Subframe casting equipment

Abstract

The application discloses a kind of subframe casting equipment, including upper and lower mould manipulator, multiple centrifugal casting device, ladle device;The application establishes ladle displacement track as the running channel of hanger auxiliary rack in smelting furnace side line, changes high-altitude hoisting of travelling crane into low posture transport, effectively reduces the risk of high fall;Horizontal track physical limit operation line makes operation more safe at the same time.Centrifugal casting device is placed beside ladle displacement track, saves transfer time, and molten water receiving is located at the opposite side of casting station The appropriate position can reduce the temperature of molten water and reduce energy consumption, the whole application saves time, effort and cost when producing subframe, effectively reduces labor intensity;Centrifugal casting has strong filling capacity, good compactness, small pouring gate and low metal consumption, which can be used at a temperature of 5-10 ℃ lower than gravity casting, effectively reducing the air intake phenomenon, reducing the occurrence of product porosity and pinhole.

Description

Technical Field

[0001] This invention relates to the field of vehicle frame casting technology, and more particularly to a subframe casting equipment. Background Technology

[0002] Originally used in high-end sedans, subframes differ from existing sedan suspensions in that the suspension is mounted on the subframe before being connected to the body, eliminating the direct connection between the suspension and the body. Using a subframe reduces vibration transmission to the body in five stages, significantly improving sedan comfort. Subframes include welded steel plate subframes, welded steel tube subframes, cast subframes, and other forms. The automotive chassis subframe is a crucial structural safety component, connecting and securing the suspension system, steering system, and other load-bearing systems. It requires high performance in terms of strength, stiffness, modal characteristics, and handling stability. To reduce subframe weight and achieve lightweighting, domestic and international OEMs have been researching and some have successfully implemented various aluminum alloy subframes using different forming processes. Current forming processes for automotive aluminum alloy parts include die casting, extrusion forming, forging, aluminum tube hydroforming, aluminum sheet stamping, and welded composite forming. All these methods involve re-forming profiles into modular components, followed by welding and riveting to complete the subframe assembly. The nominal size of an aluminum alloy auxiliary workshop is generally approximately 1500-2000 mm.

[0003] The structure, ranging from 500-800 mm to 300-500 mm, is complex at both ends and relatively simple in the middle. It is a cavity structure with uneven wall thickness. The wall thickness at the mounting holes at both ends reaches 200-400 mm, and the frame wall thickness is about 10 mm. The above manufacturing method uses component manufacturing of the assembly, and its strength and rigidity are affected by welding and riveting. Stress concentration is likely to occur, affecting its service life and firmness. At the same time, there are many processing steps and welding difficulties. After welding, complex aging treatment is required. The strength of complex welds will be much lower than that of the base material, thus affecting the performance of the assembly.

[0004] Integrated hollow casting of subframes is characterized by its light weight, high strength, low manufacturing cost, and high production efficiency. Its strength, hardness, and structural stability are all higher than welded assemblies. However, due to the complex and hollow structure of integrated hollow casting subframes, and in addition to the inherent characteristics of aluminum alloys being prone to oxidation and gas absorption, the subframes themselves are also characterized by complex structures and uneven wall thicknesses. The middle section has a simple structure and thin walls, resulting in faster solidification, while the ends have relatively complex structures and solidify more slowly. Isolated molten pools can easily appear at the ends of the casting, preventing the last solidified portion from receiving effective feeding. Therefore, ordinary gravity casting cannot meet the technical requirements. Gravity casting also suffers from poor fluidity, easily leading to incomplete filling, cold shuts, shrinkage cavities, and severe porosity in products of varying thicknesses.

[0005] Therefore, it is necessary to develop a subframe casting equipment to solve the above problems. Summary of the Invention

[0006] The purpose of this invention is to design a subframe casting equipment to solve the above problems.

[0007] The present invention achieves the above objectives through the following technical solutions:

[0008] Subframe casting equipment, including:

[0009] Manipulator for loading and unloading molds;

[0010] Multiple centrifugal casting devices; the multiple centrifugal casting devices are arranged in a straight line. The centrifugal casting device includes a centrifugal barrel drive device, a centrifugal drive shaft, and a centrifugal barrel. The mold is installed inside the centrifugal barrel. The centrifugal barrel is set vertically with its opening end facing upward. The lower end of the centrifugal barrel is fixedly connected to the upper end of the centrifugal drive shaft, and the lower end of the centrifugal drive shaft is connected to the drive end of the centrifugal barrel drive device.

[0011] A ladle pouring device; the ladle pouring device includes a main frame of a hanger, a secondary frame of a hanger, a horizontal drive device, and a ladle hanger assembly; the secondary frame of the hanger is located inside the main frame of the hanger, and its upper end can slide horizontally along a first direction on the upper part of the main frame of the hanger; the horizontal drive device includes two ladle displacement tracks, a servo motor, a transmission shaft gear, a reducer gear, a main roller assembly, and at least one auxiliary roller assembly; both the main roller assembly and the auxiliary roller assembly include two traveling rollers and a drive roller transmission shaft; the drive roller transmission shaft of the main roller assembly and the auxiliary roller assembly... The drive shaft is rotatably mounted on the lower end of the hanger auxiliary frame; two traveling rollers are mounted on both ends of the drive roller transmission shaft; the servo motor is connected to the reducer gear, the reducer gear meshes with the transmission shaft gear, and the transmission shaft gear is mounted on the drive roller transmission shaft of the main roller assembly; the two traveling rollers are respectively rotatably placed on two ladle displacement tracks, the two ladle displacement tracks are arranged in parallel, and the setting direction of the two ladle displacement tracks is the first direction; the servo motor and reducer gear are fixedly mounted on the lower end of the hanger auxiliary frame, and the two ladle displacement tracks are placed on... Below the main frame of the ladle; the ladle hanger device includes a ladle, a ladle height adjustment device, a ladle traveling device, and a ladle casting device; the ladle traveling device includes two hanger slides, two slide cylinders, a slide shaft, and two slide grooves set on the two main hanger beams at the upper end of the main frame ... The upper part of the ladle is connected to the upper part of the two slide plates, and the action direction of the two slide plates is the second direction. The ladle height adjustment device includes two ladle adjustment cylinders, the fixed ends of the two ladle adjustment cylinders are connected to the two slide plates, and the action ends of the two ladle adjustment cylinders are rotatably connected to the center of both sides of the ladle. The ladle casting device includes two casting cylinders, the fixed ends of the two casting cylinders are fixedly connected to the two slide plates, and the action ends of the two casting cylinders are rotatably connected to the center of both sides of the ladle.

[0012] Automatic casting device; upper and lower mold manipulators, multiple centrifugal casting devices, ladle devices, and automatic casting devices are arranged side by side; the automatic casting device includes a smelting furnace, a smelting furnace support, and a smelting water discharge cylinder. The middle part of the smelting furnace is rotatably mounted on the smelting furnace support via a smelting furnace shaft. The fixed end of the smelting water discharge cylinder is fixed inside the lower part of the smelting furnace support, and the active end of the smelting water discharge cylinder is rotatably connected to one end of the bottom of the smelting furnace.

[0013] The beneficial effects of this invention are as follows:

[0014] This application applies to technical solutions for projects built on sidelines in areas with limited space and without the need for overhead cranes or disruption of existing production lines. The invention utilizes a ladle displacement track established beside the smelting furnace as the operating channel for the crane's auxiliary frame, transforming high-altitude lifting by overhead cranes into low-profile transport, effectively reducing the risk of falls. Simultaneously, the horizontal track physically restricts the operating route, making operations safer. The centrifugal casting device is placed next to the ladle displacement track, saving transfer time. The molten metal receiving device is located at an appropriate position opposite the casting station, lowering the molten metal temperature and reducing energy consumption. The entire application saves time, labor, and costs during subframe production, effectively reducing labor intensity. Centrifugal casting boasts strong filling capacity, good density, small casting opening, and low metal consumption, allowing for casting temperatures 5-10°C lower than gravity casting temperatures, effectively reducing air intake and minimizing product porosity and pinholes. Attached Figure Description

[0015] Figure 1 This is the front view of the present invention;

[0016] Figure 2 This is a top view of the present invention;

[0017] Figure 3 This is a schematic diagram of the automatic ladle pouring device in this invention;

[0018] Figure 4 This is a schematic diagram of the structure of the hanger drive device in this invention;

[0019] Figure 5 for Figure 4 Enlarged schematic diagram of some of the structures in the diagram;

[0020] Figure 6 for Figure 5 The left view;

[0021] In the diagram: 1. Ladle track baffle; 2. Limit protection device; 3. Ladle displacement track; 6. Centrifugal casting station; 7. Upper and lower mold robot arm; 8. Upper and lower mold gripper hook; 9. Robot arm; 10. Ladle; 11. Centrifuge barrel drive device; 12. Centrifuge drive shaft; 13. Centrifuge frame; 14. Centrifuge barrel base; 15. Centrifuge barrel ball bearing; 16. Centrifuge barrel; 17. Mold stop block; 18. Stop block slot; 19. Upper and lower mold tie rods; 20. Mold lifting block; 21. Hanger main beam; 22. Connecting plate; 23. Slide shaft; 24. Slide cylinder; 25. Slide cylinder support plate; 26. Hanger slide plate; 27. Casting cylinder; 28. 1. Smelting furnace shaft; 29. ​​Smelting furnace; 30. Smelting furnace bracket; 31. Smelting water outlet cylinder; 32. Water outlet cylinder base; 321. Ladle adjustment cylinder; 33. Hanger frame; 34. Hanger base; 35. Horizontal traveling mechanism; 36. Ladle reinforcing ring; 37. Ladle shaft; 38. Ladle boom; 39. Boom sleeve; 40. Weight and temperature sensor; 41. Boom shaft; 43. Inner roller guard plate; 44. Outer roller guard plate; 45. Traveling roller; 47. Drive roller transmission shaft; 48. Servo motor; 49. Transmission shaft gear; 50. Reducer gear; 51. Limiting device; 52. Roller shaft; 53. Slide plate groove. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0023] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0024] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0025] In the description of this invention, it should be understood that the terms "upper," "lower," "inner," "outer," "left," "right," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this invention is in use, or the orientation or positional relationship commonly understood by those skilled in the art. They are only used to facilitate the description of this invention and to simplify the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0026] Furthermore, the terms "first," "second," etc., are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.

[0027] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, terms such as "set" and "connection" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0028] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0029] like Figure 1-6 As shown, the subframe casting equipment includes:

[0030] 7. Mold loading and unloading robotic arms;

[0031] Multiple centrifugal casting devices are arranged in a straight line. Each centrifugal casting device includes a centrifugal barrel drive device 11, a centrifugal drive shaft 12, and a centrifugal barrel 16. The mold is installed inside the centrifugal barrel 16. The centrifugal barrel 16 is set vertically with its open end facing upward. The lower end of the centrifugal barrel 16 is fixedly connected to the upper end of the centrifugal drive shaft 12, and the lower end of the centrifugal drive shaft 12 is connected to the drive end of the centrifugal barrel drive device 11.

[0032] The ladle 10 device includes a hanger frame 33, a horizontal drive device, and a ladle hanger assembly. The horizontal drive device includes two ladle displacement tracks 3, a servo motor 48, a transmission shaft gear 49, a reducer gear 50, a main roller assembly, and at least one auxiliary roller assembly. The hanger frame 33 is horizontally slidable along a first direction and is positioned on top of the two ladle displacement tracks 3. Both the main roller assembly and the auxiliary roller assembly include two traveling rollers 45 and a drive roller drive shaft 47. The drive roller drive shafts 47 of both the main roller assembly and the auxiliary roller assembly are rotatably mounted on the lower end of the hanger frame 33. Wheels 45 are installed at both ends of the drive roller drive shaft 47; servo motor 48 is connected to reducer gear 50, reducer gear 50 meshes with drive shaft gear 49, drive shaft gear 49 is mounted on the drive roller drive shaft 47 of the main roller assembly, two traveling rollers 45 are respectively rotatably placed on two ladle displacement tracks 3, the two ladle displacement tracks 3 are arranged in parallel, and the setting direction of the two ladle displacement tracks 3 is the first direction; servo motor 48 and reducer gear 50 are fixedly installed on the lower end of the hanger frame 33, and the two ladle displacement tracks 3 are placed below the hanger frame 33; the ladle hanger device includes ladle 10. Ladle height adjustment device, ladle traveling device, ladle casting device; the ladle traveling device includes two hanger slide plates 26, two slide plate cylinders 24, a slide plate shaft 23, and two slide plate grooves 53 set on the two hanger main beams 21 at the upper end of the hanger frame 33. The slide plate grooves 53 are set along the second direction, and the first and second directions are perpendicular. The two ends of the slide plate shaft 23 are slidably placed in the two slide plate grooves 53. The two ends of the slide plate shaft 23 are respectively connected to the two hanger slide plates 26. The two slide plate cylinders 24 are fixed on the two hanger main beams 21 at the upper end of the hanger frame 33, and the function of the two slide plate cylinders 24 is to... The two ends are respectively connected to the upper ends of the two hanger slide plates 26 via a connecting plate 22. The action direction of the two slide plate cylinders 24 is the second direction. The ladle height adjustment device includes two ladle adjustment cylinders 321. The fixed ends of the two ladle adjustment cylinders 321 are respectively connected to the two hanger slide plates 26. The action ends of the two ladle adjustment cylinders 321 are respectively rotatably connected to the center of both sides of the ladle 10. The ladle casting device includes two casting cylinders 27. The fixed ends of the two casting cylinders 27 are respectively fixedly connected to the two hanger slide plates 26. The action ends of the two casting cylinders 27 are respectively rotatably connected to the center of both sides of the ladle 10.

[0033] Automatic casting device; upper and lower mold manipulator 7, multiple centrifugal casting devices, ladle device 10, and automatic casting device are arranged side by side; the automatic casting device includes a smelting furnace 29, a smelting furnace 29 support, and a smelting water outlet cylinder 31. The middle part of the smelting furnace 29 is rotatably mounted on the smelting furnace 29 support through a smelting furnace rotating shaft 28. The fixed end of the smelting water outlet cylinder 31 is fixed inside the lower part of the smelting furnace 29 support, and the working end of the smelting water outlet cylinder 31 is rotatably connected to one end of the bottom of the smelting furnace 29.

[0034] like Figure 2 As shown, ladle track baffles 1 are installed at both ends of the ladle displacement track 3. A limit protection device 2 is also installed in the middle of the baffle, which includes a collision contact and a limit relay. Water sampling marks and casting marks are also installed on both sides of the ladle displacement track 3.

[0035] The hanger frame 33 consists of a rectangular frame structure composed of four hanger supports mounted on the hanger base 34, two hanger main beams 21 on the front and rear supports, and the hanger base 34. Two hanger main beam support plates are installed at both ends of the hanger main beams 21, which stabilize the hanger main beams 21 and form a stable hanger structure. A sliding cylinder support plate 25 is installed to the right rear of the two front and rear hanger main beams 21. In addition to housing the sliding cylinder, the sliding cylinder support plate 25, together with the hanger main beam support plates, reinforces the hanger frame 33. When the device is started, it will move the ladle 10 left and right on the hanger according to computer instructions, enabling the ladle 10 to move left and right between the water intake position of the smelting furnace 29 and the casting position of the centrifugal casting machine. Considering the impact of the high temperature of the molten water in the ladle 10 on the slide plate cylinder 24, there are two slide plate cylinders 24, which are installed on the main beams 21 of the front and rear hangers respectively to avoid being exposed to high temperatures. The two cylinders are linked and controlled by a computer to move synchronously.

[0036] A reinforcing ring 36 is provided on the annular side wall of the ladle to ensure the strength of the ladle.

[0037] like Figure 1-2 As shown, the upper and lower mold manipulator 7 is connected to the robotic arm 9. The upper end of the mold is equipped with a mold lifting block 20 and upper and lower mold grippers 8. During operation, the robotic arm 9 grabs the mold lifting block 20 and upper and lower mold grippers 8 to transfer the mold.

[0038] like Figure 1 As shown, the centrifugal casting device also includes a centrifuge frame 13, a centrifuge tank base 14, and multiple centrifuge tank balls 15. The centrifuge tank base 14 is mounted on the upper end of the centrifuge frame 13. A bearing is fitted on the centrifugal drive shaft 12, and the bearing is mounted on the centrifuge tank base 14. Multiple ball grooves are provided on the upper surface of the centrifuge tank base 14, and the multiple centrifuge tank balls 15 are rotatably disposed in the multiple ball grooves. The bottom of the centrifuge tank 16 is in contact with the centrifuge tank balls 15. This device uses the centrifuge frame 13 and multiple centrifuge tank balls 15 to support the centrifuge tank 16. The multiple centrifuge tank balls 15 form a circle, and the arrangement of the multiple centrifuge tank balls 15 can reduce the friction force when the centrifuge tank 16 rotates. The rotational speed of the centrifuge tank 16 is adjusted by computer control through the servo motor 48 of the centrifuge tank drive device 11 according to different product requirements.

[0039] like Figure 1As shown, at least two mold stops 17 are evenly arranged on the inner wall of the centrifuge tank 16, and correspondingly, at least two stop slots 18 are arranged on the outer wall of the mold. The at least two mold stops 17 are respectively fitted with the at least two stop slots 18 with clearance. When the mold is placed into the centrifuge tank 16, the slots on the mold are inserted into the mold stops 17. When the centrifuge tank 16 rotates, the two are locked by centrifugal force, preventing the mold from rotating.

[0040] In some embodiments, the mold consists of upper and lower sub-molds, which are held together by upper and lower mold tie rods 19.

[0041] like Figure 3 As shown, the height adjustment device also includes two ladle rotating shafts 37, two boom shafts 41, two ladle booms 38, and two boom sliding sleeves 39. The fixed end of the ladle adjusting cylinder 321 is rotatably connected to the hanger slide plate 26 through a boom shaft 41, and the working end of the ladle adjusting cylinder 321 is rotatably connected to the center of the ladle 10 through a ladle rotating shaft 37. The lower end of the boom sliding sleeve 39 is rotatably fitted on the ladle rotating shaft 37, the upper end of the ladle boom 38 is rotatably fitted on the boom shaft 41, and the lower end of the ladle boom 38 is slidably placed inside the boom sliding sleeve 39.

[0042] like Figure 3 As shown, a rotating groove is provided at the lower end of the hanger slide plate 26, the boom shaft 41 is arranged horizontally through the rotating groove, and the upper end of the ladle boom 38 is placed in the rotating groove.

[0043] like Figure 1 As shown, the automatic casting device also includes a water outlet cylinder base 32, which is placed at the bottom of the support of the smelting furnace 29. The upper surface of the water outlet cylinder base 32 is inclined, and the fixed end of the smelting water outlet cylinder 31 is fixed on the upper surface of the water outlet cylinder base 32.

[0044] like Figure 4 and 5 As shown, an inner roller guard plate 43 and an outer roller guard plate 44 are respectively provided on both sides of each traveling roller 45. The upper ends of the inner roller guard plate 43 and the outer roller guard plate 44 are fixedly connected to the hanger base 34, and the lower ends of the inner roller guard plate 43 and the outer roller guard plate 44 can be rotatably mounted on the drive roller drive shaft 47. In some embodiments, the lower end of the outer roller guard plate 44 can be rotatably mounted on the roller shaft 52.

[0045] In some embodiments, when the size and weight of the ladle 10 are both large, there is more than one auxiliary roller assembly; when the size and weight of the ladle 10 are both small, generally only one auxiliary roller assembly is needed to ensure the stability of the ladle 10's movement posture.

[0046] The ladle height adjustment device is suspended on the hanger slide plate 26 to adjust the height of the ladle 10. The main hardware of the device consists of the ladle boom 38, boom sleeve 39, and ladle adjustment cylinder 321. The lower end of the ladle boom 38 is inserted into the ladle sleeve of the ladle 10, and the lower end of the ladle sleeve is connected to the ladle shaft 37. The ladle shaft 37 is located at the center of gravity of the ladle 10, facilitating the balance of the ladle 10. The ladle 10's vertical position is adjusted by the up-and-down sliding of the ladle sleeve within the ladle boom 38. As the piston of the ladle cylinder retracts, it drives the boom sleeve 39 to slide up and down on the ladle boom 38, thus adjusting the height of the ladle 10. During the height adjustment of the ladle 10, the computer synchronously adjusts the extension and retraction of the casting cylinder 27 to ensure that the ladle 10 remains horizontal. Inside the sliding sleeve of ladle 10, a weight and temperature sensor 40 is installed. The sensor detects the weight and temperature of the molten water in ladle 10. When the preset initial pouring temperature is detected and the ladle is in the pouring position, the computer controls the pouring cylinder 27 to complete the pouring action. In the non-pouring position, the pouring cylinder 27 and the ladle adjustment cylinder 321 work together to adjust ladle 10.

[0047] To ensure the quality of the castings, tensile strength, yield strength, and elongation are directly related to the casting temperature. To guarantee that the molten metal temperature meets these requirements for specific products, a weight-temperature sensor is installed on the hanger slide. When the temperature sensor detects that the molten metal inside the ladle 10 has reached the set casting temperature, it activates the casting cylinder 27 to pour molten metal into the mold. Simultaneously, based on the temperature change after the first casting, the lifting speed of the casting cylinder 27 is adjusted to ensure timely solidification and shrinkage compensation within the mold. The weight sensor controls the lifting time of the casting cylinder 27 to terminate casting based on the required molten metal in the mold. As the core component of this intelligent automatic casting system, it provides the main control conditions for computer control.

[0048] After the system stops when the drive mechanism pushes the ladle 10 to the rear of the system, the sliding cylinder pulls the hanger slide plate 26 backward, stopping the ladle 10 at the sprue of the melting furnace 29. The molten water discharge cylinder 31 rises, allowing the molten water in the melting furnace 29 to flow into the ladle 10. When the molten water poured into the ladle 10 reaches the predetermined weight, it is sensed by the weight and temperature sensor 40, which triggers the computer to drive the molten water discharge cylinder to retract, and the melting furnace 29 returns to its original position. At the same time, the slide plate cylinder 24 pushes the hanger slide plate 26 to the left, positioning the ladle 10 at the upper center of the ladle displacement track 3, ensuring system balance. The servo motor 48 of the horizontal walking mechanism 35, mounted on the hanger base 34, starts, driving the walking roller 45 forward through the reduction gear to the position of mold No. 1 and stopping. The slide plate cylinder 24 pushes the hanger slide plate 26 to the left to the pouring position and stops, waiting. When the temperature in the weight temperature sensor 40 reaches the preset casting temperature, the casting cylinder 27 rises, causing the ladle 10 to pour molten metal into the mold. The casting cylinder 27 also adjusts the pouring lifting speed according to preset shrinkage requirements to ensure the poured molten metal meets these requirements. When the weight temperature sensor 40 detects that the weight has reached the set requirement, it pushes the ladle 10 downwards to balance it. After the first pour, the servo motor 482 times of the horizontal traveling mechanism 35 mounted on the hanger base 34 drives the traveling roller 45 forward through the reduction gear to the position of mold number 2 and stop. The casting cylinder 27 rises, causing the ladle 10 to pour molten metal into the mold. The casting cylinder 27 also adjusts the pouring lifting speed according to preset shrinkage requirements to ensure the poured molten metal meets these requirements. This repeated action completes the pouring of molten metal from the ladle 10. The servo motor 48 of the horizontal traveling mechanism 35, mounted on the hanger base 34, starts according to the water intake program, pushing the hanger backward to the water intake position and stopping. At the same time, the slide plate cylinder 24 pulls the hanger slide plate 26 to the right, so that the ladle 10 reaches the water intake position to take water. Then, under the control of the computer, the casting is automatically carried out, and the above actions are repeated until the operation is completed.

[0049] The control computer system in this application comprises a set of weight and temperature sensors 40, a set of hanger sliding controls, a set of ladle 10 adjustment controls, a set of casting controls, a set of hanger displacement controls, six sets of hydraulic cylinders, a set of servo motors 48, control mechanisms, and a main control computer, sensing devices, and safety protection mechanisms connected to them, forming a control system. This system detects the weight and temperature of the molten water in the ladle 10 and the start / stop markers on the track. Based on these detection signals, the computer, through a control program, completes the hydraulic-gas linkage of the system to achieve intelligent centrifugal casting.

[0050] This application upgrades the manual casting process to an intelligent, automated casting system controlled by computer programs, servo robotic arms, and hydraulics. The centrifugal casting machine's rotation speed, casting temperature, and casting speed are all automatically controlled by the intelligent system according to pre-set data. The invention uses a servo motor 48 to control the centrifugal casting device, allowing the rotation speed to be set between 200-1000 rpm with a rotational error accurate to ±5 rpm; the casting temperature is controlled to ±5℃ of the set temperature; the casting speed is controlled to ±1 second per mold based on the tilt angle of the casting cylinder 27; the casting volume is measured by a weight sensor on the ladle 10 and controlled by a computer. The ladle 10 contains 190 kg of molten iron, and three molds are cast per ladle. Each mold contains 60 kg of molten iron, and the casting time is 5-8 seconds. The entire ladle casting process is completed in 30-50 seconds, ensuring the casting temperature is not lower than ±5℃ of the required temperature after casting, thus guaranteeing product quality.

[0051] Gravity casting suffers from poor fluidity, easily leading to incomplete filling, cold shuts, shrinkage cavities, and severe porosity in products of varying thicknesses. Centrifugal casting, on the other hand, offers strong filling capacity, good density, and a small gating gate with low metal consumption. It allows for casting temperatures 5-10°C lower than gravity casting, effectively reducing air absorption and minimizing porosity and pinholes. However, due to the unique characteristics of aluminum alloy casting, casting temperature significantly impacts strength and elongation. Standard ZL101 test bar casting tests showed that at 690°C... b 232MPa, δ at 700 degrees b 202.8 MPa, at 740 degrees δ b 169.5 MPa; while δ s At 690 degrees δ s 5.9 MPa, δ at 700 degrees s 3.1 MPa, at 740 degrees δ s 2.0MPa; Even within the same ladle, temperature variations before and after casting can significantly alter the mechanical properties of the product. Accurate temperature control is crucial for ensuring product consistency. Centrifuge speed is another important factor in controlling casting quality. Too low a speed can lead to poor filling, internal porosity, and inclusions; for horizontal casting, it can also cause molten metal rain. Too high a speed can result in cracks, segregation, expansion of the casting, and vibration. Therefore, choosing a lower speed while ensuring casting quality yields optimal results.

[0052] This invention, considering the need for product diversity, employs a computer-controlled servo system. During testing, system parameters for different products, alloy compositions, and mechanical performance requirements are compared and stored in the computer. Through weight sensing, ladle temperature detection, computer-controlled ladle speed, ladle tilt angle control by casting cylinder 27, and servo motor 48 control, parameters such as ladle running time, ladle temperature, and casting speed are verified, optimized, and stored in the computer. Subsequent data retrieval precisely controls the system's operation, ensuring casting parameters operate under strict control. Simultaneously, the system reduces human interference and labor intensity through system control, and minimizes safety risks through remote operation. Except for equipment maintenance, the system operates unattended on-site, achieving intelligent automation.

[0053] This invention transmits the weight and temperature information of the molten iron in the ladle 10 to a control computer via a weight and temperature sensor 40 installed on the hanger's auxiliary frame. The control computer, based on pre-set data, controls the computer control system to transmit the temperature of the molten iron in the ladle 10 measured by the automatic temperature measuring device to the computer system. After receiving the temperature data, the computer issues a start command to the centrifugal casting device according to the control instructions stored in the computer. Simultaneously, it activates the horizontal drive device to move the ladle 10's auxiliary frame along the ladle displacement track 3, lifting the ladle 10 to the casting position. The control computer then installs the casting cylinder 27 to perform casting operations on centrifuges 1, 2, and 3 respectively. After casting is completed, the control computer activates the horizontal drive device to move the hanger to the melting furnace 29 position, awaiting the receipt of molten iron. This system achieves unmanned, intelligent operation.

[0054] This application applies to technical solutions for projects built on sidelines in areas with limited space and without the need for overhead cranes or disruption of existing production lines. The invention employs a ladle displacement track 3 established beside the smelting furnace 29 as the operating channel for the crane's auxiliary frame, changing the high-altitude lifting of the overhead crane to low-profile transport, effectively reducing the risk of falls. Simultaneously, the horizontal track physically restricts the operating route, making the operation safer. The centrifugal casting device is placed next to the ladle displacement track 3, saving transfer time. The molten water receiving device is located at an appropriate position opposite the centrifugal casting station 6, which can lower the molten water temperature and reduce energy consumption. The entire application saves time, labor, and costs during subframe production, effectively reducing labor intensity.

[0055] The entire working process of this application is as follows:

[0056] The centrifugal casting machine unit can be configured on the left side of the system as needed. Depending on the size, it can be installed in groups of 1 to 9. According to the present invention, the weight of the 10 casting ladles is 190Kg, and 3 molds are cast at one time. With the most economical casting method, it can be configured in groups of 3, 6, or 9. When there are more machine host positions, the length of the ladle displacement track 3 can also be increased.

[0057] A track-type conveyor is installed to deliver the casting mold to the centrifugal casting station 6. A ladle displacement track 3 is installed on the right side of the centrifugal casting station 6, and a hanger drive mechanism, a traveling mechanism, and a hanger device are installed on the ladle displacement track 3. An intelligent ladle device 10 is installed on the hanger, and the left rear of the above devices is matched with the melting furnace 29. The control and drive systems of all devices are connected to the main control computer. Before system startup, according to the product's requirements for tensile strength, yield strength, and elongation, and considering the special characteristics of aluminum alloy product performance being affected by casting temperature, different casting start temperatures and casting speeds need to be set in the main control computer to control the casting cylinder 27. Simultaneously, based on product models of different sizes and experimental data, the centrifuge speeds under different mechanical properties and sizes are input into the main control computer and called upon according to different product casting times. In the system, the computer will start the hanger to move, collect water, and cast according to the preset conditions and program.

[0058] System startup equipment:

[0059] 1. Set the water intake parameters for ladle 10: Start the servo motor 48 and move it to the rear limit device 51 of the track at the water intake level adjustment of the smelting furnace 29 on the right rear side of the track. Set the rear limit point and adjust the physical limit device 51 simultaneously. Set the rear stop point of the traveling mechanism. Start the slide plate cylinder 24 and adjust the hanger slide plate 26 backward to the right side of the molten water intake position. Set the water intake position and enter it into the computer main control system. Start the slide plate cylinder 24 again to move it to the left, pushing the ladle 10 hanger to the right and moving the ladle 10 to the center above the ladle displacement track 3. Set the ladle 10 conveying position and input the parameters into the main control computer to complete the setting of the water intake and conveying start position of ladle 10.

[0060] 2. Casting Parameter Setting: Start the servo motor 48 to drive the walking mechanism, which in turn moves the hanger frame 33 and the main beam 21 on the hanger base 34 along the ladle displacement track 3 from the rear starting position to the No. 1 casting position and stops. Set the parameters. Then, based on the product strength and other performance indicators, set the initial casting temperature. When the weight temperature sensor detects that the ladle 10 temperature has reached the set temperature, start the casting cylinder 27 to begin casting into the No. 1 centrifugal casting machine. Set the weight parameter. When the casting weight of the ladle 10 reaches the casting amount, it is sensed by the weight temperature sensor 40, and the piston of the casting cylinder 27 extends downward, making the ladle 10 horizontal. The servo drive motor restarts, driving the hanger mechanism forward to the casting position of centrifugal casting machine No. 2. Casting parameters are set, and casting cylinder 27 is raised again, allowing ladle 10 to pour into casting position No. 2. When the temperature and weight sensor detects the preset pouring volume, casting cylinder 27 raises ladle 10 to a horizontal position, stopping the pouring. The servo drive motor restarts, driving the hanger mechanism forward to the casting position of centrifugal casting machine No. 3. Casting parameters are set, and casting cylinder 27 is raised again, allowing ladle 10 to pour into casting position No. 3. When the temperature and weight sensor detects the preset pouring volume, casting cylinder 27 raises ladle 10 to a horizontal position, completing one pouring cycle of ladle 10. After ladle 10 pouring is complete, the program for ladle 10 to receive molten iron is set. The sliding plate cylinder 24 is activated, pulling the hanger sliding plate 26 to the right, positioning ladle 10 on the right side of the hanger to receive molten iron from furnace 29. The program for the second ladle 10 to receive molten iron from furnace 29 is then set. As the hydraulic cylinder 24 pulls the ladle 10 into the molten iron receiving area, the servo motor 48 starts, driving the hanger base 34 to move the intelligent ladle 10 system device mounted on the hanger backward to its initial position and then stop. The second receiving of molten iron from the melting furnace 29 and the second casting process then begin. Once the program settings are complete, the casting process is executed automatically without product adjustments.

[0061] 3. Centrifugal Casting Sequence Setting: The servo system of the centrifugal casting machine is connected to the main control computer and equipped with a braking device. When stopping, the mold lifting block 20 is positioned parallel to the ladle displacement track 3. A rotary robot arm is installed on the left side of the centrifugal casting machine, and the robot arm's retrieval device uses a rigid pickup claw. This facilitates the accurate placement of the casting mold into the centrifugal drum 16 and the accurate insertion of the mold stop block 17 slot 5 into the mold stop block 17 in the centrifugal drum 16. When the centrifugal drum 16 is stationary, the rotary robot arm picks up the mold lifting block 20 and rotates to the right side above the centrifugal drum 16, aligning the mold slot with the mold stop block 17 in the centrifugal drum 16. This process of placing the mold is completed sequentially. After the mold core is installed and the upper and lower mold tie rods 19 are attached, the mold is installed in the specified direction and placed in the material loading area. The centrifugal speed and rotation time need to be set according to the product performance requirements. Since the subframe is an unbalanced structural component, there are strict requirements for the demolding time. Demolding must be performed within the specified time parameters to prevent thermal cracking. The centrifuge parameters are set according to the product's mechanical properties. When ladle 10 reaches casting position 1, the computer controls the casting machine to start at the predetermined speed, and then sets the stop time. When the first casting is completed and ladle 10 reaches casting position 2, the computer controls the casting machine to start at the predetermined speed, and then sets the stop time. Similarly, when the first casting is completed and ladle 10 reaches casting position 3, the computer controls the casting machine to start at the predetermined speed, and then sets the stop time. The casting parameters are then set. The device also includes a mechanism to prevent the centrifuge tank 16 from starting and the ladle 10 from casting if the mold is not detected.

[0062] 4. Control Computer System. The centrifugal casting system's parameters, including the centrifugal casting machine parameters, the weight and temperature of the ladle 10, the sliding of the hanger, the adjustment of the ladle 10, the casting process, and the water output from the melting furnace 29, are all pre-set in the main control computer. The computer system controls the centrifugal drum drive device 11, the sliding cylinder, the ladle adjustment cylinder 321, the servo motor 48 of the hanger, the casting cylinder 27, and the loading robot, achieving intelligent control of the system.

[0063] Working principle: Based on the casting test results of standard ZL101 test bars, the product performance varies at different temperatures. At a temperature of 690 degrees Celsius... b 232MPa, δ at 700 degrees b 202.8 MPa, at 740 degrees δ b 169.5 MPa; while δ s At 690 degrees δ s 5.9 MPa, δ at 700 degrees s 3.1 MPa, at 740 degrees δ s2.0MPa. The performance parameters of the packaged product are preset in the computer. If it is necessary to adjust the mechanical performance parameters of the product, the initial casting temperature can be adjusted appropriately in the computer to achieve the need for rapid adjustment of strength, yield strength, etc.

[0064] According to the performance requirements of the product, set the linkage computer parameters. Start the servo motor 48 on the hanger base 34, driving the hanger base 34 to push the ladle 10 along the ladle displacement track 3 to the rear end point of the ladle displacement track 3. The ladle 10 cylinder starts, pulling the ladle 10 located on the central hanger of the ladle displacement track 3 to the right side of the hanger main beam 21, the molten water outlet position of the smelting furnace 29. Stop, the molten water outlet cylinder of the smelting furnace 29 rises, and the molten water in the smelting furnace 29 is poured into the ladle 10. During the pouring process, the weight and temperature sensor 40 senses that the molten water entering the ladle 10 has reached the set 190Kg, and the molten water outlet cylinder of the smelting furnace 29 retracts, stopping the water discharge. At this time, the slide cylinder 24 extends to the left, pushing the hanger slide 26 to move to the center of the ladle displacement track 3 (at this time, the ladle 10 is full, and for safety reasons, to make the system most balanced and stable), and stops; the servo motor 48 installed on the hanger base 34 starts, driving the reducer gear 50 to drive the transmission shaft gear 49 on the drive roller transmission shaft 47, which drives the hanger drive mechanism to move from the starting position at the rear end of the ladle displacement track 3. When the mechanism moves from the 1st casting position, it stops, and the slide cylinder 24 extends to the left again, pushing the hanger slide 26 to the left to the casting position set by the computer and stopping, waiting. The temperature probe in the weight temperature sensor 40 initially installed on the hanger slide sleeve detects the temperature of the molten water in the ladle 10. When the molten water temperature reaches the set initial casting temperature, the centrifugal barrel drive device 11 is started, driving the centrifugal barrel 16 to rotate. At the same time, the casting cylinder 27 retracts upward, causing the ladle 10 to pour molten water into mold No. 1 for casting. During casting, after the weight temperature sensor detects that the molten water poured out of the ladle 10 has reached the preset weight, the piston of the casting cylinder 27 extends downward, stopping the casting. At this time, the servo motor 48 installed on the hanger base 34 starts, driving the reducer gear 50 to drive the transmission shaft gear 49 on the drive roller transmission shaft 47, causing the hanger drive mechanism to move from the starting position at the rear end of the ladle displacement track 3. When the mechanism moves from the 2nd casting position, it stops. At the same time, the centrifugal barrel drive device 11 starts, driving the centrifugal barrel 16 to rotate, and the casting cylinder 27 retracts upward, causing the ladle 10 to pour molten water into the No. 2 mold for casting. During the casting process, after the weight and temperature sensing device detects that the molten water poured out of the ladle 10 has reached the preset weight, the piston of the casting cylinder 27 extends downward, stopping the casting. At the same time as the above movement, the No. 1 casting machine stops after reaching the predetermined rotation time. The robot arm removes the casting mold from the No. 1 casting machine for heat preservation or mold removal processing, and at the same time picks up another mold and puts it into the casting machine.Simultaneously, the servo motor 48 mounted on the hanger base 34 restarts, driving the reducer gear 50 to drive the transmission shaft gear 49 on the drive roller transmission shaft 47, moving the hanger drive mechanism from the rearmost starting position of the ladle displacement track 3. The mechanism stops when it moves from the 3rd casting position. At the same time, the centrifugal drum drive device 11 at position 3 starts, rotating the centrifugal drum 16. The casting cylinder 27 retracts upwards, causing the ladle 10 to pour molten water into the 3rd mold for casting. During casting, once the weight and temperature sensing device detects that the molten water poured from the ladle 10 has reached the preset weight, the piston of the casting cylinder 27 extends downwards, stopping the casting. At this point, the molten water in the ladle 10 has been poured. The servo motor 48 on the hanger base 34 starts, pushing the hanger backwards to the rearmost position of the 3rd ladle displacement track 3. Then, the 24th slide cylinder 24 starts, pulling the slide cylinder 24 to the right, positioning the ladle 10 at the molten water intake position of the melting furnace 29 for the second ladle 10 casting. This process is repeated to achieve intelligent casting.

[0065] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. Subframe casting equipment, characterized in that, include: Manipulator for loading and unloading molds; Multiple centrifugal casting devices; Multiple centrifugal casting devices are arranged in a straight line. The centrifugal casting device includes a centrifugal barrel drive device, a centrifugal drive shaft, and a centrifugal barrel. The mold is installed inside the centrifugal barrel, which is set vertically with its opening facing upward. The lower end of the centrifugal barrel is fixedly connected to the upper end of the centrifugal drive shaft, and the lower end of the centrifugal drive shaft is connected to the drive end of the centrifugal barrel drive device. The pouring device includes a hanger frame, a horizontal drive unit, and a pouring ladle hanger assembly. The horizontal drive unit includes two pouring ladle displacement tracks, a servo motor, a transmission shaft gear, a reducer gear, a main roller assembly, and at least one auxiliary roller assembly. The hanger frame is horizontally slidable along a first direction and positioned above the two pouring ladle displacement tracks. Both the main roller assembly and the auxiliary roller assembly include two traveling rollers and a drive roller drive shaft. The drive roller drive shafts of both the main roller assembly and the auxiliary roller assembly are rotatably mounted at the lower end of the hanger frame. Two traveling rollers are installed at both ends of the drive roller transmission shaft; the servo motor is connected to the reducer gear, the reducer gear meshes with the transmission shaft gear, and the transmission shaft gear is mounted on the drive roller transmission shaft of the main roller assembly. The two traveling rollers are rotatably placed on two ladle displacement tracks, which are arranged in parallel and in the first direction; the servo motor and reducer gear are fixedly installed on the lower end of the hanger frame, and the two ladle displacement tracks are located below the hanger frame; the ladle hanger... The ladle assembly includes a ladle, a ladle height adjustment device, a ladle traveling device, and a ladle casting device. The ladle traveling device includes two hanger slides, two slide cylinders, a slide shaft, and two slide grooves set on the two hanger main beams at the upper end of the hanger frame. The slide grooves are arranged along a second direction, and the first and second directions are perpendicular. The two ends of the slide shaft are slidably placed in the two slide grooves, and the two ends of the slide shaft are respectively connected to the two hanger slides. The two slide cylinders are fixed on the two hanger main beams at the upper end of the hanger frame, and the working ends of the two slide cylinders are respectively connected to the upper ends of the two hanger slides. The working direction of the two slide cylinders is the second direction. The ladle height adjustment device includes two ladle adjustment cylinders. The fixed ends of the two ladle adjustment cylinders are respectively connected to the two hanger slides, and the working ends of the two ladle adjustment cylinders are rotatably connected to the center of both sides of the ladle. The ladle casting device includes two casting cylinders. The fixed ends of the two casting cylinders are respectively fixedly connected to the two hanger slides, and the working ends of the two casting cylinders are rotatably connected to the center of both sides of the ladle. Automatic casting device; upper and lower mold manipulators, multiple centrifugal casting devices, ladle devices, and automatic casting devices are arranged side by side; the automatic casting device includes a smelting furnace, a smelting furnace support, and a smelting water discharge cylinder. The middle part of the smelting furnace is rotatably mounted on the smelting furnace support via a smelting furnace shaft. The fixed end of the smelting water discharge cylinder is fixed inside the lower part of the smelting furnace support, and the active end of the smelting water discharge cylinder is rotatably connected to one end of the bottom of the smelting furnace.

2. The subframe casting equipment according to claim 1, characterized in that, The upper and lower mold manipulators are connected to the robotic arm. The upper end of the mold is equipped with a mold lifting block and upper and lower mold grippers. During operation, the robotic arm grabs the mold lifting block and upper and lower mold grippers to transfer the mold.

3. The subframe casting equipment according to claim 1, characterized in that, The centrifugal casting device also includes a centrifuge frame, a centrifuge barrel base, and multiple centrifuge barrel balls. The centrifuge barrel base is installed on the upper end of the centrifuge frame. A bearing is fitted on the centrifugal drive shaft and is installed on the centrifuge barrel base. Multiple ball grooves are provided on the upper surface of the centrifuge barrel base, and the multiple centrifuge barrel balls are rotatably arranged in the multiple ball grooves. The bottom of the centrifuge barrel is in contact with the centrifuge barrel balls.

4. The subframe casting equipment according to claim 1, characterized in that, At least two mold blocks are evenly arranged on the inner wall of the centrifuge tank, and at least two block slots are correspondingly arranged on the outer wall of the mold. The at least two mold blocks are respectively fitted with the at least two block slots with clearance.

5. The subframe casting equipment according to claim 1, characterized in that, The height adjustment device also includes two ladle rotating shafts, two boom shafts, two ladle booms, and two boom sliding sleeves. The fixed end of the ladle adjusting cylinder is rotatably connected to the hanger slide plate through one boom shaft, and the working end of the ladle adjusting cylinder is rotatably connected to the center of the ladle through one ladle rotating shaft. The lower end of the boom sliding sleeve is rotatably fitted onto the ladle rotating shaft, the upper end of the ladle boom is rotatably fitted onto the boom shaft, and the lower end of the ladle boom is slidably placed inside the boom sliding sleeve.

6. The subframe casting equipment according to claim 5, characterized in that, A rotating groove is provided at the lower end of the hanger slide plate, the boom shaft is set horizontally through the rotating groove, and the upper end of the ladle boom is placed in the rotating groove.

7. The subframe casting equipment according to claim 1, characterized in that, The automatic casting device also includes a water outlet cylinder base, which is placed at the bottom of the smelting furnace support. The upper surface of the water outlet cylinder base is inclined, and the fixed end of the smelting water outlet cylinder is fixed on the upper surface of the water outlet cylinder base.

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