respectively. The three heating blocks 18, the three adjusting blocks 19, and the three telescopic springs 21 are located in the three receiving cavities respectively. The three adjusting blocks 19 expand and contract in the three receiving cavities respectively. The three sensors 22 are electrically connected to the three heating plates 17 respectively.

[0036] All three liquid outlet pipes 4 are connected to the casting pipe 3. The three liquid outlet pipes 4 are arranged at equal distances on the casting tank 1. The three agent outlet pipes 5 are arranged at equal distances on the defoaming tank 2. The defoaming tank 2 is equipped with an inlet pipe 25, through which defoaming agent can be added to the defoaming tank 2. A sealing cap 26 is movably connected to the casting tank 1.

[0037] The casting tank 1 is provided with three heating chambers, which are arranged at equal distances on the casting tank 1. The three heating plates 17 are located inside the three heating chambers respectively, and the three sensors 22 are electrically connected to the distance sensor 24.

[0038] A protective cover 23 is fixedly connected to the inside of the casting tank 1. The distance sensor 24 is fixedly connected to the protective cover 23. The distance sensor 24 is located inside the protective cover 23. The protective cover 23 is made of a material that is resistant to high temperature, has low thermal conductivity, and has low signal penetration loss to the sensor, such as engineering ceramics with specific compositions, high-temperature glass, or heat-resistant alloys with surface treatment, to withstand extreme thermal environments and ensure effective signal penetration of the distance sensor 24. It isolates the high-temperature molten metal, splashing slag, metal vapor, and thermal radiation in the casting tank 1 from the direct impact and interference of the distance sensor 24, creating a relatively stable local working environment for the sensor, thereby ensuring the long-term stability and reliability of the liquid level detection signal.

[0039] An intelligent controller 27 is fixedly connected to the casting tank 1. The three heating plates 17, distance sensor 24, video sensor 16, three sensors 22 and motor 6 are all electrically connected to the intelligent controller 27. The intelligent controller 27 can control the timed driving of the three heating plates 17, distance sensor 24, video sensor 16, three sensors 22 and motor 6.

[0040] Fill casting tank 1 with molten metal, then fill defoaming tank 2 with defoamer. The amount of defoamer in defoaming tank 2 should match the required amount of defoamer in the molten metal in casting tank 1, achieving precise dosage. Defoaming tank 2 will simultaneously discharge defoamer when molten metal is discharged from casting tank 1, ensuring consistent addition rates of molten metal and defoamer. By adding a matching amount of defoamer to defoaming tank 2 when adding molten metal to casting tank 1, it is possible to prevent the molten metal from exceeding the gas content limit or being overfilled due to a mismatch in the amount of defoamer in defoaming tank 2 during discharge. This leads to wasted costs. Every time molten metal is added to casting tank 1, defoamer of the same proportion must be added to defoamer tank 2 simultaneously. This is to prevent the addition rate from getting out of control due to the difference in static pressure head caused by the mismatch in the amount of the two. If the liquid level in defoamer tank 2 is lower than that in casting tank 1, the addition rate of defoamer will be delayed due to insufficient static pressure head, causing the molten metal to enter the mold cavity without being fully defoamed, resulting in porosity defects. If the liquid level in defoamer tank 2 is too high, the addition of defoamer too quickly may wash away the surface of the molten metal and cause secondary air entrapment. By strictly matching the amount and addition rhythm of molten metal and defoamer, the stability of casting quality can be guaranteed.

[0041] In existing casting equipment, when multiple molds are continuously poured, the natural trend of the molten metal flow rate is a gradual decrease. This is a physical inevitability caused by the combined effects of a decrease in static pressure head and a drop in temperature. During the casting process, the flow of molten metal is driven by pressure difference. When multiple molds are poured simultaneously, as molten metal continuously flows into each mold, the pressure in the gating system gradually decreases. Pressure difference is the driving force for fluid flow. A decrease in pressure leads to a reduction in the driving force for molten metal flow, thereby gradually slowing down the flow rate of the molten metal. The fluidity of molten metal is extremely sensitive to temperature. As the pouring process proceeds, the heat of the molten metal in the ladle is continuously dissipated through the ladle wall, surface radiation, and the pouring process, causing the temperature to gradually decrease. The decrease in temperature leads to an increase in the viscosity of the molten metal and a decrease in fluidity.

[0042] When casting shells with different wall thicknesses, the pouring speed of the molten metal needs to be adjusted. Adjusting the pouring speed is a necessary physical requirement for achieving qualified castings. The fundamental reason is that differences in wall thickness directly disrupt the core contradiction in the filling and solidification processes. Without targeted adjustments, casting defects will occur, failing to meet the stringent internal quality requirements of lightweight shells. For thin-walled shells, the pouring speed needs to be accelerated because thin-walled shells have a very large heat dissipation area, resulting in extremely rapid cooling of the molten metal. If the pouring speed is too slow, the molten metal will lose its fluidity before flowing through the narrow, complex thin-walled channels, leading to casting defects. Insufficient or cold shuts can prevent the molten metal from filling the cavity or from merging properly. For thick-walled shells, the casting speed of the molten metal needs to be slowed down because the solidification time window of thick-walled shells is longer, and filling the mold is relatively easy. If the casting speed is too fast, the high-speed flowing molten metal will produce violent turbulence, jetting and splashing, which will entrain air and cavity gas, forming pores. At the same time, it will scour the mold wall, causing sand erosion or metal mold coating to fall off, resulting in sand inclusion and inclusion defects. Therefore, for thin-walled parts, adjusting the speed is to complete the layout before the heat dissipates, while for thick-walled parts, adjusting the speed is to guide the heat to retreat in an orderly manner, leaving a smooth feeding channel.

[0043] To ensure the quality of the hull section castings, the casting process must strictly adhere to the core principle of high-temperature tapping to guarantee fluidity and low-temperature casting to suppress crystallization coarsening. The optimal tapping temperature for the aluminum alloy molten metal is 730°C to 760°C, and the optimal casting temperature is 650°C to 750°C. To avoid affecting the casting speed of the molten metal due to a drop in static pressure head and temperature when casting multiple molds in the casting tank 1, proactive dynamic compensation measures must be implemented at the equipment and control levels to ensure the consistency of quality for each casting. The optimal casting temperature for the molten metal is 650°C to 750°C. After passing through the heating block 18 and then being conducted to the regulating block 19, the heating temperature of the regulating block 19 will also decrease. Therefore, the preferred material for the regulating block 19 is a high-temperature alloy. Under other operating conditions, special ceramics, refractory materials, high-temperature plastic polymers, and intermetallic compounds can also be used. The material used is any material that can expand and contract within the optimal casting temperature of the molten metal. Controllable thermal expansion behavior and the selection of materials with excellent high-temperature performance, mechanical strength, fatigue resistance, and corrosion resistance ensure the long-term use of the regulating block 19 and guarantee its effectiveness in temperature detection. In existing technologies, the method of controlling the heating plate 17 based on temperature timing typically uses a temperature sensor to control contact with the molten metal. However, temperature sensors are easily interfered with and damaged in high-temperature environments, thus compromising the accuracy of the timed driving of the heating plate 17 and the effectiveness of molten metal control. Furthermore, prolonged contact between the temperature sensor and the molten metal can lead to corrosion and affect its lifespan. Compared to temperature sensor control, using a mechanical linkage structure to control the heating plate 17's timed driving offers advantages such as high reliability, fast response speed, no need for external energy, lower cost, and better environmental adaptability.

[0044] The implementation principle of the lightweight compartment-type hull casting equipment and casting process in this application embodiment is as follows: (1) By opening the sealing cover 26, molten metal can be poured into the casting tank 1. The casting tank 1, defoaming tank 2, casting pipe 3 and video sensor 16 can be moved above multiple molds by the conveying mechanism so that the casting pipe 3 can be connected to the casting port of multiple molds in turn, thereby enabling the casting tank 1 to cast molten metal into multiple molds one by one, and realizing the batch casting of compartment shells. (2) The motor 6 can drive the threaded rod 7 to rotate, which in turn can drive the threaded block 8 and the drive rod 9 to move up and down in sequence, so that the drive rod 9 can fit with the designated wedge block 10. At the same time, the position of the drive rod 9 on the designated wedge block 10 can be adjusted. When the drive rod 9 moves on the wedge block 10, it can drive the wedge block 10 and the liquid outlet plate 12 to move in sequence, so that the ring spring 11 is in a compressed state. When the liquid outlet plate 12 moves in the liquid outlet pipe 4, it can slide in the receiving groove. By the range of movement of the drive rod 9 on the wedge block 10, the size of the opening of the liquid outlet plate 12 to the liquid outlet pipe 4 can be controlled, which can then control the liquid outlet speed of the molten metal in the casting tank 1. The molten metal in the casting tank 1 can flow into the casting pipe 3 through the opened liquid outlet pipe 4, and then the molten metal can be cast into the current mold for casting the shell. (3) When the wedge block 10 moves, it will also drive the movable rack 15 to move. The movable rack 15 can drive the movable gear 14 to rotate. The number of rotations of the movable gear 14 can control the opening size of the control valve 13, and thus control the discharge speed of the defoamer in the defoaming tank 2. The defoamer in the defoaming tank 2 can flow through the open discharge pipe 5 to the connected liquid discharge pipe 4 to mix with the molten metal. Through the mixing of the defoamer and the molten metal, the molten metal can be defoamed and optimized to ensure the quality of the subsequent molten metal casting of the shell. (4) When the video sensor 16 moves, it can detect the mold model that needs to be cast below. According to the detected mold model, the video sensor 16 will drive the motor 6 and control the drive rod 9 to move up and down within the specified range of the wedge block 10. When it is detected that the mold is casting a thin shell, the drive rod 9 can be pushed more against the wedge block 10 that is currently attached, so that the liquid outlet plate 12 opens more to the liquid outlet pipe 4 and the movable gear 14 opens more to the control valve 13, thereby increasing the discharge speed of the molten metal and defoamer and allowing the molten metal to be quickly filled into the mold for casting. When it is detected that the mold is casting a thick shell, the drive rod 9 can be pushed less against the wedge block 10 that is currently attached, so that the liquid outlet plate 12 opens less to the liquid outlet pipe 4 and the movable gear 14 opens less to the control valve 13, thereby reducing the discharge speed of the molten metal and defoamer and allowing the molten metal to be smoothly filled into the mold for casting. The discharge speed of the molten metal and defoamer can be controlled according to the size of the mold model to ensure the quality of casting shells with different wall thicknesses. (5) The remaining amount of molten metal in the casting tank 1 can be detected by the distance sensor 24. Based on the detected amount, the distance sensor 24 will drive the motor 6 to control the drive rod 9 to engage with the wedge block 10 at a specified height. When the amount of molten metal in the casting tank 1 is large, the drive rod 9 can engage with the top wedge block 10, causing the molten metal to flow from the top outlet pipe 4 and the defoamer to flow out from the top outlet pipe 5. When the amount of molten metal in the casting tank 1 is moderate, the drive rod 9 can engage with the middle wedge block 10, causing the molten metal to flow from the middle outlet pipe 5. The liquid flows in the outlet pipe 4 of the middle part, and the defoamer flows out from the outlet pipe 5 of the middle part. When the amount of molten metal in the casting tank 1 is small, the drive rod 9 can be made to fit with the wedge block 10 at the bottom part, so that the molten metal flows out from the outlet pipe 4 at the bottom part and the defoamer flows out from the outlet pipe 5 at the bottom part. This avoids the molten metal and defoamer outlet speed being affected by the static pressure head as much as possible, and ensures the casting effect of the casting tank 1 on multiple different molds. It also allows different molds to control the optimal casting speed when casting molten metal, and ensures the casting effect of different shells. (6) When the drive rod 9 separates from the designated wedge block 10, the wedge block 10 will lose resistance. The elastic force of the ring spring 11 can sequentially drive the wedge block 10, the liquid outlet plate 12 and the movable rack 15 to move and automatically restore the original state, so that the liquid outlet plate 12 automatically closes the liquid outlet pipe 4, and the control valve 13 automatically closes the dispensing pipe 5, so that the drive rod 9 closes only one liquid outlet pipe 4 and one dispensing pipe 5 each time. (7) The three heating plates 17 can heat and keep the molten metal at different positions in the casting tank 1. After the molten metal is poured into the casting tank 1, the three heating blocks 18 will be heated and will transfer the heat to the regulating blocks 19. The three regulating blocks 19 at different heights can detect the heat of the molten metal at three different heights in the casting tank 1. When the heat of the molten metal is higher than the optimal casting temperature, the regulating block 19 will expand due to the heat, which can drive the regulating frame 20 to move, compress the telescopic spring 21, separate the regulating frame 20 from the sensor 22, and turn off the heating plates 17 to stop heating the molten metal and prevent the molten metal from exceeding the optimal casting temperature. When the heat of the molten metal is lower than the optimal casting temperature, the heating plates 17 will be turned off to stop heating the molten metal and prevent the molten metal from exceeding the optimal casting temperature. When the casting temperature is reached, the adjusting block 19 will gradually contract and return to its original shape. The speed of the adjustment block 19's return can be increased by the telescopic spring 21, which can then allow the adjusting frame 20 to re-fit with the sensor 22, allowing the heating plate 17 to be turned on and reheat the molten metal. This prevents the molten metal from falling below the optimal casting temperature, ensures the heating and heat preservation effect of the molten metal at different locations, and minimizes the difference in heat between different locations of the molten metal, which could affect the casting effect of the shell. At the same time, it can prevent the heating plate 17 from being turned on too much due to insufficient molten metal in the casting tank 1, thus avoiding excessive energy consumption and preventing overheating of the molten metal. It can also prevent the molten metal temperature from dropping and affecting the flow rate of the liquid, ensuring that the molten metal flows at the optimal flow rate. (8) The distance sensor 24 can activate a specified number of heating plates 17 and sensors 22 according to the amount of molten metal in the casting tank 1. When the amount of molten metal in the casting tank 1 is large, three heating plates 17 and three sensors 22 can be activated. When the amount of molten metal in the casting tank 1 is moderate, the heating plates 17 in the middle and bottom and sensors 22 can be activated. When the amount of molten metal in the casting tank 1 is small, the heating plate 17 at the bottom and sensors 22 can be activated. The three heating plates 17 and three adjusting blocks 19 can heat and detect the molten metal at three different positions respectively. Therefore, when there is no molten metal on the heating plate 17 at the specified position, the heating plate 17 and sensor 22 at the current position can be turned off to avoid energy consumption.

[0045] This application also discloses a lightweight compartment-type hull casting process, based on a lightweight compartment-type hull casting equipment, including the following steps: S1. The casting tank 1, the defoaming tank 2 and the casting pipe 3 can move above multiple molds through the conveying mechanism, so that the casting tank 1 can cast molten metal into multiple molds one by one; S2. The motor 6 can drive the threaded rod 7 to rotate, which can drive the threaded block 8 and the drive rod 9 to move up and down, and fit with the designated wedge block 10. The position of the drive rod 9 on the designated wedge block 10 can be adjusted, which can drive the wedge block 10 and the liquid outlet plate 12 to move, control the liquid outlet speed of the molten metal. When the wedge block 10 moves, it will also drive the movable rack 15 to move, so that the movable gear 14 rotates to control the opening size of the control valve 13, control the liquid outlet speed of the defoamer, and enable the defoamer to defoam and optimize the molten metal. S3. When the video sensor 16 moves, it can detect the model of the mold to be cast below. When it detects that the mold is casting a thin shell, it opens the liquid outlet pipe 4 and the control valve 13 to a larger extent, thereby increasing the discharge speed of the molten metal and the defoamer. When it detects that the mold is casting a thick shell, it opens the liquid outlet pipe 4 and the control valve 13 to a smaller extent, thereby reducing the discharge speed of the molten metal and the defoamer. S4. Distance sensor 24 detects the remaining amount of molten metal in casting tank 1 and controls the opening and closing of different outlet pipes 4 and outlet pipes 5. When the liquid level is in different ranges of high, medium and low, the outlets of molten metal and defoamer are automatically switched to the corresponding height outlet pipes 4 and 5 to ensure precise control of the casting speed of different mold types. S5. The distance sensor 24 can activate a specified number of heating plates 17 and sensors 22 to heat and maintain the temperature of the molten metal according to the amount of molten metal in the casting tank 1 and detect the temperature. When the temperature of the molten metal is higher than the optimal casting temperature, the adjusting block 19 will expand due to the heat, which can drive the adjusting frame 20 to move and separate from the sensor 22, so that the heating plate 17 is turned off and stops heating the molten metal. When the temperature of the molten metal is lower than the optimal casting temperature, the adjusting block 19 will gradually shrink and return to its original state, so that the adjusting frame 20 is re-attached to the sensor 22, which can turn on the heating plate 17 and reheat the molten metal.

[0046] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A lightweight compartment-type shell casting equipment, characterized in that: It includes a casting tank (1), a defoaming tank (2) fixed on the casting tank (1), a casting pipe (3) set on the casting tank (1), a video sensor (16) for detecting the mold model, a distance sensor (24) for detecting the amount of molten metal in the casting tank (1), a heat preservation component for heat preservation of molten metal in the casting tank (1), and a casting component for quantitative casting of molten metal; The casting assembly includes three liquid outlet pipes (4) connected to the casting tank (1), three agent outlet pipes (5) connected to the defoaming tank (2), liquid outlet plates (12) movably disposed on the three liquid outlet pipes (4), control valves (13) fixed on the three agent outlet pipes (5), a moving part for adjusting the moving range of the liquid outlet plate (12), an adjusting part for adjusting the opening size of the control valve (13), a synchronizing part for synchronously driving the moving part and the adjusting part, and a switching part for switching the opening of the three liquid outlet pipes (4) and the three agent outlet pipes (5). The synchronizing part is automatically driven by the switching part. The heat preservation component includes three heating plates (17) fixed inside the casting tank (1), three adjusting blocks (19) set on the casting tank (1), and a driving component for timing the heating plates (17).

2. The lightweight compartment-type shell casting equipment according to claim 1, characterized in that: The movable component includes three wedge blocks (10) fixed on three liquid outlet plates (12) respectively, and three annular springs (11) fixed on three wedge blocks (10) respectively. The three annular springs (11) are fixedly connected to three liquid outlet pipes (4) respectively. Each of the three liquid outlet pipes (4) is provided with a receiving groove. The three receiving grooves are slidably connected to the three liquid outlet plates (12) respectively.

3. The lightweight compartment-type shell casting equipment according to claim 2, characterized in that: The regulating component includes movable gears (14) fixed on three control valves (13) and movable racks (15) fixed on three wedge blocks (10). The three movable gears (14) are respectively engaged with the three movable racks (15), and the three dispensing pipes (5) are respectively connected to the three liquid dispensing pipes (4).

4. The lightweight compartment-type shell casting equipment according to claim 3, characterized in that: The switching component includes a threaded rod (7) rotatably mounted on the casting tank (1), a threaded block (8) movably mounted on the casting tank (1), and a motor (6) fixed on the casting tank (1). The threaded rod (7) is fixedly connected to the output end of the motor (6), and the threaded rod (7) is threadedly connected to the threaded block (8).

5. The lightweight compartment-type shell casting equipment according to claim 4, characterized in that: The synchronizing element includes a drive rod (9) fixed on a threaded block (8), the inclined surfaces of the three wedge blocks (10) are all in contact with the drive rod (9), the video sensor (16) is fixedly connected to the casting pipe (3), and the distance sensor (24) and the video sensor (16) are both electrically connected to the motor (6).

6. The lightweight compartment-type shell casting equipment according to claim 1, characterized in that: The driving component includes three heating blocks (18) fixed on the casting tank (1), three receiving cavities and three sensors (22), adjusting frames (20) fixed on the three adjusting blocks (19) respectively, and telescopic springs (21) fixed on the three adjusting frames (20) respectively. The three telescopic springs (21) are all fixedly connected to the casting tank (1), the three heating blocks (18) are fixedly connected to the three adjusting blocks (19) respectively, the three sensors (22) are movably attached to the three adjusting frames (20) respectively, the three adjusting blocks (19) expand and contract in the three receiving cavities respectively, and the three sensors (22) are electrically connected to the three heating plates (17) respectively.

7. The lightweight compartment-type shell casting equipment according to claim 1, characterized in that: All three liquid outlet pipes (4) are connected to the casting pipe (3). The three liquid outlet pipes (4) are arranged at equal distances on the casting tank (1), and the three agent outlet pipes (5) are arranged at equal distances on the defoaming tank (2).

8. A lightweight compartment-type shell casting equipment according to claim 6, characterized in that: The casting tank (1) is provided with three heating chambers, which are arranged at equal distances on the casting tank (1). The three heating plates (17) are located on the inner side of the three heating chambers respectively. The three sensors (22) are electrically connected to the distance sensor (24).

9. A lightweight compartment-type shell casting equipment according to claim 1, characterized in that: A protective cover (23) is fixedly connected to the inner side of the casting tank (1), and a distance sensor (24) is fixedly connected to the protective cover (23). The distance sensor (24) is located inside the protective cover (23).

10. A lightweight compartment-type hull casting process, based on a lightweight compartment-type hull casting equipment as described in any one of claims 1-9, characterized in that, Includes the following steps: S1. The casting tank (1), defoaming tank (2) and casting pipe (3) can be moved above multiple molds by the conveying mechanism, so that the casting tank (1) can cast molten metal into multiple molds one by one; S2. The motor (6) can drive the threaded rod (7) to rotate, which can drive the threaded block (8) and the drive rod (9) to move up and down, and fit with the designated wedge block (10). The position of the drive rod (9) on the designated wedge block (10) can be adjusted, which can drive the wedge block (10) and the liquid outlet plate (12) to move, control the liquid outlet speed of the molten metal. When the wedge block (10) moves, it will also drive the movable rack (15) to move, so that the movable gear (14) rotates to control the opening size of the control valve (13), control the liquid outlet speed of the defoamer, and make the defoamer defoam and optimize the molten metal. S3. When the video sensor (16) moves, it can detect the mold model that needs to be cast below. When it detects that the mold is casting a thin shell, it opens the liquid outlet pipe (4) and the control valve (13) to a larger extent, thereby increasing the discharge speed of the molten metal and the defoamer. When it detects that the mold is casting a thick shell, it opens the liquid outlet pipe (4) and the control valve (13) to a smaller extent, thereby reducing the discharge speed of the molten metal and the defoamer. S4. The distance sensor (24) detects the remaining amount of molten metal in the casting tank (1) and controls the opening and closing of different liquid outlet pipes (4) and liquid outlet pipes (5). When the liquid level is in different ranges of high, medium and low, the outlets of molten metal and defoamer are automatically switched to the corresponding height of the liquid outlet pipe (4) and liquid outlet pipe (5) to ensure accurate control of the casting speed of different mold types. S5. The distance sensor (24) can activate a specified number of heating plates (17) and sensors (22) to heat and keep the molten metal in the casting tank (1) according to the amount of molten metal. When the heat of the molten metal is higher than the optimal casting temperature, the regulating block (19) will expand due to the heat, which can drive the regulating frame (20) to move and separate from the sensor (22) so that the heating plate (17) can be turned off and the heating of the molten metal can be stopped. When the heat of the molten metal is lower than the optimal casting temperature, the regulating block (19) will gradually shrink and return to its original state, so that the regulating frame (20) can be re-attached to the sensor (22) so that the heating plate (17) can be turned on again to reheat the molten metal.

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