A safe automatic control flow casting equipment and a process method thereof

Abstract

The application discloses a kind of safety automatic control flow's casting equipment, including melt pool, aluminium water inlet pool and pump chamber, melt pool is connected to aluminium water inlet pool by aluminium water channel in furnace, pump chamber is connected with aluminium water inlet pool by bottom inlet channel, impeller is provided in pump chamber, aluminium water outlet channel is connected with aluminium water steady flow pool above pump chamber, aluminium water steady flow pool bottom is provided with steady flow pool flow eye, steady flow pool flow eye is connected with outlet flow groove, steady flow pool flow eye outer end is provided by the plug head for plugging steady flow pool flow eye;Method, S1: melt raw material in melt pool, obtain aluminium water;S2: aluminium water flows into to pump chamber, then flows into to aluminium water steady flow pool;S3: aluminium water in aluminium water steady flow pool, flow into to outlet flow groove;S4: aluminium water in outlet flow groove flows into to corresponding aluminium piece casting tray, corresponding need to be manufactured aluminium piece can be obtained;Effect: method structure is novel, steady flow pool flow eye and melt pool are not directly communicated, increase insurance for aluminium casting safety, guarantee safety.

Description

Technical Field

[0001] This invention relates to a casting equipment, and more particularly to a safe and automatically controlled flow casting equipment. Background Technology

[0002] 1. Currently, in my country's aluminum ingot, aluminum rod, and aluminum plate production and casting industry, most enterprises use the molten aluminum flow-through (MFT) process, where the flow rate is controlled manually by adjusting the stopper and the opening of the flow-through. This process is simple in structure and inexpensive, leading to its widespread use. However, this process has significant safety defects and poses considerable safety hazards. A malfunction in the stopper or flow-through brick could result in a major safety accident. The large difference in liquid level from the start to the end of casting and the significant variations in the flow-through rate make automated production difficult, relying entirely on manual control and greatly impacting casting quality. This process will be gradually phased out in China's deep-well casting industry.

[0003] 2. Currently, in my country's aluminum ingot, aluminum rod, and aluminum plate production casting industry, the use of tilting furnaces in newly built production lines is gradually increasing. Tilting furnaces have solved the problem of flow uncontrollability and greatly improved automated production. However, tilting furnaces are very expensive to build, and the subsequent maintenance costs are also relatively high. Due to the limitations of mechanical structural strength, the furnace capacity is also relatively small. Under the current market conditions, most companies find it very difficult to invest in and upgrade this equipment. In addition, in the event of a power outage or accident, the tilting furnace returns to its original position slowly, which is not conducive to accident handling.

[0004] 3. Currently, in the upgrading of the domestic foundry industry, the existing enterprises' production equipment renovation is difficult to significantly alter due to the original site design. At the same time, the renovation cost is very high, and given the current situation, many enterprises are experiencing operational difficulties, making it hard to achieve. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a safe and automatically controlled casting equipment and its process method, which addresses the shortcomings of the prior art.

[0006] To achieve the above objectives, the present invention adopts the following measures:

[0007] A safe and automatically controlled flow casting device includes a molten pool, an aluminum inlet pool, and a pump chamber. The molten pool is connected to the aluminum inlet pool through an aluminum inlet channel inside the furnace. The pump chamber is connected to the aluminum inlet pool through a bottom inlet channel. An impeller is installed in the pump chamber. An aluminum outlet channel is installed above the pump chamber and connected to an aluminum flow stabilization tank. A flow stabilization tank outlet is installed at the bottom of the aluminum flow stabilization tank. The flow stabilization tank outlet is connected to an outlet channel. The outlet channel is used to connect to an aluminum casting plate. A plug for sealing the flow stabilization tank outlet is installed at the outer end of the flow stabilization tank outlet. The plug is fixed to one end of a plug rod. The other end of the plug rod is fixed to a plug controller. The plug controller is electrically connected to a control cabinet.

[0008] The impeller is connected to the impeller rotation mechanism via an impeller connecting rod, and the impeller rotation mechanism is electrically connected to the control cabinet;

[0009] A laser rangefinder for the stabilizing aluminum slurry is installed above the stabilizing slurry tank, and the laser rangefinder for the stabilizing slurry tank is electrically connected to the control cabinet;

[0010] A laser rangefinder for the water outlet channel is installed above the water outlet channel, and the laser rangefinder for the water outlet channel is electrically connected to the control cabinet.

[0011] An overflow trough is provided above the pump chamber, and the overflow trough is connected to the aluminum molten water inlet pool. The position of the overflow trough is higher than the height of the aluminum molten water outlet channel.

[0012] The flow stabilizing pool orifice is a cone-shaped structure that gradually expands from the inside out, and the plug is a corresponding cone-shaped structure.

[0013] A process for processing castings using the aforementioned casting equipment,

[0014] S1: Melt the raw materials in the molten pool to obtain molten aluminum;

[0015] S2: Molten aluminum flows into the pump chamber, where it is lifted upwards by the impeller rotation and flows into the molten aluminum stabilization tank through the molten aluminum outlet channel at the top.

[0016] S3: The molten aluminum in the molten aluminum stabilization tank flows into the outlet trough through the bottom stabilization tank outlet.

[0017] S4: Molten aluminum in the outlet channel flows into the corresponding aluminum casting plate, thus obtaining the corresponding aluminum part to be manufactured.

[0018] The flow stabilizing tank is equipped with a stopper for controlling the flow rate. The stopper is fixed to one end of the stopper rod, and the other end of the stopper rod is fixed to the stopper controller. The stopper controller is electrically connected to the control cabinet.

[0019] The impeller is connected to the impeller rotation mechanism via an impeller connecting rod, and the impeller rotation mechanism is electrically connected to the control cabinet; an overflow trough is provided above the pump chamber, and the overflow trough is connected to the aluminum water inlet pool, with the overflow trough positioned higher than the aluminum water outlet channel.

[0020] A laser rangefinder for the stabilizing aluminum water flow tank is installed above it, and the laser rangefinder for the stabilizing flow tank is electrically connected to the control cabinet; a laser rangefinder for the outlet flow channel is installed above it, and the laser rangefinder for the outlet flow channel is electrically connected to the control cabinet.

[0021] The beneficial effects of this invention are as follows: The novel structure, where the flow channel and the molten pool are not directly connected, is completely different from traditional flow channels, eliminating the risk of aluminum leakage and providing added safety for aluminum casting. Even in extreme cases, molten aluminum will not continuously flow out, preventing secondary risks and ensuring safety. The use of dual-stage level detection and a dual-stage flow control mechanism enables automated casting, ensuring stable casting levels and casting quality. The equipment is convenient to use and simple to operate. The entire system occupies a small area, has low site requirements, and is highly adaptable. New construction or renovation requires minimal changes to traditional process equipment; existing flow channels and plates do not need modification, resulting in lower overall and maintenance costs, significantly reducing enterprise investment and improving efficiency. Attached Figure Description

[0022] Figure 1 This is a top-view planar structural diagram of the present invention.

[0023] Figure 2 This is a schematic diagram of the side planar structure of the present invention.

[0024] Figure 3 This is a schematic diagram of the internal cross-sectional structure of the present invention. Detailed Implementation

[0025] A safe and automatically controlled casting device includes a molten pool 100, an aluminum molten water inlet pool 2, and a pump chamber 3. The molten pool 100 is connected to the aluminum molten water inlet pool 2 through an aluminum molten water channel 1 inside the furnace. The pump chamber 3 is connected to the aluminum molten water inlet pool 2 through a bottom water inlet channel 12. An impeller 13 is installed in the pump chamber 3. An aluminum molten water outlet channel 4 is installed above the pump chamber 3 and connected to an aluminum molten water stabilizing pool 5. A stabilizing pool flow eye 6 is installed at the bottom of the aluminum molten water stabilizing pool 5. The stabilizing pool flow eye 6 is connected to an outlet flow channel 10. The outlet flow channel 10 is used to connect to an aluminum casting plate. A plug 7 for sealing the stabilizing pool flow eye 6 is installed at the outer end of the stabilizing pool flow eye 6. The plug 7 is fixed to one end of a plug rod 8. The other end of the plug rod 8 is fixed to a plug controller 9. The plug controller 9 is electrically connected to a control cabinet.

[0026] The impeller 13 is connected to the impeller rotation mechanism 15 via the impeller connecting rod 14, and the impeller rotation mechanism 15 is electrically connected to the control cabinet.

[0027] A laser rangefinder 16 is installed above the aluminum slurry stabilizing tank 5, and the laser rangefinder 16 is electrically connected to the control cabinet.

[0028] A laser rangefinder 17 for the water outlet channel 10 is installed above the water outlet channel 10, and the laser rangefinder 17 for the water outlet channel 10 is electrically connected to the control cabinet.

[0029] An overflow trough 11 is provided above the pump chamber 3. The overflow trough 11 is connected to the aluminum water inlet pool 2. The position of the overflow trough 11 is higher than the height of the aluminum water outlet channel 4.

[0030] The flow stabilizing pool orifice 6 is a cone-shaped structure that gradually expands from the inside to the outside, and the plug 7 is a corresponding cone-shaped structure.

[0031] like Figure 1-3 As shown, the impeller rotation mechanism 15 is controlled by the control cabinet. The impeller rotation mechanism 15 drives the impeller 13 to rotate rapidly in the pump chamber 3 through the impeller connecting rod 14, and the molten aluminum enters the molten aluminum stabilization tank 5. Molten aluminum in the molten pool 100 continuously enters the molten aluminum inlet pool 2 from the molten aluminum channel 1 in the furnace, and then enters the pump chamber 3 to replenish the molten aluminum that has flowed away. The stabilization tank laser rangefinder 16 above the molten aluminum stabilization tank 5 monitors the liquid level in the molten aluminum stabilization tank 5 in real time and provides millisecond-level feedback to the PLC in the control cabinet. The PLC continuously sends commands to adjust the speed of the impeller rotation mechanism 15 so that the liquid level of the molten aluminum in the molten aluminum stabilization tank 5 remains stable. The molten aluminum in the molten aluminum stabilization tank 5 flows through the stabilization tank outlet 6 into the outlet channel 10. The molten aluminum in the outlet channel 10 flows to the aluminum casting tray, where the corresponding aluminum parts can be made, such as aluminum ingots, aluminum rods, aluminum plates, etc. The laser rangefinder 17 on the outlet flow channel 10 monitors the liquid level in the channel in real time. The laser rangefinder 17 continuously transmits the liquid level information to the PLC in the control cabinet. The PLC continuously sends commands to control the plug controller 9. The plug controller 9 continuously adjusts the opening and closing degree of the plug 7 and the flow stabilizing tank orifice 6, thereby controlling the aluminum flow rate, ensuring the liquid level in the outlet flow channel 10, and achieving stable aluminum flow throughout the entire flow direction. This ensures the stability of the aluminum surface level required for casting and meets the requirements for fully automated casting. The dual-stage flow control mechanism can efficiently control the aluminum flow rate, ensure stable aluminum surface level, reduce aluminum surface fluctuations, and improve the casting quality of aluminum parts.

[0032] In the device of this invention, the flow stabilizing tank orifice 6 is not directly connected to the molten pool 100, but is separated by the pump chamber 3. The flow stabilizing tank orifice 6 is only connected to the molten aluminum flow stabilizing tank 5; the molten aluminum flow stabilizing tank 5 is also not directly connected to the molten pool 100. The molten aluminum flow stabilizing tank 5 has a relatively small capacity, ensuring safety by preventing accidents when problems occur with the flow stabilizing tank orifice 6 or plug 7. In contrast, in traditional systems, the flow stabilizing tank orifice is directly connected to the molten pool, which could lead to major safety accidents if problems occur with the flow stabilizing tank brick or plug cap.

[0033] A process for processing castings using the aforementioned casting equipment,

[0034] S1: Melt the raw materials in the molten pool 100 to obtain molten aluminum;

[0035] S2: Molten aluminum flows into pump chamber 3. The molten aluminum is lifted upward by the impeller 13 in pump chamber 3 and flows into molten aluminum stabilizing tank 5 through molten aluminum outlet channel 4 at the top.

[0036] S3: The molten aluminum in the molten aluminum stabilizing tank 5 flows into the outlet trough 10 through the bottom stabilizing tank flow hole 6;

[0037] S4: The molten aluminum in the water outlet channel 10 flows into the corresponding aluminum casting plate, and the corresponding aluminum part to be manufactured can be obtained.

[0038] The flow stabilizing tank flow hole 6 is equipped with a stopper 7 for controlling the flow rate. The stopper 7 is fixed to one end of the stopper rod 8, and the other end of the stopper rod 8 is fixed to the stopper controller 9. The stopper controller 9 is electrically connected to the control cabinet.

[0039] The impeller 13 is connected to the impeller rotation mechanism 15 via the impeller connecting rod 14, and the impeller rotation mechanism 15 is electrically connected to the control cabinet; an overflow trough 11 is provided above the pump chamber 3, and the overflow trough 11 is connected to the aluminum water inlet pool 2, and the position of the overflow trough 11 is higher than the height of the aluminum water outlet channel 4.

[0040] A laser rangefinder 16 is installed above the aluminum water stabilizing tank 5, and the laser rangefinder 16 is electrically connected to the control cabinet; a laser rangefinder 17 is installed above the water outlet channel 10, and the laser rangefinder 17 is electrically connected to the control cabinet.

[0041] This invention addresses this issue by adding a pump chamber 3 and an aluminum molten water stabilizing tank 5 between the flow port 6 and the molten pool 100; and by adding a laser rangefinder 16 for the stabilizing tank and a laser rangefinder 17 for the outlet flow channel. This improved method ensures that the flow port 6 and the molten pool 100 are not directly connected, with the pump chamber 3 acting as a barrier. The flow port 6 is only connected to the aluminum molten water stabilizing tank 5; the aluminum molten water stabilizing tank 5 is also not directly connected to the molten pool 100. The aluminum molten water stabilizing tank 5 has a relatively small capacity, ensuring safety by preventing accidents should problems occur with the flow port 6 or the plug 7. In contrast, traditional flow ports are directly connected to the molten pool, and problems with the flow port brick or plug could lead to serious safety accidents. The system includes a laser rangefinder 16 above the stabilizing pool 5, which monitors the liquid level in real time and provides millisecond-level feedback to the PLC in the control cabinet. The PLC continuously sends commands to adjust the speed of the impeller rotation mechanism 15, ensuring a stable liquid level in the stabilizing pool 5. A laser rangefinder 17 on the outlet flow channel 10 monitors the liquid level in the channel in real time and continuously transmits this information to the PLC in the control cabinet. The PLC then sends commands to control the plug controller 9, which adjusts the opening and closing of the plug 7 and the flow outlet 6 in the stabilizing pool to control the flow rate of the molten aluminum, ensuring a stable liquid level in the outlet flow channel 10 and achieving the desired flow direction. This ensures a stable molten aluminum level for casting and enables fully automated casting. This dual-stage flow control mechanism efficiently controls the flow rate of the molten aluminum, ensuring a stable liquid level, reducing surface fluctuations, and improving the quality of the cast aluminum parts.

Claims

1. A safe and automatically controlled casting equipment, comprising a molten pool (100), an aluminum molten water inlet pool (2), and a pump chamber (3), characterized in that: The molten pool (100) is connected to the aluminum water inlet pool (2) through the aluminum water channel (1) in the furnace. The pump chamber (3) is connected to the aluminum water inlet pool (2) through the bottom water inlet channel (12). An impeller (13) is provided in the pump chamber (3). An aluminum water outlet channel (4) is provided above the pump chamber (3) and connected to the aluminum water stabilizing pool (5). A stabilizing pool flow eye (6) is provided at the bottom of the aluminum water stabilizing pool (5). The stabilizing pool flow eye (6) is connected to the water outlet channel (10). The water outlet channel (10) is used to connect with the aluminum casting plate. A plug (7) for sealing the stabilizing pool flow eye (6) is provided at the outer end of the stabilizing pool flow eye (6). The plug (7) is fixed at one end of the plug rod (8). The other end of the plug rod (8) is fixed on the plug controller (9). The plug controller (9) is electrically connected to the control cabinet.

2. The casting equipment with safe automatic flow control according to claim 1, characterized in that: The impeller (13) is connected to the impeller rotation mechanism (15) via the impeller connecting rod (14), and the impeller rotation mechanism (15) is electrically connected to the control cabinet.

3. A safe and automatically controlled flow casting equipment according to claim 1 or 2, characterized in that: A laser rangefinder (16) for the stabilizing aluminum water pool (5) is installed above it, and the laser rangefinder (16) for the stabilizing water pool is electrically connected to the control cabinet.

4. The casting equipment with safe automatic flow control according to claim 3, characterized in that: A laser rangefinder (17) for the water outlet channel (10) is installed above it, and the laser rangefinder (17) for the water outlet channel is electrically connected to the control cabinet.

5. A safe and automatically controlled flow casting equipment according to claim 4, characterized in that: An overflow trough (11) is provided above the pump chamber (3). The overflow trough (11) is connected to the aluminum water inlet pool (2). The position of the overflow trough (11) is higher than the height of the aluminum water outlet channel (4).

6. The casting equipment with safe automatic flow control according to claim 5, characterized in that: The flow stabilizing pool eye (6) is a cone-shaped structure that gradually expands from the inside to the outside, and the plug (7) is a corresponding cone-shaped structure.

7. A process method for processing castings using the above-mentioned casting equipment, characterized in that: S1: Melt the raw materials in the molten pool (100) to obtain molten aluminum; S2: The aluminum water flows into the pump chamber (3). The aluminum water is lifted upward by the impeller (13) in the pump chamber (3) and flows into the aluminum water stabilization tank (5) through the aluminum water outlet channel (4) at the top. S3: The aluminum molten metal in the aluminum molten metal stabilization tank (5) flows into the outlet trough (10) through the bottom stabilization tank flow hole (6). S4: The molten aluminum in the water outlet channel (10) flows into the corresponding aluminum casting plate, and the corresponding aluminum part to be manufactured can be obtained.

8. The process method according to claim 7, characterized in that: The flow stabilizing pool flow eye (6) is equipped with a stopper (7) for controlling the flow rate. The stopper (7) is fixed to one end of the stopper rod (8), and the other end of the stopper rod (8) is fixed to the stopper controller (9). The stopper controller (9) is electrically connected to the control cabinet.

9. The process method according to claim 8, characterized in that: The impeller (13) is connected to the impeller rotation mechanism (15) via the impeller connecting rod (14), and the impeller rotation mechanism (15) is electrically connected to the control cabinet; an overflow trough (11) is provided above the pump room (3), and the overflow trough (11) is connected to the aluminum water inlet pool (2). The position of the overflow trough (11) is higher than the height of the aluminum water outlet channel (4).

10. The process method according to claim 9, characterized in that: A laser rangefinder (16) for the stabilizing pool (5) is installed above the stabilizing pool, and the laser rangefinder (16) for the stabilizing pool is electrically connected to the control cabinet; a laser rangefinder (17) for the outlet channel (10) is installed above the outlet channel, and the laser rangefinder (17) for the outlet channel is electrically connected to the control cabinet.

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