Casting device

Abstract

The present invention relates to a casting apparatus comprising: an injection unit for injecting an inoculant into a molten metal pouring stream according to an inoculation setting value including at least one of an injection amount and an injection time of the inoculant; and a setting change unit for changing the setting value to reduce a deviation between the quality of the casting indicated by the test results of a test for evaluating the quality of the produced casting and a predetermined reference. In the casting apparatus, if the casting quality does not meet the reference, the setting change unit changes the setting value, and the injection unit injects the inoculant into the pouring stream according to the changed setting value, performing the following process at least once.

Description

Technical Field

[0001] The invention relates to a casting device. Background Art

[0002] In the production of cast iron, inoculation is performed by adding additives called inoculants to the molten metal to improve the material's properties. There are several inoculation methods, including molten iron inoculation, ladle inoculation, and mold inoculation.

[0003] Japanese Patent Application Laid-Open No. 6-114498 describes a method for inoculating a casting solution using a tube to add an inoculant to the casting solution. In the technique described in Japanese Patent Application Laid-Open No. 6-114498, one front end opening of the tube is immersed in the casting solution flowing from a ladle toward the mold. The other front end opening of the tube is connected to a screw conveyor for supplying the inoculant into the tube. Inoculant stored in a tank is fed into the tube via the screw conveyor. The introduced inoculant passes through the tube and is added to the casting solution flow through the other front end opening of the tube. Summary of the Invention

[0004] In order to make the quality of the manufactured casting meet the specified benchmark, it is necessary to add an inoculant of an appropriate amount to the molten metal at an appropriate time. In the technology described in Japanese Patent Laid-Open No. 6-114498, by determining the rotation speed of the screw of the screw conveyor and the rotation time as the length of time for the screw to rotate, an inoculant of an appropriate amount can be added to the pouring liquid flow at an appropriate time. In the case where the manufactured casting is changed, a skilled operator is required to repeatedly adjust and determine the appropriate rotation speed and rotation time until the quality of the newly manufactured casting meets the specified benchmark. Alternatively, in the case where the manufactured casting is changed, it is sometimes necessary to replace the screw conveyor itself. In this case, replacing the screw conveyor requires effort. In this way, in the prior art, a lot of effort is spent.

[0005] The present invention can be implemented in the following forms.

[0006] (1) According to an embodiment of the present invention, a casting device is provided. The casting device includes: an injection unit that injects an inoculant into a molten metal pouring stream according to an inoculation setting value including at least one of an injection amount and an injection time of the inoculant; and a setting change unit that changes the setting value so as to reduce the deviation between the quality of the casting indicated by the test results of a test for evaluating the quality of the manufactured casting and a predetermined benchmark. If the quality of the casting does not meet the benchmark, the casting device performs the following process one or more times: the setting change unit changes the setting value; and the injection unit injects the inoculant into the pouring stream according to the changed setting value.

[0007] According to the above aspect, when the quality of the manufactured casting does not meet the predetermined standard, the setting value of inoculation can be automatically changed and inoculation can be performed based on the changed setting value, eliminating the need for tedious effort in adjusting the setting of the inoculant.

[0008] (2) The casting apparatus of the above aspect may further include a determination unit for determining whether the quality of the cast product satisfies a standard based on a test result related to the produced cast product.

[0009] According to the above aspect, the quality of the casting is determined in the casting apparatus, and therefore a series of processes including the production of the casting, determination of the quality, and adjustment of the inoculant can be smoothly performed.

[0010] (3) In the casting apparatus of the above embodiment, the setting changing unit may change the setting value, and the feeding unit may feed the inoculant into the pouring liquid flow according to the changed setting value, repeatedly until the judging unit judges that the casting meets the standard.

[0011] According to the above aspect, the inoculation settings can be automatically adjusted until the quality of the produced casting satisfies a predetermined standard, without requiring tedious effort.

[0012] (4) In the casting device of the above-mentioned method, the input part may also include: a receiving part, which is a container for receiving the inoculant and has an opening formed at the bottom; a bottom cover part, which can change the opening area of ​​the opening of the receiving part; and a control part, which controls the opening of the bottom cover part so that the opening area becomes corresponding to the input amount per unit time calculated based on the input amount and the input time.

[0013] According to the above aspect, it is easy to adjust the amount of inoculant fed per unit time.

[0014] (5) In the casting apparatus of the above aspect, as the control of the opening of the bottom cover, the control unit may change the opening of the bottom cover before adding the inoculant to the pouring liquid flow.

[0015] According to the above aspect, before adding the inoculant to the casting liquid flow, the amount of inoculant to be fed per unit time can be set.

[0016] (6) In the casting apparatus of the above aspect, as control of the opening of the bottom cover, the control unit changes the opening of the bottom cover while the inoculant is being added to the pouring liquid flow.

[0017] According to the above aspect, during the period of injecting the inoculant, the injection amount of the inoculant per unit time can be changed.

[0018] (7) In the casting device of the above aspect, the bottom cover portion includes an aperture mechanism capable of changing the opening area of ​​the opening.

[0019] According to the above aspect, the opening area is changed while the outer shape of the opening is maintained by the aperture mechanism, so that the amount and timing of the inoculant to be fed can be easily adjusted. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Hereinafter, features, advantages, and technical and industrial significance of exemplary embodiments of the present invention will be described with reference to the accompanying drawings, in which like numerals denote like elements.

[0021] Figure 1 It is a schematic cross-sectional view showing the structure of a casting device according to an embodiment.

[0022] Figure 2A It is a figure which shows the state which fully closed the 2nd bottom cover part.

[0023] Figure 2B This is a diagram showing a state in which a portion of the second bottom cover is opened.

[0024] Figure 2C This is a diagram showing a state in which a portion of the second bottom cover is opened.

[0025] Figure 2D This is a diagram showing a state where the second bottom cover portion is completely opened.

[0026] Figure 3 It is a flowchart of the casting process.

[0027] Figure 4 It is a diagram showing examples of the time-dependent changes of the tilting angle of the ladle, the weight of the pouring liquid, and the injection rate of the inoculant. DETAILED DESCRIPTION

[0028] A. Implementation Method

[0029] Figure 1 1 is a schematic cross-sectional view showing the structure of a casting apparatus 1 according to an embodiment. The casting apparatus 1 is used to manufacture cast iron parts by casting. In the embodiment, an example of manufacturing spheroidal graphite cast iron by the casting apparatus 1 is described. Spheroidal graphite cast iron is, for example, FDC400 specified in JIS G5502. The parts manufactured by the casting apparatus 1 are, for example, cylinder blocks of automobile engines. Figure 1 For ease of understanding, an XYZ orthogonal coordinate system is used. The X-axis is the horizontal direction. The Y-axis is the vertical direction. The Z-axis is perpendicular to the X-axis and Y-axis.

[0030] The casting apparatus 1 includes a casting mold 100, an automatic pouring machine 200, an injection device 300, and a control device 400. The injection device 300 is also referred to as an injection unit. The casting mold 100 includes a fixed mold 101 and a movable mold 102. The fixed mold 101 and the movable mold 102 form a cavity 103, which serves as a gap filled with molten material. The movable mold 102 is moved, for example, by a mold clamping device.

[0031] The automatic pouring machine 200 is a device for automatically pouring molten metal into the mold 100. The automatic pouring machine 200 includes a ladle 210, a tilting device 220, a load cell weight scale 230, a first liquid level sensor 240, and a second liquid level sensor 250.

[0032] The ladle 210 is a container for pouring molten material into the mold 100. The tilting device 220 controls the tilting angle of the ladle 210 under the control of the control device 400. The tilting angle of the ladle 210 is centered around a rotation axis parallel to the Z-axis of the ladle 210. Decreasing the tilting angle of the ladle 210 reduces the amount of molten metal poured into the mold 100 per unit time. Increasing the tilting angle of the ladle 210 increases the amount of molten metal poured into the mold 100 per unit time.

[0033] The load cell scale 230 is a sensor that detects the total weight of the ladle 210 containing the molten metal. The load cell scale 230 transmits a value indicating the detected total weight of the ladle 210 to the control device 400. The first liquid level sensor 240 includes a camera that captures the flow of the molten metal flowing into the receiving port 100a of the mold 100. The first liquid level sensor 240 transmits the captured dynamic image data to the control device 400. The second liquid level sensor 250 includes a camera that captures the molten metal near the discharge port of the ladle 210. The second liquid level sensor 250 transmits the captured dynamic image data to the control device 400.

[0034] The injection device 300 injects an inoculant into the molten metal poured into the mold 100. In the production of spheroidal graphite cast iron, inoculation is performed for the following purposes: preventing quenching of the molten metal, increasing the number of graphite particles, and promoting ferritization. The injection device 300 uses a pouring liquid flow inoculation process, performing inoculation before the molten metal is poured into the mold 100. Specifically, a fluid inoculant is mixed into the molten metal flow flowing from the ladle 210 before reaching the mold 100. Injecting an inoculant is also called cutting out an inoculant.

[0035] The feeding device 300 includes a hopper 310 and a pipe 320. The hopper 310 and the pipe 320 are supported by a supporting mechanism (not shown). Figure 1Although not shown in the figure, a prevention plate is arranged around the hopper 310 to prevent the molten metal from scattering into the hopper 310.

[0036] The hopper 310 is a container made of resin and stores an inoculant. The hopper 310 includes a main body 311 , a first bottom cover 312 , and a second bottom cover 313 .

[0037] The main body 311 includes a first opening 311a for injecting inoculant, a reservoir 311b for storing the inoculant, an outlet 311c for discharging the inoculant, a discharge channel 311d connecting the reservoir 311b and the outlet 311c, and an opening 311e formed at the bottom of the reservoir 311b. The opening 311e is connected to one end of the discharge channel 311d. The main body 311 is also referred to as a storage unit.

[0038] The first bottom cover 312 is a plate-shaped member that closes or opens the discharge port 311c. The first bottom cover 312 is driven by a drive mechanism (not shown) to move in the positive or negative direction of the X-axis. The drive mechanism is controlled by the control device 400. The first bottom cover 312 is controlled to either completely close the discharge port 311c or completely open the discharge port 311c.

[0039] Figures 2A to 2D This figure shows the open and closed state of the second bottom cover 313. The second bottom cover 313 is a cover that closes or opens the opening 311e of the main body 311. The second bottom cover 313 includes multiple aperture blades arranged in a ring shape around the inner circumference of the opening 311e. The aperture blades are driven by a drive mechanism (not shown). The drive mechanism is controlled by the control device 400. By driving the aperture blades, the aperture shape inside the opening 311e is adjusted. In this way, the control device 400 controls the opening of the second bottom cover 313. This makes it easier to adjust the amount of inoculant added per unit time. The control device 400 is also referred to as the control unit. The second bottom cover 313 is also referred to as the bottom cover.

[0040] Figure 2A The second bottom cover 313 is completely closed. At this time, the opening 311 e of the main body 311 is completely closed by the second bottom cover 313 . Figure 2B This is a diagram showing a state in which a portion of the second bottom cover portion 313 is opened. Figure 2C 313 is a diagram showing a state where a portion of the second bottom cover portion 313 is opened. Figure 2C In the case shown, the area of ​​the opening 311e of the main body 311 is larger than Figure 2B The area of ​​opening 311e is shown. Figure 2DThis figure shows the second bottom cover 313 fully open. At this point, the opening 311e of the main body 311 is fully open. By adjusting the opening area of ​​the second bottom cover 313, the amount of inoculant discharged from the reservoir 311b per unit time is adjusted. The aperture mechanism of the second bottom cover 313 adjusts the opening area while maintaining the shape of the opening 311e, making it easy to adjust the amount and timing of inoculant injection. The inoculant injection time is the time from the start of inoculant injection to the end of injection.

[0041] When the first bottom cover 312 closes the discharge port 311c, the inoculant is not supplied from the hopper 310 to the pipe 320. In addition, when the first bottom cover 312 is open and the second bottom cover 313 is open, the inoculant is supplied from the hopper 310 to the pipe 320.

[0042] The tube 320 is formed of metal and serves as a supply path for supplying the inoculant discharged from the hopper 310 to the receiving port 100a of the mold 100. One open end 320a of the tube 320 is positioned below the discharge port 311c. The other open end 320b of the tube 320 is positioned above the receiving port 100a of the mold 100. The receiving port 100a is the opening of the mold 100 into which the molten metal is poured.

[0043] The inclination of the tube 320 is substantially vertical. The inclination of the tube 320 refers to the angle formed by the line connecting the opening end 320a and the opening end 320b. In the embodiment, for ease of understanding, the time it takes for the inoculant to pass through the tube 320 is not considered.

[0044] The control device 400 is a computer including a processor and a memory, and controls each part of the casting device 1 .

[0045] Figure 3 This is a flowchart of the casting process in casting apparatus 1. First, in step S10, a molten metal material is melted in an electric furnace. The composition of the molten metal, for example, is, by mass, C: 3.9%, Si: 2.4%, Mn: 0.25%, S: 0.007%, Cu: 0.345%, and Sn: 0.005%. This composition is merely an example.

[0046] In step S20, spheroidization is performed. Spheroidization is a process in which a spheroidizing material is added to the molten material. Examples of the spheroidizing material include magnesium (Mg), calcium (Ca), and cerium (Ce).

[0047] In step S30, molten metal is poured from the ladle 210 into the mold 100. During the pouring, the pouring liquid flow is inoculated. Through inoculation, a large amount of small spherical graphite can be generated. As a result, the toughness of the casting can be improved. In addition, it can prevent the occurrence of chilling. Regarding the composition of the inoculant, for example, it is preferably calculated by mass ratio: Si: 75-80%, Al: 1.8-2.3%, Ca: 0.2-0.5%, C: 0.2% or less, P: 0.5% or less, S: 0.02% or less, and the rest is Fe. In order to ensure that the inoculant is evenly mixed with the molten metal, the particle size of the inoculant is preferably 0.05-5 mm, for example.

[0048] The amount and timing of inoculant injection during the initial production of a casting are pre-calculated based on the weight of the molten metal expected to flow into the mold 100 and the pouring rate. The pouring rate represents the weight of the molten metal flowing into the mold 100 per unit time. The pouring rate is a value pre-calculated based on the cross-sectional area of ​​the ingates in the mold 100 designed in the casting plan, the weight of the molten metal expected to flow into the mold 100, and the pouring time. The pouring time is the time from the start to the completion of pouring the molten metal into the mold 100. The pouring time is calculated using a pre-set formula based on the weight of the molten metal expected to flow into the mold 100. The casting plan includes various conditions indicating how the casting is to be produced. The timing of inoculant injection during the initial production of a casting can be, for example, the same as the pouring time.

[0049] The control device 400 controls the opening of the second bottom cover portion 313 so that the opening area corresponds to the amount of inoculant added per unit time, calculated from the amount of inoculant added and the time of inoculant addition. This makes it easy to adjust the amount of inoculant added per unit time. In an embodiment, the control device 400 controls the opening of the second bottom cover portion 313 by gradually changing the opening area of ​​the opening 311e to an initial opening area, a second opening area, and a third opening area during the pouring of molten metal into the mold 100. In an embodiment, the speed at which the molten metal flows into the mold 100 is controlled to different speeds in the initial, middle, and final stages, so the amount of inoculant added per unit time also changes in three stages. When initially producing a casting, the initial opening area is calculated using a pre-set formula based on the pouring speed, the weight of the predetermined molten metal flowing into the mold 100, the amount of inoculant added, and the time of inoculant addition. The opening area in the second stage and the opening area in the third stage are pre-calculated by multiplying the opening area in the initial stage by a pre-defined ratio. For example, the opening area in the second stage is set to 25% of the opening area in the initial stage. The opening area in the third stage is set to 10% of the opening area in the initial stage.

[0050] The setting values ​​of each opening area and the pouring speed at each stage are pre-stored in the memory of the control device 400. Furthermore, the memory pre-stores setting information indicating the correspondence between the opening degree of the second bottom cover portion 313 and the opening area of ​​the opening 311e.

[0051] Figure 4 This is a diagram showing an example of how the tilt angle D of the ladle 210, the weight of the molten metal flowing into the mold 100, and the injection rate R of the inoculant are changed over time. The amount of inoculant injected is an amount that is less than 1% by weight relative to the weight of the molten metal flowing into the mold 100. For ease of understanding, Figure 4 In FIG. 3 , the inoculant charge rate R is shown, which indicates the weight ratio of the inoculant charged relative to the predetermined charge amount of the inoculant charged.

[0052] At time t0, the control device 400 controls the opening of the second bottom cover portion 313 to maintain the opening area at the initial stage. This allows the amount of inoculant to be added per unit time before it is added to the molten metal stream. Furthermore, the control device 400 opens the first bottom cover portion 312. Consequently, at time t0, inoculant discharge from the hopper 310 begins. Discharge of the inoculant is initiated before the molten metal is discharged, with the goal of fully dissolving the inoculant in the molten metal.

[0053] At time t1, the control device 400 instructs the tilting device 220 to discharge the molten metal. Consequently, the tilting device 220 gradually increases the tilting angle D of the ladle 210. As the inclination of the ladle 210 increases, the molten metal within the ladle 210 begins to be discharged. Based on the dynamic image data obtained by the second liquid level sensor 250, the control device 400 determines that pouring of the molten metal into the mold 100 has begun when it detects that the liquid level of the molten metal within the ladle 210 exceeds a predetermined position. The control device 400 may also store the start time of pouring in a memory.

[0054] The control device 400 controls the opening of the second bottom cover portion 313 in parallel with the liquid discharge instruction to achieve the opening area in the second stage. As a result, the amount of inoculant added per unit time is reduced. In this way, the amount of inoculant added per unit time can be varied during the inoculant addition period.

[0055] After instructing to discharge the molten metal, the control device 400 periodically detects the level of the molten metal in the ladle 210 based on the dynamic image data obtained by the second liquid level sensor 250. For example, the control device 400 detects the level of the molten metal by calculating the distance between the end of the discharge port of the ladle 210 and the liquid surface of the molten metal in the ladle 210.

[0056] Furthermore, after instructing to discharge the molten metal, the control device 400 periodically detects the liquid level of the molten metal in the receiving port 100a and the pouring gate 100b of the mold 100 based on the dynamic image data obtained by the first liquid level sensor 240. Specifically, the control device 400 detects the liquid level by calculating the distance between the receiving port 100a of the mold 100 and the liquid level of the molten metal poured into the mold 100. The pouring gate 100b is a passage connected to the receiving port 100a.

[0057] Furthermore, the control device 400 determines whether the liquid level of the molten metal in the receiving port 100a and the pouring port 100b of the mold 100 exceeds a predetermined position. When the control device 400 determines that the liquid level of the molten metal in the receiving port 100a and the pouring port 100b of the mold 100 exceeds a predetermined position, the tilting device 220 is controlled to gradually reduce the tilting angle D of the ladle 210. Figure 4 At time t2, the control device 400 determines that the heights of the liquid levels of the molten metal in the receiving port 100a and the pouring gate 100b of the mold 100 exceed predetermined positions.

[0058] Furthermore, after instructing the ladle to discharge, the control device 400 periodically detects the total weight of the ladle 210 using the load cell scale 230. Based on the change in the total weight of the ladle 210, the control device 400 calculates the weight of the molten metal flowing into the mold 100. The control device 400 calculates the molten metal outflow rate by dividing the weight of the molten metal flowing into the mold 100 within a set time by the set time. The molten metal outflow rate is the amount of molten metal flowing per unit time. The control device 400 may also store the calculated outflow rate and time in memory.

[0059] The control device 400 decreases the tilting angle D of the ladle 210 until time t3. The time from time t2 to time t3 is determined using a pre-set calculation formula based on the weight of the molten metal flowing into the mold 100 at time t2 and the predetermined weight of the molten metal flowing into the mold 100. Time t2 is the time when the molten metal levels in the receiving port 100a and the pouring port 100b of the mold 100 are determined to have exceeded a predetermined position. After time t3, the control device 400 controls the tilting device 220 to adjust the tilting angle D of the ladle 210 in accordance with the total weight of the ladle 210.

[0060] At time t4, upon determining that the weight of the molten metal flowing into the mold 100 has reached a set threshold, the control device 400 controls the opening of the second bottom cover portion 313 to achieve the opening area in the third stage. This further reduces the amount of inoculant added per unit time. The weight of the molten metal flowing into the mold 100 reaching the set threshold means, for example, that 80% of the planned weight of the molten metal flowing into the mold 100 has flowed into the mold 100.

[0061] At time t5 when a set time has elapsed from time t4, the control device 400 closes the second bottom cover portion 313 and the first bottom cover portion 312. Thus, the injection of the inoculant is stopped.

[0062] At time t5, upon determining that a predetermined weight of molten metal has flowed into the mold 100, the control device 400 instructs the tilting device 220 to stop discharging the liquid. Consequently, the tilting device 220 begins to flip the ladle 210. The predetermined weight refers to, for example, a weight that is a fixed ratio to the weight of the molten metal flowing into the mold 100. Based on the dynamic image data obtained by the second liquid level sensor 250, the control device 400 determines that the pouring of the molten metal has ended when it detects that the liquid level of the molten metal in the ladle 210 has reached a predetermined position. The control device 400 may also store the end time of the pouring in a memory.

[0063] like Figure 3 As shown, in step S40, the molten metal is sufficiently cooled until it reaches a temperature below the eutectoid transformation point. In step S50, the casting is removed from the mold 100.

[0064] In step S60, tests are performed to evaluate the quality of the casting. Examples of these tests include tensile strength testing, hardness testing, microscopic measurement of graphite spheroidization, and microscopic measurement of pearlite area fraction. After the tests are performed, data representing the measured values ​​is stored as test results in the memory of control device 400.

[0065] In step S70, the control device 400 determines whether the quality of the manufactured casting is qualified. Qualified quality means that the quality of the manufactured casting meets a pre-set benchmark. The control device 400 is also called a judgment unit. If the manufactured casting is judged to be unqualified (step S70; No), in step S80, the control device 400 recalculates the amount and time of inoculant injection. The control device 400 is also called a setting change unit. The amount of inoculant injection is calculated, for example, based on the measured pearlite area ratio and hardness values ​​using a pre-set calculation formula. The time of inoculant injection is calculated, for example, based on pre-defined definition data for the correlation between the pouring speed calculated from the casting plan and the tensile strength and hardness values. The control device 400 calculates the opening area of ​​the initial stage based on the calculated amount and time of inoculant injection using a pre-defined calculation formula. Furthermore, the control device 400 calculates the opening area of ​​the second stage and the opening area of ​​the third stage by multiplying the opening area of ​​the initial stage by a pre-defined ratio.

[0066] Then, the processes from step S10 onwards are executed sequentially. In the pouring and inoculation process of step S30, inoculation is performed using the recalculated values. In step S70, the casting is repeatedly produced until the produced casting is determined to be acceptable (step S70: Yes). If the produced casting is determined to be acceptable, the control device 400 stores the inoculation settings, including the inoculant dosage and duration, in memory as the optimal settings.

[0067] In this manner, in the embodiment, the casting apparatus 1 changes the inoculation settings, including the inoculant dosage and dosage time, to reduce the deviation between the test results, which evaluate the quality of the castings, and a pre-set benchmark. Furthermore, the casting apparatus 1 produces the casting again using the changed inoculation settings. According to the embodiment, the inoculant dosage and dosage time can be automatically adjusted until the casting quality meets the predetermined benchmark, eliminating the need for tedious effort.

[0068] Furthermore, in the casting apparatus 1 , a series of processes including production of castings, determination of quality, and adjustment of inoculant can be smoothly performed.

[0069] B1. Other Example 1

[0070] In the embodiment, the casting device 1 repeatedly produces castings until the castings are judged to be qualified. However, the casting device 1 does not necessarily need to repeatedly produce castings before the castings are judged to be qualified. For example, even if the casting device 1 repeatedly produces castings a set number of times, if the casting is judged to be unqualified, it can notify the manager of the manufacturing line of this fact. In other embodiment 1, similar to the embodiment, if the quality of the manufactured castings does not meet the specified standard, the set value of inoculation can be automatically changed, and inoculation can be performed according to the changed set value. Therefore, there is no need for tedious effort when adjusting the settings of the inoculant.

[0071] B2. Other embodiments

[0072] In the embodiment, an example is described in which the control device 400 recalculates the inoculant dosage and dosage time based on the test results of a previously manufactured casting. Alternatively, the control device 400 may recalculate the inoculant dosage and dosage time based on the test results of multiple castings. Specifically, for example, the control device 400 may recalculate the inoculant dosage and dosage time based on the test results of the three most recently manufactured castings.

[0073] B3. Other Examples 3

[0074] In the embodiment, the inclination of the tube 320 is substantially vertical, and the time required for the inoculant to pass through the tube 320 is not considered. However, due to the relationship between the position of the main body 311 of the injection device 300 and the position of the mold 100, the tube 320 may be inclined relative to the vertical. In this case, the time required for the inoculant to pass through the tube 320 is calculated based on the inclination of the tube 320 using a predefined calculation formula. The inoculation setting value during pouring can be calculated by taking into account the injection time and the passage time.

[0075] B4. Other Examples 4

[0076] In the embodiment, the control device 400 determines whether the quality of the produced castings is acceptable. However, the control device 400 may not perform this determination. For example, another computer may determine whether the quality of the produced castings is acceptable. Furthermore, another computer other than the control device 400 may calculate various setting parameters, including the inoculation setting value during pouring.

[0077] B5. Other Examples 5

[0078] While the embodiments describe an example in which the second bottom cover portion 313 includes multiple aperture blades, the second bottom cover portion 313 can be formed from a single plate-shaped member, similar to the first bottom cover portion 312. In this case, the position of the second bottom cover portion 313 can be adjusted based on setting data indicating the correspondence between the position of the second bottom cover portion 313 and the opening area of ​​the opening 311e. In this case, the opening area of ​​the opening 311e can also be adjusted using the second bottom cover portion 313.

[0079] B6. Other Example 6

[0080] In the embodiment, an example is described in which the amount of inoculant discharged per unit time is adjusted in the feeding device 300 by changing the opening area of ​​the opening 311e through which the inoculant is discharged from the second bottom cover portion 313. However, the feeding device 300 does not necessarily have the second bottom cover portion 313. For example, the position of the first bottom cover portion 312 can be adjusted based on setting data indicating the correspondence between the position of the first bottom cover portion 312 and the opening area of ​​the discharge port 311c. The amount of inoculant discharged from the reservoir 311b per unit time can also be adjusted by adjusting the opening area of ​​the discharge port 311c in the first bottom cover portion 312. In this case, the necessary amount of inoculant is measured and placed into the reservoir 311b before each casting is produced.

[0081] Alternatively, the first bottom cover portion 312 may include multiple aperture blades. In this case, the feeding device 300 may not include the second bottom cover portion 313. By adjusting the opening area of ​​the discharge port 311c, the first bottom cover portion 312 can adjust the amount of inoculant discharged from the reservoir 311b per unit time. In this case, the necessary amount of inoculant is measured and placed into the reservoir 311b before the casting is produced.

[0082] B7. Other Examples 7

[0083] The injection device 300 may not include the second bottom cover portion 313. The first bottom cover portion 312 may also be a cover that closes or opens the discharge port 311c, as in the previous embodiment. In this case, multiple tubes with different opening areas are prepared in advance. The inoculant may be injected into the casting liquid using an appropriate tube corresponding to the set injection time of the inoculant.

[0084] B8. Other Example 8

[0085] In the embodiments, examples have been described in which the inoculation setting values ​​include the feed amount and feed time. The inoculation setting values ​​may also include the inoculant mix. When recalculating the inoculant mix, for example, the mix ratio may be calculated using a predefined formula based on the hardness value, graphite spheroidization rate, and pearlite area ratio.

[0086] B9. Other Examples 9

[0087] In this embodiment, when the control device 400 determines that the liquid level of the molten metal in the receiving port 100a and the pouring gate 100b of the mold 100 has exceeded a predetermined position, it controls the tilting device 220 to gradually reduce the tilting angle of the ladle 210. Alternatively, the control device 400 may change the tilting angle of the ladle 210 based on the weight of the molten metal flowing into the mold 100.

[0088] While the embodiment describes an example of inoculation using molten metal flow inoculation, the casting apparatus 1 may determine, based on the test results of the casting, that the inoculation method is, for example, ladle inoculation when manufacturing a new casting. Alternatively, the casting apparatus 1 may determine, based on the test results of the casting, that a combination of molten metal flow inoculation and ladle inoculation is used for inoculation when manufacturing a new casting.

[0089] In the embodiment, an example in which spheroidal graphite cast iron is produced by the casting apparatus 1 has been described, but gray cast iron may also be produced by the casting apparatus 1. Gray cast iron is, for example, FC200 specified in JIS G5502.

[0090] The present invention is not limited to the above-described embodiments and can be implemented by various structures within the scope of its purpose. For example, in order to solve some or all of the above-mentioned problems, or to achieve some or all of the above-mentioned effects, the technical features in the embodiments corresponding to the technical features in the various forms described in the Summary of the Invention of the Present Invention can be appropriately replaced or combined. In addition, if the technical features are not described as essential content in this specification, they can be appropriately deleted.

Claims

1. A casting device comprising: an injection portion for injecting the inoculant into a pouring liquid flow of molten metal according to an inoculation setting value including at least one of an injection amount and an injection time of the inoculant; a setting changing unit that changes the setting value so that a deviation between the quality of the casting indicated by a test result of a test for evaluating the quality of the manufactured casting and a preset reference is reduced; and a judgment unit that judges whether the quality of the casting satisfies the standard based on the test result related to the manufactured casting, If the quality of the casting does not meet the above standards, The following process is performed one or more times: the setting changing unit changes the setting value, and the feeding unit feeds the inoculant into the casting liquid flow according to the changed setting value. in, The setting changing unit changes the setting value, and the injecting unit injects the inoculant into the pouring liquid flow according to the changed setting value, and repeats the process until the casting meets the reference.

2. The casting device according to claim 1, wherein The input unit includes: The receiving portion is a container for receiving the inoculant and has an opening formed at the bottom; a bottom cover portion capable of changing an opening area of ​​the opening of the receiving portion; and The control unit controls the opening degree of the bottom cover so as to obtain the opening area corresponding to the input amount per unit time calculated based on the input amount and the input time.

3. The casting device according to claim 2, wherein: As control of the opening degree of the bottom cover portion, the control portion changes the opening degree of the bottom cover portion before adding the inoculant to the casting liquid flow.

4. The casting device according to claim 2, wherein: As control of the opening of the bottom cover, the control unit changes the opening of the bottom cover while the inoculant is being added to the casting liquid flow.

5. The casting device according to any one of claims 2 to 4, wherein: The bottom cover portion includes an aperture mechanism capable of changing the opening area of ​​the opening.

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