An integrated metal melt pouring system and method

Abstract

The application discloses an integrated metal melt pouring system and a pouring method. The pouring system comprises a melting module, a transfer module, an intermediate module, a pouring module and a molding line. The transfer module can transfer the metal melt from the melting module to the intermediate module, transfer the metal melt from the intermediate module to the pouring module after processing, and complete the pouring work of the molding line by the pouring module. The melting module, the intermediate module, the pouring module and the molding line are located on the same side of the transfer track of the transfer module, thereby reducing the space requirement. The intermediate module comprises a transfer unit for transferring the metal melt. The transfer unit is provided with an inoculant adding unit and a slag removing unit on both sides. The inoculant adding unit comprises a total hopper, a distribution hopper and a feeding funnel which are sequentially arranged from top to bottom. The distribution hopper is used for weighing the inoculant, and the feeding funnel is used for adding the inoculant. The weighing waiting time is not required, the transfer efficiency is ensured, and the pouring system is more integrated.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of the steel industry, in particular to an integrated metal melt pouring system and a pouring method. BACKGROUND

[0002] Pouring forming is a common forming method in the technical field of the steel industry. According to the product material, the required metal raw material is melted into a metal liquid, and the metal liquid is poured into a mold (sand box), and the required product can be obtained after cooling.

[0003] The applicant has previously applied for related patents for the pouring and transfer process of metal melt, such as application number CN202111109593.1 for an automatic molten iron transfer system and application number CN202111071192.1 for an efficient automatic molten iron transfer system. The above two pouring and transfer systems are both from the work efficiency of molten iron transfer. According to different needs, the transfer of molten iron is completed by the cooperation of multiple transfer vehicles. In the patent documents with application numbers CN202111108220.2 for a double-station synchronous pouring system and a pouring method and CN202111109592.7 for a multi-station collaborative pouring system and a pouring method, the applicant improves the transfer efficiency of molten iron, and increases the pouring station and the intermediate transfer vehicle to improve the pouring efficiency while ensuring the transfer efficiency, thereby improving the production efficiency.

[0004] However, the above-mentioned several pouring and transfer systems are all from the transfer efficiency and pouring efficiency, and the transfer and pouring of molten iron are realized by the cooperation of multiple intermediate transfer vehicles. This structure is only suitable for large factories or large part processing and production. In some small workshops or small part pouring production work, this arrangement is obviously difficult to achieve, and the transfer process is also too redundant. Therefore, the above-mentioned molten iron transfer system which is only set from the transfer efficiency and / or pouring efficiency is not suitable for small-area, small-capacity, and small-product pouring production work. SUMMARY

[0005] To solve the technical problems in the background art, the present application provides an integrated metal melt pouring system and a pouring method. The applicant redesigns the overall layout, transfer process, and intermediate processing process of the system, including the structure of the mechanical device applied in the intermediate processing process, to achieve integrated transfer, so that it can be applied to small workshops or small part pouring production work.

[0006] The technical scheme of the present application is as follows:

[0007] The integrated metal melt pouring system comprises a melting module, a transfer module, an intermediate module, a pouring module and a molding line, wherein the melting module is used for metal melting work, the transfer module can transfer the metal melt to the intermediate module, the processed metal melt can be transferred from the intermediate module to the pouring module, and the pouring work of the metal mold on the molding line is completed by the pouring module.

[0008] In order to make the pouring system of the application applicable to small workshops or small part pouring production work, the transfer module comprises a transfer track, and the melting module, the intermediate module, the pouring module and the molding line are located on the same side of the transfer track. This arrangement can make the transfer track close to the boundary without occupying too much intermediate transfer time, thereby ensuring the transfer efficiency.

[0009] Further, the melting module comprises an electric furnace, a furnace front transfer car is arranged on the transfer track, a transfer package is loaded on the furnace front transfer car, and the furnace front transfer car is arranged to be able to load and move the transfer package to the electric furnace to receive the metal melt.

[0010] Further, the intermediate module comprises a transfer unit located on one side of the transfer track, the transfer unit is arranged to be able to dock with the furnace front transfer car to complete the transfer package handover work, and an inoculant adding unit and a slag removing unit are respectively arranged on the two sides of the transfer unit, which are respectively used for the inoculant adding work in the metal melt and the slag removing work in the metal melt.

[0011] In order to further ensure the integration of the pouring system, as the core technical concept of the application, the inoculant adding unit comprises a main frame and a feeding controller, the main frame is sequentially provided with a total hopper, a distribution hopper and a feeding funnel from top to bottom, the total hopper is used for storing the inoculant, a spiral feeding mechanism is arranged below the total hopper, and the inoculant can be added into the distribution hopper through the spiral feeding mechanism, the distribution hopper is connected with the main frame through a weighing mechanism, a turnover door is rotatably arranged at the discharge port below the distribution hopper, a feeding driving mechanism capable of driving the turnover door to turn over is arranged between the turnover door and the distribution hopper, the spiral feeding mechanism, the weighing mechanism and the feeding driving mechanism are in communication connection with the feeding controller, the feeding controller is arranged to control the working state of the spiral feeding mechanism and the feeding driving mechanism according to the feedback information (i.e. the pre-set feeding quality) of the weighing mechanism, the opening of the turnover door can be controlled through the feeding driving mechanism, at this time, the fixed quality of the inoculant in the distribution hopper can be added into the metal melt through the feeding funnel, the inoculant is designed in the form of double hoppers, so that during the transfer of the molten iron, the inoculant of the fixed weight can be pre-added into the distribution hopper through the spiral feeding mechanism, when the inoculant needs to be added, the turnover door only needs to be opened, the distribution hopper can quickly add the good weight of the inoculant into the metal melt through the feeding funnel, there is no waiting time, and the multi-layer feeding mode of the inoculant adding mechanism itself does not occupy a large space, while ensuring the pouring efficiency, the integration requirement of the pouring system is met, and the automation of the inoculant adding work is realized.

[0012] Further, the pouring module comprises a pouring track located on the side of the intermediate module away from the transfer track and parallel to the transfer track, a pouring machine is arranged on the pouring track, the pouring machine is loaded with a pouring ladle, the intermediate unit is provided with a lifting and pouring mechanism, the molding line is located on one side of the pouring track and comprises a sand box, a plurality of sand boxes are arranged along the length direction of the pouring track, the pouring machine is arranged to move the pouring ladle to the intermediate unit position to receive the metal melt and pour the metal melt into the sand box, and finally complete the pouring work, as a whole, only one furnace front transfer car and the intermediate unit can complete the intermediate transfer work of the metal melt, do not occupy a large layout space, simplify the intermediate transfer process, ensure the transfer efficiency, make the pouring system more integrated, and thus can be applied to small workshops or small part pouring production work.

[0013] As the above-mentioned integrated metal melt pouring system, as a preferred embodiment, the opening direction of the discharge port is outward, the upper side of the turnover door is rotatably connected with the upper side of the discharge port and the turning direction is outward, so as to prevent the inoculant from splashing due to too fast feeding speed, ensure that the inoculant in the feeding hopper can be added into the metal melt through the blocking action of the turnover door and the feeding funnel.

[0014] As a further preferred, the feeding drive mechanism is a linear drive device, the feeding controller is arranged to be able to control the extension / or shortening amount of the linear drive device, by controlling the extension / or shortening amount of the linear drive device, to control the opening angle of the turnover door, and further control the feeding speed, so that the addition of inoculant can be more uniform.

[0015] As the integrated metal melt pouring system described above, the screw feeding mechanism includes a screw conveyor and a rotating drive device, the feeding controller is arranged to be able to control the rotating speed of the rotating drive device, by controlling the rotating speed of the rotating drive device, to control the feeding speed of the screw conveyor, so that the pre-storage work of inoculant in the distribution hopper is more rapid and accurate.

[0016] Further, the capacity of the total hopper is greater than that of the distribution hopper, so that the total hopper does not need to be fed again for a long time after feeding is completed, so that the inoculant adding unit can operate independently for a long time, increasing the practicability of the inoculant adding unit.

[0017] As the integrated metal melt pouring system described above, the furnace front transfer trolley, the transfer unit and the pouring machine respectively include a furnace front roller way, a transfer roller way and a machine roller way, which are respectively composed of a plurality of parallel arranged rotating rollers, by driving the rotating rollers to rotate, the pouring ladle or the transfer ladle can be moved on the roller way, increasing the stability of the transfer process, the transport direction of the furnace front roller way, the transfer roller way and the machine roller way are perpendicular to the arrangement direction of the transfer track, so that the transfer work between different roller ways can be more stable and convenient.

[0018] Further, the furnace front roller way on the furnace front transfer trolley can be lifted, so that it can be connected to the roller way at different angles, increasing the applicability of the pouring system.

[0019] As the integrated metal melt pouring system described above, the pouring track is provided with a pouring ladle storage roller way away from the molding line side, and its transport direction is perpendicular to the arrangement direction of the pouring track, the transfer track is provided with a transfer ladle storage roller way on one side, and its transport direction is perpendicular to the arrangement direction of the transfer track, the pouring ladle storage roller way and the transfer ladle storage roller way are respectively used for temporary storage or maintenance work of the pouring ladle and the transfer ladle, so that the maintenance or replacement work of the transfer ladle or the pouring ladle is more simple and fast.

[0020] Further, the transfer ladle storage roller way is located on the side of the transfer track close to the melting module, so that the setting of the transfer ladle storage roller way will not affect the overall setting of the pouring system.

[0021] In order for those skilled in the art to more clearly understand the technical solutions, the application further provides an integrated metal melt pouring system and a pouring method, which comprises the following steps:

[0022] (1), in the initial state, the transfer ladle and the pouring ladle are respectively located above the transfer ladle storage roller and the pouring ladle storage roller;

[0023] (2), after the system receives a production instruction, the furnace front transfer trolley and the pouring machine are respectively connected with the transfer ladle storage roller and the pouring ladle storage roller, and under the action of the machine roller and the pouring ladle storage roller and the action of the furnace front roller and the transfer ladle storage roller, the transfer ladle and the pouring ladle are completed;

[0024] (3), the electric furnace sends a signal of pourable metal melt, and the furnace front transfer trolley carries the transfer ladle to move along the furnace front track to the electric furnace to receive the metal melt;

[0025] (4), the furnace front transfer trolley carries the transfer ladle containing the metal melt to move to the position of the transfer unit, and under the action of the transfer roller and the furnace front roller, the transfer work of the transfer ladle between the transfer unit is completed, and at this time, the transfer ladle contains the metal melt;

[0026] (5), during the steps (2), and / or, (3), and / or, (4), the feeding controller controls the spiral feeding mechanism to work to add the inoculant in the total hopper to the distribution hopper, and when the weight of the inoculant in the distribution hopper reaches the set value, the feeding controller controls the spiral feeding mechanism to stop working;

[0027] (6), during the steps (3), and / or, (4), the pouring machine carries the pouring ladle to move to the position of the transfer unit;

[0028] (7), the transfer unit pours the metal melt in the transfer ladle to the pouring ladle through the lifting and pouring mechanism, and at the same time, the feeding controller controls the feeding driving mechanism to open the turnover door, and the inoculant is added to the transfer ladle in which the metal melt is being poured through the feeding funnel, and after the inoculant addition is completed, the feeding controller controls the feeding driving mechanism to close the turnover door, and it should be noted that the inoculant addition work must be carried out at the same time as the pouring work of the metal melt, and the end time of the inoculant addition work must be before the completion of the pouring work of the metal melt, or the inoculant addition work is completed at the same time as the pouring work of the metal melt;

[0029] (8), after the pouring of the metal melt is completed, the transfer unit is connected with the furnace front transfer trolley to complete the transfer work of the empty transfer ladle, and the furnace front transfer trolley continues to wait for the signal of pourable metal melt from the electric furnace;

[0030] (9), when or after step (8) is performed, the pouring machine carrying the ladle containing the molten metal is moved to the slagging unit for manual slagging, after the slagging is completed, the pouring work is carried out, and after the pouring is completed, the pouring machine carrying the empty ladle is moved to the transfer unit to wait for the next round of molten metal receiving work;

[0031] (10), repeat steps (3)-(9) to complete the continuous pouring work;

[0032] (11), the system receives a stop production instruction, and after the molten metal in the ladle and the transfer package is poured, the furnace transfer trolley and the pouring machine are respectively connected with the transfer package storage roller and the ladle storage roller, and the transfer package and the ladle are connected.

[0033] The beneficial effects of the present application are:

[0034] (1), the present application is an integrated molten metal pouring system and pouring method, the melting module, the intermediate module, the pouring module and the molding line are arranged on the same side of the transfer track, which can be close to the boundary (which can be the boundary of the factory or the shed), without occupying too much intermediate transfer time or intermediate transfer space, reducing the space requirement and ensuring the transfer efficiency;

[0035] (2), the setting of the feeding controller cooperates with the double-layer hopper, so that during the transfer of molten iron, a fixed weight of inoculant can be added to the distribution hopper in advance through the screw feeding mechanism, when the inoculant needs to be added, only the turnover door needs to be opened, the distribution hopper can quickly add the good weight of inoculant to the molten metal through the feeding funnel, and there is no waiting time, and the multi-layer feeding setting of the inoculant adding mechanism itself does not occupy a large space, which meets the integration requirement of the pouring system while ensuring the pouring efficiency, and realizes the automation of the inoculant adding work;

[0036] (3), as for the pouring system as a whole and the pouring method provided by the present application, only one furnace transfer trolley and intermediate unit can complete the intermediate transfer of molten metal, without occupying a large layout space, simplifying the intermediate transfer process, ensuring the transfer efficiency, making the pouring system more integrated, and thus it can be applied to small workshops or small part pouring production work. BRIEF DESCRIPTION OF DRAWINGS

[0037] The scheme and advantages of the present application will become clear to those skilled in the art by reading the detailed description of the preferred embodiments below. The drawings are only for the purpose of illustrating the preferred embodiments and are not considered as limiting the present application.

[0038] In the drawings:

[0039] Figure 1 Overall layout of the pouring system in the embodiment;

[0040] Figure 2 Structure of the inoculant adding mechanism in the embodiment;

[0041] Figure 3 Structure of the distribution hopper in the embodiment (the turnover door is fully closed);

[0042] Figure 4 Structure of the distribution hopper in the embodiment (the turnover door is fully opened);

[0043] Figure 5 Workflow of the pouring system in the embodiment;

[0044] The components represented by the reference numerals in the drawings are as follows:

[0045] 1, melting module; 11, electric furnace; 12, smoke exhaust unit; 121, on-machine smoke exhaust device; 122, front-of-machine smoke exhaust device; 2, transfer module; 21, transfer track; 22, front-of-furnace transfer car; 3, intermediate module; 31, intermediate transfer unit; 32, inoculant adding unit; 321, main frame; 322, general hopper; 3221, screw feeding mechanism; 323, distribution hopper; 3231, feeding driving mechanism; 3232, turnover door; 3233, weighing mechanism; 324, feeding funnel; 3241, receiving hopper; 3242, feeding pipe; 33, slagging unit; 331, slagging platform; 332, slag hopper; 4, pouring module; 41, pouring track; 42, pouring machine; 5, molding line; 51, sand box; 6, transfer ladle storage roller; 7, pouring ladle storage roller. DETAILED DESCRIPTION

[0046] Exemplary embodiments of the present disclosure will be described in greater detail below with reference to the accompanying drawings.

[0047] Embodiment

[0048] The present embodiment first provides an integrated metal melt pouring system, as shown in Figure 1 , which comprises a melting module 1, a transfer module 2, an intermediate module 3, a pouring module 4, and a molding line 5. The melting module 1 is used for metal melting work. The transfer module 2 can transfer the metal melt to the intermediate module 3. The intermediate module 3 is used for intermediate processing and transfer work of the metal melt. The processed metal melt can be transferred from the intermediate module 3 to the pouring module 4. The pouring module 4 completes the pouring work of the metal mold on the molding line 5. Details are described below.

[0049] In the embodiment, the melting module 1 comprises an electric furnace 11, which can be linearly arranged in multiple, and the melting module 1 further comprises a smoke exhaust unit 12, which comprises an on-machine smoke exhaust device 121 located above the electric furnace 11 and a front-machine smoke exhaust device 122 located above the liquid outlet on the front side of the electric furnace 11, and the smoke exhaust unit 12 further comprises a fan and a smoke exhaust pipeline, and the on-machine smoke exhaust device 121 and the front-machine smoke exhaust device 122 are in communication with the smoke exhaust pipeline, so that the smoke and dust at the electric furnace 11 can be exhausted through the smoke exhaust pipeline under the action of the fan.

[0050] In the embodiment, the transfer module 2 comprises a transfer track 21, in order to enable the pouring system to be applicable to small workshops or small part pouring production work, the melting module 1, the intermediate module 3, the pouring module 4 and the molding line 5 are located on the same side of the transfer track 21, and this arrangement can enable the transfer track 21 to be close to the boundary, without occupying too much intermediate transfer time and transfer space, thereby ensuring the transfer efficiency.

[0051] Further, the transfer track 21 is provided with a furnace front transfer trolley 22, the furnace front transfer trolley 22 is loaded with a transfer package, and the furnace front transfer trolley 22 is arranged to be capable of loading the transfer package to move to the electric furnace 11 to receive the molten metal, in order to enable the furnace front roller way on the furnace front transfer trolley 22 to be capable of being at different heights, the furnace front roller way on the furnace front transfer trolley 22 is capable of being lifted, for example, the furnace front transfer trolley 22 in the present application can be the furnace front lifting transfer trolley provided in the patent document with the patent number CN202111071194.0 previously applied by the applicant, by setting the height of the second transfer module 2 on the furnace front lifting transfer trolley, so that it can be docked with the melting module 1 or the intermediate module 3, so that when the melting module 1 or the intermediate module 3 is higher or lower, the first transfer module 2 can be lifted to realize the docking work with the workstations at different heights, thereby increasing the applicability of the pouring system, based on the already disclosed furnace front lifting transfer trolley, the specific structure of the furnace front transfer trolley 22 will not be described here.

[0052] Further, one side of the transfer track 21 is provided with a transfer package storage roller way 6, which comprises a plurality of linearly arranged rotating rollers, and the transportation direction is perpendicular to the arrangement direction of the transfer track 21, and the transfer package storage roller way 6 is used for temporary storage or maintenance work of the transfer package, so that the maintenance or replacement work of the transfer package is more simple and fast.

[0053] Further, the transfer package storage roller way 6 is located on the side of the transfer track 21 close to the melting module 1, so that the arrangement of the transfer package storage roller way 6 will not affect the overall layout of the pouring system.

[0054] In this embodiment, the intermediate module 3 includes a transfer unit 31 located on one side of the transfer track 21, which is arranged to be able to dock with the furnace front transfer car 22 to complete the handover work of the transfer package, and the transfer unit 31 is provided with an inoculant adding unit 32 and a slagging unit 33 on both sides, respectively, which are used for adding inoculant in the metal melt and removing waste slag in the metal melt, respectively.

[0055] Specifically, the transfer unit 31 is arranged at one end of the transfer track 21 away from the electric furnace 11, which includes a transfer roller way, and the furnace front transfer car 22 is provided with a furnace front roller way, and the furnace front roller way and the transfer roller way are respectively composed of a plurality of parallel arranged rotating rollers, which can drive the rotating rollers to rotate to move the transfer package on the roller way, thereby increasing the stability of the transfer process, and the transport directions of the furnace front roller way and the transfer roller way are perpendicular to the arrangement direction of the transfer track 21, so that the transfer work between the furnace front roller way and the transfer roller way can be more stable and convenient.

[0056] Further, the transfer roller way is provided with a lifting and dumping mechanism, and the transfer package can complete the dumping work of the internal metal melt under the action of the lifting and dumping mechanism, for example, the transfer unit 31 in the present application can adopt the lifting and dumping transfer car disclosed in the patent document with the patent number CN202020488062.2 applied by the applicant previously, the difference is that the transfer unit 31 in the present application does not need to move, of course, the transfer roller way in the present application can also be arranged as a fixed type, and the lifting and dumping mechanism is arranged as a rotating movable type, based on the disclosed lifting and dumping transfer car, the specific structure of the transfer unit 31 will not be described here.

[0057] In this embodiment, in order to further ensure the integration of the pouring system, as the core technical concept of the present application, combined with Figure 2 , the inoculant adding unit 32 includes a main frame 321 located on one side of the transfer unit 31, and the main frame 321 is sequentially provided with a total hopper 322, a distribution hopper 323 and a feeding funnel 324 from top to bottom.

[0058] Further, the total hopper 322 is used for storing inoculant, which includes a spiral feeding mechanism 3221 below, and the inoculant can be added into the distribution hopper 323 through the spiral feeding mechanism 3221, and the capacity of the total hopper 322 is greater than that of the distribution hopper 323, so that the total hopper 322 does not need to be refilled for a long time after the feeding is completed, so that the inoculant adding unit 32 can run independently for a long time, thereby increasing the practicability of the inoculant adding unit 32.

[0059] Further, combined with Figure 3 and Figure 4The distribution hopper 323 is connected with the main frame 321 through the weighing mechanism 3233, a turnover door 3232 is rotatably arranged at the discharge port below the distribution hopper 323, the turnover door 3232 and the distribution hopper 323 are provided with a feeding driving mechanism 3231 capable of driving the turnover door 3232 to turn, and the inoculant can be added to the feeding hopper 324 by opening the turnover door 3232.

[0060] Further, the feeding hopper 324 comprises a receiving hopper 3241 for receiving the inoculant and a feeding pipe 3242 connected to the lower end of the receiving hopper 3241, the lower end of the feeding pipe 3242 is inclined downward and points to one side close to the transfer unit 31, and the inoculant can be added to the pouring ladle on the pouring machine 42.

[0061] In the embodiment, the inoculant adding unit 32 further comprises a feeding controller, which can be a PLC controller. As for the control mode of the feeding controller, the screw feeding mechanism 3221, the weighing mechanism 3233 and the feeding driving mechanism 3231 are all communicatively connected with the feeding controller, the feeding controller is configured to control the working state of the screw feeding mechanism 3221 and the feeding driving mechanism 3231 according to the feedback information (i.e. the pre-set feeding quality) of the weighing mechanism 3233, and the turnover door 3232 can be opened by the feeding driving mechanism 3231. At this time, the fixed quality of inoculant in the distribution hopper 323 can be added to the metal melt through the feeding hopper 324. The design of double hoppers for inoculant makes it possible to add the fixed weight of inoculant to the distribution hopper 323 in advance through the screw feeding mechanism 3221 during the transfer of molten iron. When it is necessary to add inoculant, the turnover door 3232 only needs to be opened, and the distribution hopper 323 can quickly add the good weight of inoculant to the metal melt through the feeding hopper 324 without waiting time. The multi-layer feeding mode of the inoculant adding mechanism itself does not occupy a large space, and meets the integration requirements of the pouring system while ensuring the pouring efficiency, and realizes the automation of the inoculant adding work.

[0062] Further, the screw feeding mechanism 3221 comprises a screw conveyor and a rotating driving device, the feeding controller is configured to control the rotating speed of the rotating driving device, and the feeding speed of the screw conveyor is controlled by controlling the rotating speed of the rotating driving device, so that the pre-storage work of the inoculant in the distribution hopper 323 is more rapid and accurate. As one of the embodiments, the rotating speed of the rotating driving device under the control of the feeding controller is fast at first and then slow, which ensures that the inoculant can be quickly added to the distribution hopper 323 at the beginning, and the slow feeding in the later stage makes the addition amount of the inoculant in the distribution hopper 323 more accurate.

[0063] Further, the discharge port opening direction is outward, the upper side of the turnover door 3232 is rotationally connected with the upper side of the discharge port and the turnover direction is outward, preventing the spattering of inoculant due to too fast feeding speed, ensuring that the inoculant in the feeding hopper can pass through the blocking effect of the turnover door 3232 and be added to the metal melt through the feeding funnel 324.

[0064] Further, the feeding driving mechanism 3231 is a linear driving device, which is a linear motor, and the feeding controller is configured to control the elongation / shrinkage amount of the linear driving device, thereby controlling the opening angle of the turnover door 3232 and further controlling the feeding speed, so that the addition of inoculant can be more uniform. As one of the embodiments, the linear driving device drives the turnover door 3232 to open to a certain degree under the control of the feeding controller, and then keeps the opening angle of the turnover door 3232 expanding at a constant speed, ensuring that the addition of inoculant is more uniform.

[0065] As for the feeding controller, two are provided, which are a first PLC control unit and a second PLC control unit. The load bearing mechanism is in communication connection with the first PLC control unit and the second PLC control unit. The metal melt outlet of the electric furnace is also provided with a weighing roller, and the transfer package completes the receiving work of the metal melt on the weighing roller. The weighing roller includes a weight measuring mechanism for detecting the weight of the metal melt received in the transfer package. The weighing measuring mechanism is in communication connection with the first PLC control unit and the second PLC control unit, and transmits the weight information of the metal melt in the transfer package to the first PLC control unit and the second PLC control unit respectively. The following will be described in detail.

[0066] As for the screw feeding mechanism, after the first PLC control unit receives the weight information of the metal melt in the transfer package, the total weight W of the required inoculant is calculated according to the following formula 料 :

[0067] W 料 = k W 金 ;

[0068] Wherein:

[0069] W 料 ——the total weight of the required inoculant;

[0070] k——a constant preset according to the type of inoculant or the type of metal melt;

[0071] W 金 ——the weight of the metal melt in the transfer package;

[0072] The first PLC control unit calculates the total weight W of the required inoculant according to the weight of the metal melt in the transfer package料 The control rotary drive device rotates at a first speed to complete rapid feeding. When the total amount of inoculant in the distribution hopper reaches the required total weight W of inoculant to be added... 料 When the volume reaches 80%, the first PLC control unit controls the drive device to rotate at a second speed (the second speed is less than the first speed). When the weight of the inoculant in the dispensing hopper reaches the total weight W of the required inoculant to be added... 料 At that time, the first PLC control unit controls the rotation drive to stop working, and the feeding operation stops.

[0073] For linear drive devices, with the same inoculant weight, the larger the opening angle of the flip door, the more material is discharged from the discharge port below the discharge hopper per unit time, and the faster the discharge speed. When the flip door is opened to a certain angle, the greater the weight of the inoculant in the distribution hopper, the more material is discharged from the discharge port below the discharge hopper per unit time (affected by the gravity and / or squeezing effect of the inoculant), and the faster the discharge speed. Moreover, as the weight of the inoculant in the distribution hopper gradually decreases, the discharge speed becomes slower and slower.

[0074] The discharge time of the inoculant must be less than or equal to the time required for all the molten metal in the transfer bag to be completely poured out. The time required for all the molten metal in the transfer bag to be completely poured out is obtained by the following formula:

[0075] T 金 =zW 金 ;

[0076] in:

[0077] T 金 —The time required for all the molten metal in the transfer package to be completely poured out;

[0078] z — a constant preset according to the tipping speed of the lifting and tipping mechanism;

[0079] W 金 —The mass of the molten metal inside the transfer package;

[0080] The preferred setting for the inoculant discharge time is equal to the time required for all the molten metal in the transfer bag to be poured out. This yields the time T required for all the inoculant in the distribution hopper to be added to the molten metal. 料 =T 金 .

[0081] Based on historical data, the total weight W of the required added prenatal agent 料 The time T required for all the inoculant in the dispensing hopper to be added to the molten metal. 料 The opening angle α of the flip-top door and the control process of the opening angle of the flip-top door during the addition of the probiotic were simulated, and several sets of simulation results were obtained. Each set of simulation results includes the total weight W' of the probiotic to be added. 料The time T' required for all the inoculant in the dispensing hopper to be added to the molten metal. 料 The data includes four items: the opening angle α' of the flip-up door, the control process of the opening angle of the flip-up door during the addition of the inoculant, and the total weight W' of the inoculant to be added. 料 The time T' required for all the inoculant in the dispensing hopper to be added to the molten metal. 料 The combinations of these results are all unique. These sets of simulation results are pre-stored in the second PLC control unit.

[0082] The second PLC control unit obtains the total weight W of the required incubator. 料 The time T required for all the inoculant in the dispensing hopper to be added to the molten metal. 料 After obtaining the information, W' is compared with several pre-stored simulation results. 料 With T' 料 The information is compared, and if W' is in a certain simulation result... 料 With T' 料 Match successful, i.e., W' 料 =W' 料 And T 料 =T' 料 Then, the second PLC control unit sets the current opening angle α = α' of the flip door according to the opening angle α' of the successfully matched simulation result. The control process of the opening angle of the flip door during the inoculant addition process is controlled according to the control process in the successfully matched simulation result.

[0083] If the second PLC control unit obtains the total weight W of the required inoculant to be added 料 The time T required for all the inoculant in the dispensing hopper to be added to the molten metal. 料 After obtaining the information, W' is compared with several pre-stored simulation results. 料 With T' 料 When comparing information, if it cannot be matched with W' in any simulation result... 料 With T' 料 Match successful, meaning W does not exist. 料 =W' 料 And T 料 =T' 料 In such cases, the following approach will be used to resolve the issue:

[0084] a. The second PLC control unit first determines whether W exists. 料 =W' 料 In this case, if W exists 料 =W' 料 Then first match W 料 =W' 料 From all simulation results, select T. 料T' 料 and |T 料 -T' 料 | the smallest simulation result as the matching result, the second PLC control unit sets the opening angle of the current turnover door α = α' according to the opening angle of the turnover door in the simulation result of the matching result, and the control process of the opening angle of the turnover door in the inoculant adding process is controlled according to the control process in the simulation result of the matching success.

[0085] b. If there is no W 料 = W' 料 In this case, the second PLC control unit continues to judge whether there is T 料 = T' 料 In this case, if there is T 料 = T' 料 In this case, all simulation results of T 料 = T' 料 are matched out first, and W' 料 > W 料 and |W' 料 - W 料 | the smallest simulation result as the matching result, the second PLC control unit sets the opening angle of the current turnover door α = α' according to the opening angle of the turnover door in the simulation result of the matching result, and the control process of the opening angle of the turnover door in the inoculant adding process is controlled according to the control process in the simulation result of the matching success.

[0086] c. If there is no T 料 = T' 料 In this case, all simulation results satisfying W' 料 > W 料 and T 料 > T' 料 are selected, and |W' 料 - W 料 | the smallest simulation result as the matching result, the second PLC control unit sets the opening angle of the current turnover door α = α' according to the opening angle of the turnover door in the simulation result of the matching result, and the control process of the opening angle of the turnover door in the inoculant adding process is controlled according to the control process in the simulation result of the matching success.

[0087] Further, the slag removing unit 33 includes a slag bucket 332 located on the side of the transfer unit 31 away from the inoculant adding unit 32, and a slag removing platform 331 is arranged on the side of the slag bucket 332 away from the transfer unit 31. Through the slag removing platform 331, the waste slag in the metal melt can be manually removed to the slag bucket 332.

[0088] In the embodiment, the pouring module 4 includes a pouring track 41 located on the side of the intermediate module 3 away from the transfer track 21 and parallel to the transfer track 21, and a pouring machine 42 is arranged on the pouring track 41, and the pouring machine 42 is loaded with a pouring ladle. The molding line 5 is located on the side of the pouring track 41 away from the intermediate module 3, and includes a plurality of sand boxes 51 arranged (length) linearly along the pouring track 41. The pouring machine 42 is arranged to be capable of moving the pouring ladle to the position of the intermediate unit 31 to receive the molten metal and pour the molten metal into the sand box 51, and finally complete the pouring work. As a whole, only one furnace front transfer trolley 22 and intermediate unit are arranged to complete the intermediate transfer of the molten metal, without occupying a large layout space, simplifying the intermediate transfer process, ensuring the transfer efficiency, and making the pouring system more integrated, thereby enabling the pouring system to be applied to small workshops or small part pouring production work.

[0089] Further, the pouring machine 42 includes an on-machine roller, which is composed of a plurality of parallel arranged rotating rollers. By driving the rotating rollers to rotate, the pouring ladle can be moved on the roller, thereby increasing the stability of the transfer process. The transport direction of the on-machine roller is perpendicular to the arrangement direction of the transfer track 21, so that the pouring ladle can be more stable and convenient when moving to the intermediate unit 31 to receive the molten metal.

[0090] Further, the pouring track 41 further includes a pouring ladle storage roller 7 located on the side away from the molding line 5, which includes a plurality of parallel arranged rotating rollers, and the transport direction is perpendicular to the arrangement direction of the pouring track 41. The pouring ladle storage roller 7 is used for temporary storage or maintenance of the pouring ladle, so that the maintenance or replacement of the pouring ladle is more simple and convenient.

[0091] In order to enable those skilled in the art to more clearly understand the technical solution, the embodiment further provides an integrated molten metal pouring system and a pouring method, which are combined with the above-mentioned molten metal pouring system. Figure 5 which includes the following steps:

[0092] (1) In the initial state, the transfer ladle and the pouring ladle are located above the transfer ladle storage roller 6 and the pouring ladle storage roller 7, respectively;

[0093] (2) After the system receives the production instruction, the furnace front transfer trolley 22 and the pouring machine 42 are respectively connected with the transfer ladle storage roller 6 and the pouring ladle storage roller 7. Under the action of the on-machine roller and the pouring ladle storage roller 7 and the action of the furnace front roller and the transfer ladle storage roller 6, the transfer ladle and the pouring ladle are connected;

[0094] (3) The electric furnace 11 sends a signal that the molten metal can be poured, and the furnace front transfer trolley 22 loads the transfer ladle to move along the furnace front track to the electric furnace 11 to receive the molten metal;

[0095] (4), the furnace transfer trolley 22 loaded with molten metal transfer ladle moves to the position of the transfer unit 31, and under the action of the transfer roller and the furnace roller, the transfer ladle is completed with the transfer unit 31 The transfer work of the ladle, at this time the transfer ladle contains molten metal;

[0096] (5), steps (2), and / or, (3), and / or, (4) are carried out, the feeder controller controls the screw feeding mechanism 3221 to work to add the inoculant in the total hopper 322 to the distribution hopper 323, the feeding speed is fast first and then slow, when the weight of the inoculant in the distribution hopper 322 reaches the set value, the feeder controller controls the screw feeding mechanism 3221 to stop working;

[0097] (6), steps (3), and / or, (4) are carried out, the pouring machine 42 loaded with pouring ladle moves to the position of the transfer unit 31;

[0098] (7), the transfer unit 31 pours the molten metal in the transfer ladle into the pouring ladle through the lifting and pouring mechanism, at the same time, the feeder controller controls the feeding drive mechanism 3231 to open the turning door 3232, it should be noted that the turning door 3232 is opened to a certain extent in advance under the action of the feeding drive mechanism 3231, then gradually expands under the action of the feeding drive mechanism 3231, the inoculant is added to the transfer ladle which is pouring the molten metal through the feeding hopper 324, after the inoculant addition is completed, the feeder controller controls the feeding drive mechanism 3231 to close the turning door 3232, it should be noted that the inoculant addition work must be carried out at the same time as the pouring of the molten metal, and the end time of the inoculant addition work must be before the completion of the pouring of the molten metal, or completed at the same time as the pouring of the molten metal;

[0099] (8), after the pouring of the molten metal is completed, the transfer unit 31 and the furnace transfer trolley 22 are connected to complete the transfer work of the empty transfer ladle, and the furnace transfer trolley 22 continues to wait for the signal of the electric furnace 11 that the molten metal can be poured;

[0100] (9), steps (8) are carried out or completed, the pouring machine 42 loaded with molten metal pouring ladle moves to the slag removal unit 33 to manually remove the slag, after the slag removal is completed, the pouring work is carried out, and after the pouring is completed, the pouring machine 42 carries the empty pouring ladle to the transfer unit 31 to wait for the next round of molten metal receiving work;

[0101] (10), repeat steps (3)-(9) to complete the continuous pouring work;

[0102] (11) The system receives a stop production instruction, and after the pouring of the metal melt in the transfer ladle and the transfer ladle is completed, the transfer ladle storage roller 6 and the pouring ladle storage roller 7 are respectively connected with the furnace front transfer trolley 22 and the pouring machine 42, and the transfer of the transfer ladle and the pouring ladle is completed.

Claims

1. An integrated metal melt pouring system, characterized by, The device comprises a melting module (1), a transfer module (2), an intermediate module (3), a pouring module (4), a molding line (5) and a PLC control unit. The transfer module (2) comprises a transfer track (21), and the melting module (1), the intermediate module (3), the pouring module (4) and the molding line (5) are located on the same side of the transfer track (21). The melting module (1) comprises an electric furnace (11), and a furnace front transfer trolley (22) is arranged on the transfer track (21), the furnace front transfer trolley (22) carries a transfer ladle, and the furnace front transfer trolley (22) is arranged to be capable of carrying the transfer ladle to move to the electric furnace (11) to receive molten metal. The intermediate module (3) comprises a transfer unit (31) located on one side of the transfer track (21), the transfer unit (31) is arranged to be capable of being connected with the furnace front transfer trolley (22) to complete the transfer of the transfer ladle, and the transfer unit (31) is provided with an inoculant adding unit (32) and a slagging unit (33) on the two sides thereof. The inoculant adding unit (32) comprises a main frame (321) and a feeding controller, the main frame (321) is sequentially provided with a total hopper (322), a distribution hopper (323) and a feeding funnel (324) from top to bottom, a spiral feeding mechanism (3221) is arranged below the total hopper (322), the distribution hopper (323) is connected with the main frame (321) through a weighing mechanism (3233), a turnover door (3232) is rotatably arranged at a discharge port of the distribution hopper (323), a feeding driving mechanism (3231) capable of driving the turnover door (3232) to turn over is arranged between the turnover door (3232) and the distribution hopper (323), and the spiral feeding mechanism (3221), the weighing mechanism (3233) and the feeding driving mechanism (3231) are in communication connection with the feeding controller, and the feeding controller is arranged to be capable of controlling the working states of the spiral feeding mechanism (3221) and the feeding driving mechanism (3231) according to the feedback information of the weighing mechanism (3233). The pouring module (4) comprises a pouring track (41) located on the side, away from the transfer track (21), of the intermediate module (3) and parallel to the transfer track (21), a pouring machine (42) is arranged on the pouring track (41), the pouring machine (42) carries a pouring ladle, a lifting and pouring mechanism is arranged on the transfer unit (31), and the molding line (5) is located on one side of the pouring track (41) and comprises a sand box (51); the pouring machine (42) is arranged to be capable of carrying the pouring ladle to move to the position of the transfer unit (31) to receive molten metal and pour the molten metal into the sand box (51). The PLC control unit pre-stores several groups of simulation results, each group of simulation results including the total weight W' of the required inoculant to be added 料 , the time T' required for the inoculant in the distribution hopper to be added to the metal melt 料 , the opening angle α' of the tilting gate, and the control process of the opening angle of the tilting gate during the inoculant addition process The PLC control unit obtains the total weight W of the required inoculant to be added. 料 The time T required for all the inoculant in the dispensing hopper to be added to the molten metal. 料 After obtaining the information, W' is compared with several pre-stored simulation results. 料 The information is compared with that of material T'. If, in a certain simulation result, W material = W' material and T material = T' material, the PLC control unit sets the current opening angle of the tilting door based on the opening angle α' of the tilting door in this successfully matched simulation result. The control process for the opening angle of the tilting door during the inoculant addition process is controlled according to the control process in this successfully matched simulation result. If W material does not exist... 料 =W' 料 And T 料 =T' 料 In the case of: a、PLC control unit first determines whether there is W 料 = W' 料 , if there is first match W 料 = W' 料 all simulation results, select T 料 > T' 料 and | T 料 - T' 料 | minimum simulation results as the matching results; b. If W does not exist 料 = W' 料 , the PLC control unit continues to determine whether T exists 料 = T' 料 , if T exists 料 = T' 料 , all simulation results of T 料 = T' 料 are matched out first, and W' 料 > W 料 and |W' 料 - W 料 | minimum simulation results are selected as the matching results; c. if T 料 = T' 料 is also not present, then from all simulation results satisfying W' 料 > W 料 and T 料 > T' 料 , the simulation result with the smallest |W' 料 - W 料 | is selected as the matching result; a, b and c, the PLC control unit is arranged to set the opening angle of the current turnover door according to the opening angle of the turnover door in the simulation result of the matching result, and the control process of the opening angle of the turnover door in the inoculant adding process is controlled according to the control process in the simulation result of the successful matching.

2. An integrated metal melt pouring system according to claim 1, wherein The discharge port is outwardly open, and the upper side of the turnover door (3232) is rotatably connected with the upper side of the discharge port and turns outwardly.

3. An integrated metal melt pouring system according to claim 2, wherein The feeding driving mechanism (3231) is a linear driving device, and the feeding controller is arranged to be capable of controlling the extension and / or shortening amount of the linear driving device.

4. The integrated metal melt pouring system of claim 1, wherein The screw feeding mechanism (3221) comprises a screw conveyor and a rotating driving device, and the feeding controller is configured to control the rotating speed of the rotating driving device.

5. The integrated metal melt pouring system of claim 1, wherein The total hopper (322) has a larger capacity than the sub-hopper (323).

6. An integrated metal melt pouring system according to any one of claims 1 to 5, wherein The furnace front transfer trolley (22), the transfer unit (31) and the pouring machine (42) respectively comprise a furnace front roller way, a transfer roller way and a machine roller way, and the transport directions of the furnace front roller way, the transfer roller way and the machine roller way are perpendicular to the arrangement direction of the transfer track (21).

7. An integrated metal melt pouring system according to any one of claims 1 to 5, wherein The furnace front roller way of the furnace front transfer trolley (22) is capable of lifting.

8. An integrated metal melt pouring system according to any one of claims 1 to 5, wherein The pouring track (41) is provided with a pouring ladle storage roller way (7) on the side away from the molding line (5), and the transport direction of the pouring ladle storage roller way (7) is perpendicular to the arrangement direction of the pouring track (41). The transfer track (21) is provided with a transfer ladle storage roller way (6) on one side, and the transport direction of the transfer ladle storage roller way (6) is perpendicular to the arrangement direction of the transfer track (21).

9. An integrated metal melt delivery system as defined in claim 8, wherein The transfer ladle storage roller way (6) is located on the side of the transfer track (21) close to the melting module (1).

10. The integrated metal melt pouring system of claim 8, wherein, The method comprises the following steps: (1) In the initial state, the transfer ladle and the pouring ladle are respectively located above the transfer ladle storage roller way (6) and the pouring ladle storage roller way (7); (2) After the system receives a production instruction, the furnace front transfer trolley (22) and the pouring machine (42) are respectively connected with the transfer ladle storage roller way (6) and the pouring ladle storage roller way (7) to complete the transfer of the transfer ladle and the pouring ladle; (3) When the electric furnace (11) sends a signal that the metal melt can be poured, the furnace front transfer trolley (22) moves to the electric furnace (11) to receive the metal melt; (4) The furnace front transfer trolley (22) moves to the position of the transfer unit (31) to complete the transfer of the transfer ladle between the furnace front transfer trolley (22) and the transfer unit (31); (5) When steps (2), (3) and / or (4) are performed, the feeding controller controls the screw feeding mechanism (3221) to work to add the inoculant in the total hopper (322) to the sub-hopper (323), and when the weight of the inoculant in the sub-hopper (323) reaches a set value, the feeding controller controls the screw feeding mechanism (3221) to stop working; (6) When steps (3) and / or (4) are performed, the pouring machine (42) moves to the position of the transfer unit (31) to carry the pouring ladle; (7) The transfer unit (31) pours the metal melt in the transfer ladle into the pouring ladle through a lifting and pouring mechanism, and at the same time, the feeding controller controls the feeding driving mechanism (3231) to open the turning door (3232) to add the inoculant into the transfer ladle in which the metal melt is being poured through the feeding funnel (324), and after the inoculant is added, the feeding controller controls the feeding driving mechanism (3231) to close the turning door (3232); (8) After the pouring of the metal melt is completed, the transfer unit (31) is connected with the furnace front transfer trolley (22) to complete the transfer of the empty transfer ladle, and the furnace front transfer trolley (22) continues to wait for the signal that the metal melt can be poured from the electric furnace (11). (9) When step (8) is performed or completed, the pouring machine (42) carrying the ladle containing the metal melt moves to the slag removing unit (33) for manual slag removing, and after the slag removing is completed, the pouring work is performed, and after the pouring is completed, the pouring machine (42) carrying the empty ladle moves to the transfer unit (31) to wait for the next round of metal melt receiving work; (10) Repeat steps (3)-(9) to complete the continuous pouring work; (11) The system receives a stop production instruction, and after the metal melt in the ladle and the transfer ladle is poured out, the furnace front transfer trolley (22) and the pouring machine (42) are respectively connected with the transfer ladle storage roller (6) and the ladle storage roller (7), and the transfer of the transfer ladle and the ladle is completed.

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