MOLDING SYSTEM.

Abstract

The invention is a molding system (1) for a low-pressure light alloy casting plant. The molding system (1) extends vertically along the main axis (XX) and comprises a mold (S) comprising a lower mold half (S1) and an upper mold half (S2).The molding system (1) comprises: i) a first fixed lower plate (11) in which the lower mold half (S1) is housed; ii) a movable plate (12) in which the upper mold half (S2) is housed; iii) a second fixed upper plate (13), positioned on top of the movable plate (12); iv) a movement group (2) suitable for moving the movable plate (12) along the main axis (XX), comprising an electrically driven motor (20) and transmission members (21) operatively connected to the electrically driven motor (20) and the movable plate (12); v) a part ejection group (3) comprising an electric ejector motor (30) and ejection members (31) that can be moved by the electric ejector motor (30) into an ejection position in which the part is released from the upper mold half (S2); vi) a command unit suitable for controlling the operation of the electric activation motor (20) and the electric ejector motor (30).

Description

MOLDING SYSTEM FIELD OF INVENTION

[0001] The present invention relates to a specific molding system for molding light alloy parts obtained by means of a low-pressure forming process. In particular, the present invention also relates to a low-pressure light alloy part forming plant comprising said molding system. BACKGROUND OF THE INVENTION

[0002] In this analysis, the term “part” refers to the product obtained through molding. In other words, the “part” is the product obtained after injecting molten metal into the mold and allowing it to solidify. Typically, the “part” also includes several components necessary for the optimal success of the part-making operations, which are subsequently discarded: sprues, cast rotors, wells, vacuum branches, casting chips, and / or other components. These operations are carried out on specialized machines or in specialized plants, which are not included in this analysis.

[0003] In the present analysis, “light alloy” means metallic alloy of aluminum, magnesium, zinc, etc.

[0004] Furthermore, in the present analysis, the creation of parts by means of low pressure light alloy means that the production mode, in which the light alloy in the molten state is injected into the mold at a specified pressure of approximately 1-2 bar, preferably close to 1 bar.

[0005] In accordance with the above, therefore, the characteristics of the parts creation plant and the molding system, the subject matter of the present invention, are a function of the characteristics of the light alloy, for example, its temperature, viscosity, cooling times and its injection forces.

[0006] Therefore, the “parts” obtained through such parts creation plants are components with structural mechanical characteristics, which usually have an application in the automotive world.

[0007] In the prior art, a plurality of molding system solutions, sometimes referred to as "presses," are known. In these known solutions, there are molds, usually in two or more parts, known as half-molds or shells. These half-molds or shells are placed in an operating position and an open position. In the operating position, the mold is closed: initially, molten metal is injected into it, and then the molten metal is allowed to solidify, thus obtaining the "part." In the open position, the mold parts open, and consequently, the "part" can be removed, allowing a new cycle to be performed.

[0008] In the prior art, the innumerable modalities of the systems of Z / QCLn / ZZnZ / E / YIAI molding are known, where the control and movement actions of the mold take place by means of specific hydraulic actuators.

[0009] On the other hand, hydraulic actuators present a number of problems. For example, it should be emphasized that hydraulic actuators have uncontrollable movements: in fact, hydraulic systems only allow the positioning of a component in two positions, one position induced by the presence of hydraulic action and one position induced by the lack of hydraulic action.

[0010] Therefore, there is a great need to make this problem evident, that is, there is a great need to have a molding system in which the position of the various components can be completely controlled. SUMMARY OF THE INVENTION

[0011] The object of the present invention is to provide a molding system, which meets the aforementioned requirements, requirements that are within the specific context of low-pressure light alloy molding operations.

[0012] Said object is obtained by means of the molding system claimed in claim 1. In addition, said object is obtained by means of a low-pressure light alloy parts creation plant, which comprises said molding system according to that claimed in claim 16. The dependent claims describe variations of the preferred embodiment involving more advantageous aspects.

[0013] The object of the present invention is described in greater detail below, with the help of the accompanying figures, in which: BRIEF DESCRIPTION OF THE FIGURES

[0014] - Figure 1 shows a perspective view of the object of the molding system of the present invention, in an open configuration, according to a preferred embodiment;

[0015] - Figures 2a, 2b and 2c show a side view, a front view and a top view, respectively, of the molding system of Figure 1;

[0016] - Figure 3 shows a sectional view of the molding system according to section plane AA of Figure 2a;

[0017] - Figure 4 shows a perspective view of the object of the molding system of the present invention, in an operating or closed configuration, according to a preferred embodiment;

[0018] - Figures 5a, 5b and 5c show a side view, a front view and a top view, respectively, of the molding system of Figure 4;

[0019] - Figure 6 illustrates a sectional view of the molding system according to section plane AA of Figure 5a. 7 / QC ίΩ / 77Ω7 / B / YILI DETAILED DESCRIPTION OF THE INVENTION

[0020] With reference to the above figures, reference number 1 denotes, in its entirety, molding system 1, the subject matter of the present invention.

[0021] Molding system 1 is specific because it is part of a plant for creating parts using low-pressure light alloys, which in turn is the subject matter of the present invention. This low-pressure parts-making plant also comprises a light alloy casting injection system capable of seamlessly connecting to molding system 1.

[0022] In particular, the part creation system 1 extends in height along the main axis XX and comprises a base region R positioned at the bottom, in which the light alloy casting injection system can at least be partially housed.

[0023] In addition, wherein the molding system 1 comprises and moves, as described in detail below, a mold S.

[0024] In particular, mold S comprises a lower middle mold S1 and an upper middle mold S2, which can be positioned reciprocally between an operating position, or a closed position, in which they are mutually coupled and a plurality of open positions, in which they are axially separated from each other along the main axis XX.

[0025] Preferably, one half of the mold is fixed, while the other moves in translation.

[0026] Preferably, as fully described below, the movable mold half can be positioned on a plurality of axial portions.

[0027] Furthermore, according to a preferred embodiment, the lower mold half S1 comprises a plurality of sliding elements S11, S12, S13, S14, which can be positioned in a closed mold half position and in at least one open mold half position. Preferably, said sliding elements S11, S12, S13, S14 can be moved radially with respect to the main axis XX, which translates between a closed mold half position, in which they are close to the main axis XX, and a plurality of open mold half positions, in which they are distal to the main axis XX.

[0028] According to a preferred embodiment, as can be seen from the following description, molding system 1 has a preferred application in the creation of considerably axial and symmetrically shaped parts, such as, for example, alloy wheels for vehicles.

[0029] According to the present invention, the molding system 1 comprises a first fixed plate 11, a movable plate 12 and a second fixed plate 13.

[0030] Preferably, the molding system 1 comprises a main structure 10, which comprises said plates 11, 12, 13.

[0031] According to a preferred embodiment, the first fixed plate 11 and the second fixed plate 13 are joined to each other by means of support beams 15 included in the main structure 10. Preferably, the support beams 15 are positioned, from each other, at equal angles to one another. Z / QCLn / ZZnZ / E / YIAI of the others. Preferably, the support beams 15 are four.

[0032] According to the present invention, the first fixed plate 11 is the lower plate, which is proximal to the base plane. This first fixed plate 11 delimits the base region R with the base plane.

[0033] The lower half mold S1 is housed in the first fixed plate 11.

[0034] Furthermore, the first fixed plate 11 and the lower mold half S1 can be fluidly connected to the casting injection system. Preferably, in fact, a fluid passage 110 is provided in the first fixed plate 11 through which the molten metal flows to reach the mold S. According to a preferred embodiment, this fluid passage 110 is made of a material with a high melting point, for example, comprising an injector made from ceramic material.

[0035] On the other hand, the upper mold half S2 is housed in the movable plate 12. The axial position of the movable plate 12 corresponds to an axial position of the upper mold half S2.

[0036] Finally, the second fixed plate 13 is positioned above. The second fixed plate 13 is positioned on top of the movable plate 12.

[0037] In other words, the movable plate 12 is housed between the two fixed plates and between the support beams 15, which it integrally joins.

[0038] According to the present invention, the molding system 1 comprises a movement group 2 for moving the movable plate 12 along the main axis XX between an operating position, in which the mold S is closed, and a multiplicity of raised positions, in which the upper mold half S2 is separated from the lower mold half S1.

[0039] The motion group 2 comprises an electrically driven motor 20 housed in the second fixed upper plate 13 and the transmission members 21 operatively connected to the electrically driven motor 20 and the movable plate 12 suitable for transforming the rotary motion of the electrically driven motor 20 into translational motion.

[0040] According to a preferred embodiment, the electrically actuated motor 20 is of the brushless type.

[0041] Furthermore, according to a preferred embodiment, the transmission members 21 comprise a worm gear element 210 comprising a thrust end 211 coupled with the movable plate 12.

[0042] Preferably, the electric drive motor 20 is coupled and rotates said worm gear element 210, which causes the movable plate 12 to move along the main axis XX.

[0043] According to a preferred embodiment, the transmission members 21 also comprise a connecting element 220, preferably a belt or chain, suitable for connecting the electrically driven motor 20 to the worm gear element 210.

[0044] According to a preferred embodiment, the worm gear element 210 is positioned on the main shaft XX.

[0045] Preferably, the worm gear element 210 crosses the second fixed plate 13 to allow translation of the movable plate 12 and its coupling with the electrically driven motor 20. 7 / QC ίΠ / 77Ω7 / Β / YΙΛΙ

[0046] According to a preferred embodiment, the movement group 2 also comprises a support structure 25 coupled with the movable plate 12 and passing through the second fixed plate 13. Preferably, the support structure 25 is intended to support and hold the movable plate 12 in its position.

[0047] According to a preferred embodiment, the support structure 25 comprises a plurality of guide elements 251 extending parallel to the main axis XX through the second fixed plate 13. Preferably, the support structure 25 also comprises a base structure 255 for supporting the guide elements 251. In other words, the guide elements 251 extend between the movable plate 12 and the base structure 255. Preferably, the support structure 25 moves together with the movable plate 12.

[0048] According to the present invention, the molding system 1 also comprises a part ejection group 3, housed in the movable plate 12. The part ejection group 3 is intended to perform an action on the part whereby it detaches from the upper mold medium S2.

[0049] Said part ejection group 3 comprises an electric ejector motor 30 and ejection members 31 operatively connected to the electric ejector motor 30, to the movable plate 12, and to the upper mold half S2 movable by means of the electric ejector motor 30 in an ejection position in which the part is released from the upper mold half S2.

[0050] Preferably, the electric ejector motor 30 is of the brushless type.

[0051] Preferably, said ejection members 31 comprise one or more mechanical jacks 310 controlled by the action of the electric ejector motor 30. The movement of said mechanical jack 310 involves the axial movement of push pins 311 suitable to protrude and engage the piece in a push, causing the piece to detach from the upper mold half S2.

[0052] Preferably, the ejection members 31 comprise two mechanical jacks 310.

[0053] According to a preferred embodiment, the molding system 1 comprises an opening-closing group 4 of the lower mold half comprising said sliding element S11, S12, S13, S14, a corresponding electric sliding motor 40.

[0054] Preferably, the movement of each electric slide motor 40 involves the opening and closing of the lower mold half S1. In particular, the opening-closing group 4 of the lower mold half comprises, for each slide element S11, S12, S13, S14, a control plug 41 operatively connected to the corresponding slide element and the corresponding electric slide motor 40.

[0055] According to a preferred embodiment, the molding system 1 also comprises a parts collection group 5, which is a group of components that enable the collection of the part 5 detached from the upper mold half S2 by means of the action of the part ejection group 3. Z / QCLn / ZZnZ / E / YIAI

[0056] Preferably, the parts collection group 5 comprises a collection plate suitable for moving along a YY collection axis transverse to the main axis XX.

[0057] Likewise, the parts collection group 5 comprises an electric collection motor 50 operatively connected to the collection plate 51 to move it to an advanced position, in which the collection plate 51 is positioned on the main axis XX, and to a retracted position, in which the collection plate 51 is moved away from the main axis XX.

[0058] Preferably, the electric pickup motor 50 is a brushless motor.

[0059] According to a preferred embodiment, the electric pickup motor 50 is controlled during operation in order to control the actuator and, consequently, the translation of the pickup plate 51 to the advanced position corresponding to a raised position of the movable plate 12 and the upper mold half S1.

[0060] According to a preferred embodiment, the activation of the part ejection group 3 and the subsequent detachment of the part from the upper mold half S2 is carried out once the collection plate 51 is positioned in an advanced position.

[0061] According to the present invention, the molding system 1 comprises a control unit, operatively connected to the movement group 2 and the part ejection group 3, suitable for controlling the operation of the electric activation motor 20 and the electric ejection motor 30.

[0062] According to a preferred modality, the command unit is also operationally connected to the opening-closing group of the lower half mold 4.

[0063] According to a preferred modality, the command unit is also operationally connected to parts collection group 5.

[0064] According to the present invention, the control unit is operationally connected to the corresponding electric motors comprising the groups to which it is operationally connected. Preferably, the control unit is suitable for controlling the actuators of said electric motors.

[0065] According to a preferred embodiment, the control unit controls the electric ejector motor actuator 30 simultaneously with the electric trigger motor actuator 20. In other words, the control unit controls the ejection action of the parts during the lifting operation of the upper plate. Preferably, this command is executed after the pickup plate 51 has been positioned in an advanced position.

[0066] According to a preferred embodiment, the command unit is suitable for controlling the start of the lifting of the movable plate 12, starting from the operating position, as soon as the opening of the sliding elements S11, S12, S13, S14 is commanded.

[0067] According to the present invention, some movements are commanded by means of the command unit at a certain speed, while other movements are commanded at a different speed.

[0068] According to a preferred modality, the operating modes of the unit of The Z / QCLn / ZZnZ / E / YIAI command can be configured according to requirements. For example, and preferably, the strokes of the moving parts included in molding system 1 are a function of the size and type of mold S and workpiece. Similarly, the command unit performs control actions on the electric motors, and subsequently carries out the movements, according to the size and type of mold S and workpiece.

[0069] According to a preferred embodiment, once the positions have been reached, the control unit is suitable for controlling the shutdown of the corresponding electric motors. According to a preferred embodiment, the electric motors controlled to be shut down remain in torque and, consequently, maintain their position. For example, the control unit is suitable for controlling the shutdown of the electric sliding motors 40, once the sliding elements have been positioned in the lower half-mold closed position. For example, the control unit is suitable for controlling the shutdown of the electric trigger motor 20, once the moving plate 12 has been positioned in the operating position.

[0070] According to a preferred embodiment, the molding system 1 further comprises heat shields suitable for protecting the electric motors from the heat produced by the light alloy casting injection system.

[0071] Preferably, the heat shields comprise shields positioned on the first fixed plate 11, on the moving plate 12 and on the second fixed plate 13.

[0072] Preferably, heat shields comprise secondary shields placed around electric motors.

[0073] In accordance with the above, it should be noted that when referring to electric motors, we are referring to components, which comprise a drive unit, for example, a stator-rotor assembly, and a control unit, for example, a control board. Preferably, the control unit is operationally connected to each control board.

[0074] In an innovative manner, the molding system, the subject of the present invention, is suitable for fully achieving the intended object.

[0075] Advantageously, the molding system, the subject matter of the present invention, has electrically moved components, which demonstrates the need for hydraulic devices.

[0076] Advantageously, the presence of hydraulic supply pipes or conduits, valve assemblies for hydraulic operation, filter assemblies for cleaning hydraulic oil, oil reservoirs, and other components is avoided. Therefore, the molding system is significantly simplified.

[0077] Advantageously, the molding system, the subject matter of the present invention, can be adjusted according to the needs and according to the specific dimensions and geometries of the mold and / or the part obtained or to be obtained.

[0078] Advantageously, the speed of movement is considerably higher than that in known solutions, since it is a function of the torques of the present electric motors. 7 / QC ίΠ / 77Ω7 / Β / YΙΛΙ

[0079] Advantageously, the speed of the movements, the dimensions of the strokes and the time in accordance with which they are performed, can be specifically configured according to the needs of the mold and the part.

[0080] Advantageously, all execution times of the activities can be optimized, resulting in a cycle time that is considerably shorter than that of prior art hydraulic molding system solutions. Advantageously, some of the described movements can be performed simultaneously. Advantageously, the cycle times downstream of the light alloy injection and cooling operations are optimized.

[0081] Advantageously, the molding system, the subject matter of the present invention, is extremely safe and reliable.

[0082] Advantageously, the molding system, the subject matter of the present invention, is extremely compact.

[0083] Advantageously, the molding system, the subject matter of the present invention, has extremely low consumption.

[0084] Advantageously, the molding system, the subject matter of the present invention, has minimal or even zero environmental impact compared to known solutions.

[0085] Advantageously, the molding system, the subject matter of the present invention, requires minimal maintenance, unlike known hydraulic solutions and, consequently, provides a minimal number, and in some cases zero, of “machine stops”.

[0086] Advantageously, the molding system, the subject of the present invention, allows for high production capacities.

[0087] A person skilled in the art may make various changes or replacements of the elements with other functional equivalents of the molding system modalities in order to meet specific needs. These variations are also included within the scope of protection as defined by the following claims.

[0088] Likewise, each variant described as belonging to a possible modality can be implemented independently of other described variants.

Claims

1. A molding system (1) for a low-pressure light alloy casting plant comprising a light alloy casting injection system, wherein the molding system (1) extends vertically along the main axis (XX) and comprises a base region (R) positioned at the bottom, in which the light alloy casting injection system can at least partially be housed, wherein the molding system (1) comprises a mold (S) comprising a lower mold half (S1) and an upper mold half (S2), wherein the molding system (1) comprises: i) a first fixed lower plate (11), in which the lower mold half (S1) is housed, wherein the first fixed plate (11) and the lower mold half (S1) are fluidly connected to the casting injection system; ii) a movable plate (12) in which the upper mold half (S2) is housed;iii) a second upper fixed plate (13), positioned on top of the movable plate (12); iv) a movement group (2) suitable for moving the movable plate (12) along the main axis (XX) between an operating position, in which the mold (S) is closed, and a multiplicity of raised positions, in which the upper mold half (S2) separates from the lower mold half (S1); - an electric drive motor (20) housed in the second upper fixed plate (13); - transmission members (21) operatively connected to the electric drive motor (20) and to the movable plate (12) suitable for transforming the rotary motion of the electric drive motor (20) into translational motion; v) a part ejection group (3); housed in the movable plate (12), comprising: - an electric ejector motor (30);- ejection members (31) operatively connected to the electric ejector motor (30), the moving plate (12), and the upper mold half (S2) movable by means of the electric ejector motor (30) in an ejection position in which the part is released from the upper mold half (S2); vi) a control unit, operatively connected to the movement group (2) and the part ejection group (3), suitable for controlling the operation of the electric activation motor (20) and the electric ejector motor (30).; 2. The molding system (1) according to claim 1, wherein the control unit is suitable for simultaneously ordering the operation of the electric ejector motor (30) and the operation of the electric activation motor (20).

3. The molding system (1) according to any of the preceding claims, wherein the electrically driven motor (20) is of the brushless type.

4. The molding system (1) according to any of the preceding claims, wherein the transmission members (21) comprise a worm gear element (210) comprising a thrust end (211) coupled with the movable plate (12), wherein the electrically driven motor 7 / QC ίΠ / 77Ω7 / Β / YΙΛΙ (20) is coupled to and rotates said worm gear element (21) causing the translation of the movable plate (12) along the main axis (XX).

5. The molding system (1) according to claim 4, wherein the transmission members (21) also comprise a connecting element (220), preferably a belt or chain, suitable for connecting the electrically driven motor (20) to the worm gear element (210).

6. The molding system (1) according to any of the preceding claims, further comprising a part collection group (5) comprising: - a collection plate (51) suitable for moving along the collection axis (YY) transverse to the main axis (XX); - an electric collection motor (50) operatively connected to the collection plate (51) to move to an advanced position, in which the collection plate (51) is positioned to the main axis (XX), and to a retracted position, in which the collection plate (51) moves away from the main axis (XX).

7. The molding system (1) according to claim 6, wherein the control unit is operationally connected to the electric pickup motor (50) to command the operation thereof, and, consequently, the translation of the pickup plate (51) to the advanced position corresponding to a raised position of the movable plate (12) and the upper mold half (S1).

8. The molding system (1) according to claim 7, wherein the command unit is suitable for ordering the operation of the part ejection group (3) once the collection plate (51) is positioned in an advanced position.

9. The molding system (1) according to any of the preceding claims, wherein the lower mold half (S1) comprises a plurality of sliding elements (S11, S12, S13, S14) that can be positioned in a closed mold half position and in an open mold half position, wherein the molding system (1) comprises a lower mold half opening-closing group (4) comprising a corresponding electric sliding motor (40) for each sliding element (S11, S12, S13, S14).

10. The molding system (1) according to claim 9, wherein the control unit is operationally connected to each electric sliding motor (40) to command the operation thereof and the opening and closing of the lower mold half (S1).

11. The molding system (1) according to claims 9 and 10, wherein the opening-closing group of the lower mold half (4) comprises, for each sliding element (S11, S12, S13, S14) a control plug (41) operatively connected to the corresponding sliding element and to the corresponding electric sliding motor (40).

12. The molding system (1) according to any of the preceding claims, further comprising suitable heat shields for protecting the electric motors from the heat produced by the light alloy casting injection system. Z / QCLn / ZZnZ / E / YIAI 13. The molding system (1) according to claim 12, wherein the shields comprise primary shields positioned on the first fixed plate (11), on the movable plate (12) and on the second fixed plate (13) and / or secondary shields placed around the electric motors.

14. The molding system (1) according to any of the preceding claims, wherein the impact of the moving parts included in the molding system (1) depends on the size and type of mold (S) and the part.

15. The molding system (1) according to any of the preceding claims, wherein the control unit can be configured to perform actions or command the electric motors depending on the size and type of the mold (S) and the part.

16. A low-pressure light alloy casting plant comprising a light alloy casting injection system and a molding system (1) according to any of the preceding claims.

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