An automatic core setting method for static pressure wire molding

Abstract

The application relates to a static pressure line molding automatic core setting method and belongs to the casting technical field. The static pressure line molding automatic core setting method comprises a conveying line, a control system and at least one core setting system arranged around the conveying line, the core setting system comprises a first camera device, a second camera device, a positioning table, a core setting manipulator and a unstacking manipulator, and the control system, the first camera device, the second camera device, the positioning table, the core setting manipulator and the unstacking manipulator are in communication connection. The static pressure line molding automatic core setting method can realize full-automatic core setting molding, manual core setting is not needed, the cost is reduced, the effect of saving labor is achieved, the core is taken and placed by the manipulator according to the set program, the core setting position is accurate, and the production quality is improved.

Description

Technical Field

[0001] This invention relates to an automated core-setting method for static pressure molding, belonging to the field of casting technology. Background Technology

[0002] Brake disc sand cores are materials used for casting brake discs. They are made by mixing casting sand, binders, etc. in a certain proportion and then using a core-making machine. The casting process of brake discs generally includes sand core preparation, core making, drying in a drying oven, dip coating (which can improve the surface quality of the disc), core placement (placing the formed sand core into the mold cavity of the sand box), and casting after mold assembly.

[0003] For some simple brake discs, a single sand core can be used for casting, simply arranged in a flat layer within the mold cavity of the sand box. However, for some complex brake discs, multiple sand cores are often required to form a composite sand core, such as... Figure 17 The combined sand core 7 shown includes an upper sand core 7.1, a middle sand core 7.2, and a lower sand core 7.3. Multiple sand cores need to be stacked in the mold cavity of the sand box. Existing automated core-setting production lines are generally only suitable for flat layer molding processes. For combined sand cores, semi-automated molding processes are currently mostly used. That is, the cores are first assembled manually. The operator assembles multiple sand cores together in a fixed direction and places them in a designated position. The cylinder drives the slide table to move the sand cores to the designated position. The transfer robot transports the sand cores to the transition platform. The core-setting robot waits for the sand box to arrive. The core-setting robot carries a camera to take pictures of the location of the grinding cavity, and then sets the core.

[0004] Semi-automated processes have the following disadvantages:

[0005] (1) It requires manual placement of sand cores in fixed positions and directions. Time is tight, and people are busy and flustered. The positioning of multiple sand cores often deviates, which is not labor-saving and has a high scrap rate.

[0006] (2) The sand boxes on the conveyor line are different in size. Each sand box needs to be positioned in the mold cavity before the robot can accurately place the sand core into the mold cavity. The positioning method of using a robot to take pictures with a camera increases the core placement time.

[0007] (3) In addition, the way the core-lowering robot takes pictures with a camera is to directly photograph the position of the sand box mold cavity. Due to the reflection of the photo, this photo positioning method has a low success rate of mold cavity positioning and a long positioning time. When the positioning is unsuccessful, it is necessary to repeatedly position and take pictures, so that the equipment on the line is always in a stopped waiting state until the positioning is successful before the equipment can proceed to the next step. Summary of the Invention

[0008] The purpose of this invention is to provide a new technical solution to improve or solve the technical problems existing in the prior art as described above.

[0009] The technical solution provided by this invention is as follows: An automated core-setting method for static pressure molding includes a conveyor line, a control system, and at least one core-setting system disposed around the conveyor line. The core-setting system includes a first camera device, a second camera device, a positioning platform, a core-setting robot, and a destacking robot. The control system, the first camera device, the second camera device, the positioning platform, the core-setting robot, and the destacking robot are communicatively connected. The core-setting method is as follows:

[0010] (1) The first camera device takes photos of the palletizing and transmits the photo information to the control system;

[0011] (2) The control system identifies the quantity and model of the product currently on the top layer of the pallet based on the photo, and calculates the coordinate position of the product. The depalletizing robot adjusts the gripping posture according to the product model and coordinate position and performs the gripping operation.

[0012] (3) The destacking robot places the gripped product onto the positioning platform, and the positioning platform selects to blow and / or position the sand core according to the product model;

[0013] (4) The lower core robot adjusts the gripping posture according to the product model and then accurately grips the product;

[0014] (5) After the sand box is in place, the second camera takes a picture of the sand box positioning part. The control system calculates the coordinate information of each mold cavity in the sand box according to the picture information. The core-lowering robot adjusts the core-lowering position according to the coordinate information of the mold cavity and accurately places the sand core into the mold cavity of the sand box.

[0015] (6) Determine whether the pad needs to be removed: If the pad needs to be removed, the destacking robot adjusts its posture and uses the suction cup assembly to pick up and transfer the pad; if the pad does not need to be removed, determine whether the shaping is complete. If the shaping is complete, the core-laying operation ends.

[0016] (7) If the shape is not completed, repeat steps (1) to (6) above until the shape is completed.

[0017] Furthermore, when the automated core-laying line for static pressure molding includes three sets of core-laying systems, the three sets of core-laying systems are sequentially arranged around the conveyor line from upstream to downstream. The upstream core-laying system places the lower sand core of the combined sand core into the mold cavity of the sand box. When the sand box moves with the conveyor line to the midstream core-laying system, the midstream core-laying system places the middle sand core of the combined sand core into the mold cavity containing the lower sand core. When the sand box moves with the conveyor line to the downstream core-laying system, the downstream core-laying system places the upper sand core of the combined sand core into the mold cavity containing the lower sand core and the middle sand core.

[0018] The beneficial effect of adopting the above-mentioned further solution is that the use of three sets of core-laying systems enables the core-laying method of the present invention to be applied to the stacking molding process of composite sand cores.

[0019] Furthermore, any set of the core-lowering system includes two positioning platforms, which are arranged on both sides of the core-lowering robot.

[0020] The advantage of adopting the above-mentioned further solution is that it can reduce the downtime of the core-laying robot and improve efficiency.

[0021] Furthermore, when the core-feeding system includes two positioning platforms, in step (3), the product is first placed on which positioning platform, and the gripped product is placed on the selected positioning platform.

[0022] The beneficial effect of adopting the above-mentioned further solutions is to improve positioning and purging efficiency.

[0023] Furthermore, any set of the core-unloading system also includes a transfer robot and a flipping table. The transfer robot flips the product on the positioning table and transfers it to the flipping table, and the core-unloading robot picks up the core from the flipping table.

[0024] The beneficial effect of adopting the above-mentioned further solution is that it enables the flipping function of the sand core, which is suitable for the shaping of different types of sand cores.

[0025] Furthermore, when the core-laying system also includes a transfer robot and a flipping table, the core-laying method of the core-laying system in step (3) first determines whether there is a product on the positioning table. If there is a product, it determines whether the product needs to be positioned according to the product model. If positioning is required, the sand core is positioned and purged. If positioning is not required, only the product is purged. After purging and / or positioning, the transfer robot grabs the product from the positioning table and flips it. First, it determines whether there is a product on the flipping table. If there is a product, it waits until there is no product on the flipping table. If there is no product, it moves the grabbed product to the flipping table. In step (4), it first determines whether there is a product on the flipping table. If there is no product, it continues to stop and wait. If there is a product, it adjusts the gripping posture and accurately grabs the product from the flipping table, and continues to step (5).

[0026] Furthermore, the core-lowering system includes two second-type camera devices, which are respectively positioned at the positioning parts at both ends of the sand box on the conveyor line.

[0027] The following further beneficial effects are shown: the sand box has reference positioning sleeves at both ends, and the position of each mold cavity in the sand box is relatively fixed with respect to the position of the reference positioning sleeves. The positioning sleeves are made of a material that is easy for the camera to capture and does not reflect light, resulting in a high success rate of shooting. The positioning sleeves at both ends of the sand box are identified by taking pictures with two 2D cameras respectively. The coordinates of the mold cavity position are calculated based on the pictures, thereby obtaining the position of each mold cavity in the sand box. The core-laying robot accurately lays the core according to the position of the mold cavity.

[0028] Furthermore, the first camera device and the second camera device are 3D cameras or 2D cameras. The first camera device is used to acquire information about the products on the pallet, and the second camera device is used to identify the location information of the sand box mold cavity on the conveyor line.

[0029] Furthermore, the positioning stage includes a frame, on which a worktable is provided. On the worktable, one or more turntables, a rotation mechanism for driving the turntables to rotate, and a laser sensor are provided. Each turntable has a laser sensor on one side.

[0030] The further beneficial effect of adopting the above is that the positioning platform can achieve accurate positioning of the sand core on the turntable, which makes it convenient for the robot arm to accurately grasp the sand core and place it in the correct position in the sand box.

[0031] Furthermore, the workbench is also equipped with a blowing device, which is used to blow away the loose sand on the sand core placed on the turntable.

[0032] The further beneficial effect of adopting the above is that, while positioning, compressed air is controlled by a solenoid valve to blow away the sand core, removing excess sand particles and dust from the sand core and reducing the generation of waste.

[0033] Furthermore, the destacking robot includes a destacking robot gripper, which includes a main connecting plate, a connecting flange for connecting with the robot, a workpiece clamping mechanism, and a suction cup assembly. The connecting flange is installed on the upper end of the main connecting plate, the workpiece clamping mechanism is installed on the lower end of the main connecting plate, and the workpiece clamping mechanism is used to grip and transfer workpieces. The suction cup assembly is installed on one side of the main connecting plate, and the suction cup assembly is used to adsorb and transfer pads.

[0034] The further beneficial effects of the above are: the destacking robot gripper can disassemble the stacked sand cores layer by layer from top to bottom through the workpiece clamping mechanism. After the upper layer of sand cores is disassembled and removed, the suction cup assembly can adsorb the pad and transfer it to other positions, which facilitates the continued disassembly and separation of the sand cores below the pad.

[0035] The technical solution provided by this invention has the following advantages compared with the prior art:

[0036] 1. The static pressure line molding automated core-setting method of the present invention can realize fully automated core-setting and molding, eliminating the need for manual core assembly. This not only reduces costs and saves labor, but also ensures accurate core placement and improves production quality as the robotic arm picks up and puts in the sand core according to a predetermined program.

[0037] 2. Once the sand box is in place, use the second camera device to take automatic photos, saving time for mold positioning;

[0038] 3. The present invention uses a positioning table, which enables automatic positioning of the sand core by rotating it, and can also blow the sand core, thereby improving positioning efficiency and product quality.

[0039] 4. This invention can activate different core-laying systems according to the product model, and is suitable not only for the flat-layer molding process of a single sand core, but also for the stacked molding process of combined sand cores.

[0040] 5. The core-setting method of the present invention can automatically match the fixture according to the product model, adapting to the shape of different product models. Attached Figure Description

[0041] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0042] Figure 1 This is a plan view of the automated core-setting method for static pressure wire molding according to the present invention;

[0043] Figure 2 This is the front view of the sandbox;

[0044] Figure 3 This is a front view of the second camera device of the present invention when taking pictures and positioning the sand box;

[0045] Figure 4 This is a side view of the second camera device of the present invention when it is taking pictures and positioning the sand box;

[0046] Figure 5 This is a three-dimensional structural diagram of the destacking robot gripper of the present invention;

[0047] Figure 6 This is a three-dimensional structural diagram of the lower part of the destacking robot gripper of the present invention;

[0048] Figure 7 This is a three-dimensional structural diagram of the workpiece clamping mechanism of the destacking robot gripper of the present invention when clamping a sand core;

[0049] Figure 8 This is a three-dimensional structural diagram of the suction cup transfer pad of the destacking robot gripper of the present invention.

[0050] Figure 9 This is a three-dimensional structural diagram of the brake disc positioning platform of the present invention;

[0051] Figure 10 This is a top view of the brake disc positioning platform of the present invention;

[0052] Figure 11 This is a schematic diagram of the installation structure of the rotating mechanism of the present invention;

[0053] Figure 12 This is a three-dimensional structural diagram of the lifting mechanism of the present invention;

[0054] Figure 13 This is a schematic diagram of the lifting mechanism of the present invention without the baffle plate installed;

[0055] Figure 14 This is a three-dimensional structural diagram of the sand core placed on the brake disc positioning platform according to the present invention;

[0056] Figure 15 This is a schematic diagram of the three-dimensional structure of the sand core;

[0057] Figure 16 This is a schematic diagram of the structure where sand cores are stacked on a tray.

[0058] Figure 17 This is a cross-sectional view of the composite sand core;

[0059] Figure 18This is a flowchart of the core-laying method of the upstream core-laying system of the present invention;

[0060] Figure 19a This is a flowchart illustrating the operation of the destacking robot in the upstream core-lowering system of the present invention.

[0061] Figure 19b This is a flowchart illustrating the operation of the transfer robot in the upstream core-feeding system of the present invention.

[0062] Figure 19c This is a flowchart illustrating the operation of the unloading robot arm in the upstream unloading system of the present invention.

[0063] Figure 20 This is a flowchart of the core-laying method of the core-laying system in the middle of the present invention;

[0064] Figure 21a This is a flowchart illustrating the destacking robot operation of the downstream core system of the present invention.

[0065] Figure 21b This is a flowchart illustrating the operation of the core-lowering robot in the core-lowering system of the present invention.

[0066] Figure 22 This is a flowchart of the core-unloading method of the core-unloading system, a downstream application of the present invention.

[0067] Figure 23a This is a flowchart illustrating the destacking robot operation of the downstream core-lowering system of the present invention.

[0068] Figure 23b This is a flowchart illustrating the operation of the core-lowering robot in the downstream core-lowering system of the present invention.

[0069] In the diagram, 1. Conveyor line; 2. First camera device; 3. Second camera device; 4. Positioning platform; 4.1. Frame; 4.2. Turntable; 4.3. Rotating mechanism; 4.4. Laser sensor; 4.5. Blowing device; 4.6. Fixed base; 4.7. Slide cylinder; 4.8. Cylinder; 4.9. Cylinder connecting plate; 4.10. Shielding plate; 4.12. Sand core body; 4.13. Support boss; 4.14. Detection laser beam; 4.15. Mounting block; 5. Core lowering robot; 6. Destacking robot; 6.1. Main connection 6.1 Plate; 6.2 Connecting flange; 6.3 Workpiece clamping mechanism; 6.31 Mounting base; 6.32 Gripper cylinder; 6.33 Gripper; 6.4 Suction cup assembly; 6.41 Suction cup connecting plate; 6.42 Vacuum suction cup; 6.5 Pad plate; 6.6 Destacking robot clamp; 7. Combined sand core; 7.1 Upper sand core; 7.2 Middle sand core; 7.3 Lower sand core; 8. Sand box; 8.1 Positioning part; 8.2 Mold cavity; 9. Turning table; 11. Transfer robot; 12. Palletizing; 13. Pad plate storage station. Detailed Implementation

[0070] The principles and features of the present invention are described below with reference to examples. The examples are only used to explain the present invention and are not intended to limit the scope of the present invention.

[0071] like Figure 1 As shown, an automated core-setting method for static pressure molding includes a conveyor line 1, a control system, and at least one core-setting system arranged around the conveyor line 1. The core-setting system includes a first camera device 2, a second camera device 3, a positioning platform 4, a core-setting robot 5, and a destacking robot 6. The control system, the first camera device 2, the second camera device 3, the positioning platform 4, the core-setting robot 5, and the destacking robot 6 are communicatively connected. The core-setting method is as follows:

[0072] (1) The first camera device 2 takes a picture of the pallet 12 and transmits the picture information to the control system;

[0073] (2) The control system identifies the quantity and model of the product currently located on the top layer of the palletizing 12 based on the photo, and calculates the coordinate position of the product. The depalletizing robot 6 adjusts the gripping posture according to the product model and coordinate position and performs the gripping operation.

[0074] (3) The destacking robot 6 places the gripped product onto the positioning table 4, and the positioning table 4 selects to blow and / or position the sand core according to the product model;

[0075] (4) The lower core robot 5 adjusts the gripping posture according to the product model and then accurately grips the product;

[0076] (5) After the sand box 8 is in place, the second camera device 3 takes a picture of the positioning part 8.1 of the sand box 8. The control system calculates the coordinate information of each mold cavity 8.2 in the sand box 8 based on the picture information. The core-lowering robot 5 adjusts the core-lowering position based on the coordinate information of the mold cavity 8.2 and then accurately places the sand core into the mold cavity 8.2 of the sand box 8.

[0077] (6) Determine whether the pad 6.5 needs to be removed: If the pad 6.5 needs to be removed, the destacking robot 6 adjusts its posture and uses the suction cup assembly 6.4 to adsorb and transfer the pad 6.5 to the pad storage station 13; If the pad 6.5 does not need to be removed, determine whether the shaping is complete. If the shaping is complete, the core-laying operation ends.

[0078] (7) If the shape is not completed, repeat steps (1) to (6) above until the shape is completed.

[0079] In addition, in this embodiment,

[0080] The core-lowering system includes two second-type camera devices 3, which are respectively aligned with the positioning parts 8.1 at both ends of the sand box 8 on the conveyor line 1 (refer to...). Figures 2-4 The second camera device 3 is a 2D camera, and the first camera device 2 is a 3D camera. The first camera device 2 is used to acquire information about the products on the palletizing 12, and the second camera device 3 is used to identify the position information of the mold cavity 8.2 in the sand box 8 on the conveyor line 1. The principle of using two 2D cameras for positioning the mold cavity 8.2 is as follows: the two ends of the sand box 8 have reference positioning sleeves, and the position of each mold cavity 8.2 in the sand box 8 is relatively fixed with respect to the position of the reference positioning sleeves. The two 2D cameras take pictures of the positioning sleeves at both ends of the sand box 8, and calculate the coordinates of the position of the mold cavity 8.2 based on the pictures, thereby obtaining the position of each mold cavity 8.2 in the sand box 8. The core-laying robot 5 accurately lays the core according to the position of the mold cavity 8.2. In actual production, the position deviation of the mold cavity 8.2 acquired by the 2D camera is ≤0.02mm, and the picture positioning time is 2 seconds, which fully meets the production cycle requirements. Of course, the second camera device 3 can also use a 3D camera for cavity 8.2 positioning, but since a set of 3D cameras costs more than 200,000 yuan, the cost is high. Using two 2D cameras can achieve the cavity 8.2 positioning function, and the cost of two 2D cameras is about 8,000 yuan, which can save costs.

[0081] like Figure 4 and Figure 5 As shown, the depalletizing robot 6 includes a depalletizing robot gripper 6.6, which is mounted at the end of the robot arm via a connecting flange 6.2. The robot arm can drive the depalletizing robot gripper 6.6 to rotate around the central axis of the connecting flange 6.2, and the robot arm can also drive the depalletizing robot gripper 6.6 to flip. The depalletizing robot gripper 6.6 includes a main connecting plate 6.1, a connecting flange 6.2 for connecting to the robot arm, a workpiece clamping mechanism 6.3, and a suction cup assembly 6.4. The connecting flange 6.2 is mounted on the upper end of the main connecting plate 6.1, and the workpiece clamping mechanism 6.3 is mounted on the lower end of the main connecting plate 6.1. The workpiece clamping mechanism 6.3 is used to grip and transfer workpieces. The suction cup assembly 6.4 is mounted on one side of the main connecting plate 6.1 and is used to attract and transfer pads 6.5 to the pad storage station 13.

[0082] The suction cup assembly 6.4 includes a suction cup connecting plate 6.41 and one or more suction cups mounted on the suction cup connecting plate 6.41. The suction cup connecting plate 6.41 is vertically mounted on one side of the main connecting plate 6.1, and the suction cup connecting plate 6.41 is detachably connected to the main connecting plate 6.1. The suction cup is a vacuum suction cup 6.42, which is connected to a vacuum element assembly via a pipeline. When the vacuum element assembly is activated, it can evacuate the vacuum suction cup 6.42, causing the suction cup to grip the pad 6.5.

[0083] The workpiece clamping mechanism 6.3 includes a mounting base 6.31, a gripper cylinder 6.32, and multiple grippers 6.33. This embodiment does not limit the number of grippers 6.33; there can be three, five, or eight grippers, as long as they can stably grip the workpiece, it is within the scope of this invention. One end of the mounting base 6.31 is mounted on the main connecting plate 6.1, and the other end of the mounting base 6.31 is connected to the gripper cylinder 6.32. The multiple grippers 6.33 are evenly distributed circumferentially on the gripper cylinder 6.32, and the grippers 6.33 can slide radially. More specifically, the gripper cylinder 6.32 is provided with multiple slides, the number of which is the same as the number of grippers 6.33. Each slide has a slider, and the multiple grippers 6.33 are respectively installed in their respective slides via sliders. The gripper cylinder 6.32 is connected to an air source, and the reciprocating movement of the slider is realized by switching the air intake and exhaust states in the cylinder chamber of the gripper cylinder 6.32. The grippers 6.33 can follow the slider and slide back and forth along the slides to realize the gripping and putting down of the workpiece.

[0084] In this embodiment, four workpiece clamping mechanisms 6.3 and two sets of suction cup assemblies 6.4 are installed on the main connecting plate 6.11. Each set of suction cup assemblies 6.4 is equipped with four vacuum suction cups 6.42. Through the destacking robot gripper 6.6, the destacking robot 6 can grab four workpieces at a time. After the workpieces of the upper layer are destacking, the two sets of suction cup assemblies 6.4 can stably adsorb the pad 6.5 and transfer it to the pad storage station 13, which facilitates the further disassembly and separation of the sand core under the pad 6.5.

[0085] Reference Figure 6 and Figure 7The working method of the destacking robot 6 in this embodiment is as follows: the destacking robot gripper 6.6 is installed on the robot arm of the robot through the connecting flange 6.2, and the destacking robot 6 drives the destacking robot gripper 6.6 to move and flip. During destacking, the robotic arm first moves the destacking robotic gripper 6.6 above the stack 12. After the workpiece clamping mechanism 6.3 aligns with the part of the sand core to be clamped, the gripper cylinder 6.32 is activated, and the gripper 6.33 opens, picking up the sand core and moving it to the designated station. After the first layer of sand cores is removed, the destacking robotic arm 6 drives the destacking robotic gripper 6.6 to flip, making the suction cup connecting plate 6.41 of the suction cup assembly 6.4 parallel to the pad 6.5. When the robotic arm moves the suction cup assembly 6.4 downwards until the suction cup picks up the pad 6.5, the pad 6.5 is removed. The destacking robotic arm 6 drives the destacking robotic gripper 6.6 to flip in the opposite direction to the gripping state, continuing to grip the second layer of sand cores until destacking is complete.

[0086] It should be noted that the destacking robot gripper 6.6 can pick up four sand cores at the same time or pick up the sand cores one by one. The destacking robot gripper 6.6 can rotate around the central axis of the connecting flange 6.2. When it is necessary to pick up the sand cores one by one, the destacking robot gripper 6.6 can be rotated and moved to adjust any one of the workpiece clamping mechanisms 6.3 to be above the sand core for picking.

[0087] The destacking robot gripper 6.6 of the present invention can disassemble the stacked sand cores layer by layer from top to bottom through the workpiece clamping mechanism 6.3. After the upper layer of sand cores is disassembled and removed, the suction cup assembly 6.4 can adsorb the pad 6.5 and transfer it to other positions, so as to facilitate the continued disassembly and separation of the sand cores below the pad 6.5.

[0088] like Figures 9-14 As shown, the casting process of the brake disc, specifically positioning platform 4, generally includes sand core preparation, core making, drying in a drying oven, dip coating (which can improve the surface quality), core placement (placing the formed sand core into the mold cavity of sand box 8), and casting after mold assembly. In production, to match the cycle time of the core making machine and the drying oven, three supporting bosses 4.13 are designed for the sand cores. These bosses are used for stacking and drying the sand cores after dip coating to prevent deformation. (Refer to...) Figure 15 and Figure 16 The sand box 8 is designed with positioning grooves that match the three supporting protrusions 4.13 on the sand core. When placing the sand core, the three supporting protrusions 4.13 on the sand core need to be aligned with the positioning grooves in the sand box 8. The positioning platform 4 is set on one side of the core-laying robot 5. The positioning platform 4 can realize the accurate positioning of the sand core on the turntable 4.2, which facilitates the core-laying robot 5 to accurately grasp the sand core and place it in the correct position in the sand box 8.

[0089] The positioning stage 4 includes a frame 4.1, on which a worktable is mounted. One or more turntables 4.2, a rotation mechanism 4.3 for driving the turntables 4.2, and laser sensors 4.4 are mounted on the worktable. Each turntable 4.2 has a laser sensor 4.4 on one side. More specifically, the rotation mechanism 4.3 is mounted on the frame 4.1. The drive shaft of the rotation mechanism 4.3 passes through the worktable and is connected to the turntable 4.2. This embodiment does not limit the structure of the rotation mechanism 4.3; it can be a servo motor or a stepper motor, as long as it can drive the turntables 4.2 to rotate, it is within the scope of this invention. This embodiment does not limit the number of turntables 4.2; there can be one, two, three, or four turntables, as long as production requirements are met, it is within the scope of this invention. This embodiment does not limit the shape of the turntables 4.2; they can be circular or square pallets. The workbench is also equipped with a blowing device 4.5, which is used to blow away loose sand from the sand core placed on the turntable 4.2. The blowing device 4.5 includes a compressed air pipe, which is supported on the workbench by a bracket and connected to a compressed gas generator. A solenoid valve is installed on the compressed air pipe. The solenoid valve controls the compressed air to blow away excess sand and dust from the sand core, improving the casting quality of the brake disc and reducing scrap. The laser sensor 4.4 is mounted on the workbench via a lifting mechanism, allowing for height adjustment of the laser sensor 4.4, suitable for positioning and detecting brake discs of different sizes. In this embodiment, the lifting mechanism includes a fixed base 4.6, a sliding cylinder 4.7, and cylinders. The fixed base 4.6 is fixed to the worktable. The cylinder body of the sliding cylinder 4.7 is mounted on the fixed base 4.6. Two cylinders are mounted on the sliding table of the sliding cylinder 4.7 via a cylinder connecting plate 4.9. The output shaft ends of the two cylinders are provided with mounting blocks 4.15, which can stably support the mounting blocks 4.15. The laser sensor 4.4 is mounted on the mounting blocks 4.15. The lifting mechanism drives the laser sensor 4.4 up and down through one sliding cylinder 4.7 and two ordinary cylinders, enabling adjustment within four height ranges to accommodate the positioning of various types of sand cores. A baffle plate 4.10 is also provided above the cylinder fixed base 4.6 to prevent environmental factors from affecting the online detection accuracy of the laser sensor 4.4.

[0090] The working process of positioning and cleaning the sand core using the brake disc positioning platform 4 of the present invention is as follows: (1) By adjusting the lifting mechanism, the height of the laser beam emitted by the laser sensor 4.4 is higher than the height of the sand core body 4.12 but lower than the height of the support boss 4.13; (2) The sand core is placed on the turntable 4.2, and the rotating mechanism 4.3 and the laser sensor 4.4 are started. While the turntable 4.2 drives the sand core to rotate, the laser sensor 4.4 emits a parallel detection laser beam 4.14. When the sand core rotates to the position where its support boss 4.13 blocks the detection laser beam 4.14, the laser sensor 4.4 sends a signal to the control system. The control system controls the rotating mechanism 4.3 to stop rotating, thereby achieving accurate positioning of the sand core. At this time, the sand core is positioned to a position suitable for the robot to grasp; (3) While positioning, the control system controls the compressed air through the solenoid valve to clean the sand core and remove excess sand particles and dust.

[0091] The brake disc positioning platform 4 of this invention can also select whether to enable the positioning function and whether to adjust the height of the laser sensor 4.4 according to the model of the sand core. If the sand core does not have a supporting boss 4.13 structure, only the blowing function can be enabled. The sand core is circular, and a servo motor drives the turntable 4.2 to rotate the sand core. On the automated production line, the control system calls up the corresponding model data according to the production model to determine whether positioning is required and whether the height of the laser sensor 4.4 needs to be adjusted. The laser sensor 4.4 detects the signal changes of the rising and falling edges of the sand core, thereby detecting the position of the supporting boss 4.13 on the sand core. Then, according to the algorithm, the center point position of the supporting boss 4.13 is calculated, thereby achieving precise positioning of the sand core. The positioning accuracy can reach ±1.5mm, and the positioning time is about 1.6 seconds. At the same time as positioning, compressed air is controlled by a solenoid valve to blow away the sand core, removing excess sand particles and dust, and reducing the generation of waste products.

[0092] In this embodiment, the automated core-laying line for static pressure molding includes three sets of core-laying systems. The three sets of core-laying systems are arranged sequentially from upstream to downstream along the conveyor line 1. The upstream core-laying system places the lower sand core 7.3 of the combined sand core 7 into the mold cavity 8.2 of the sand box 8. When the sand box 8 moves with the conveyor line 1 to the midstream core-laying system, the midstream core-laying system places the middle sand core 7.2 of the combined sand core 7 into the mold cavity 8.2 containing the lower sand core 7.3. When the sand box 8 moves with the conveyor line 1 to the downstream core-laying system, the downstream core-laying system places the upper sand core 7.1 of the combined sand core 7 into the mold cavity 8.2 containing the lower sand core 7.3 and the middle sand core 7.2.

[0093] Reference Figure 18 , 19a , Figure 19b and Figure 19cThe automated core-laying line allows the lower sand core 7.3, middle sand core 7.2, and upper sand core 7.1 of the composite sand core 7 to be sequentially loaded into the mold cavity 8.2 of the sand box 8. In actual production, the lower sand core 7.3, middle sand core 7.2, and upper sand core 7.1 are stacked separately. The lower sand core 7.3 is stacked face up (see reference). Figure 16 When placing the core, the lower sand core 7.3 needs to be flipped over before being placed into the mold cavity 8.2. The state of the lower sand core 7.3, the middle sand core 7.2, and the upper sand core 7.1 in the mold cavity 8.2 is as follows. Figure 17 Therefore, the upstream core-unloading system also includes a transfer robot 11 and a flipping table 9. The transfer robot 11 flips the product on the positioning table 4 and transfers it to the flipping table 9. The core-unloading robot 5 picks up the core from the flipping table 9. The core-unloading method of the upstream core-unloading system performs the following steps:

[0094] (1) The first camera device 2 takes a picture of the stacking 12 of the sand core 7.3 and transmits the picture information to the control system;

[0095] (2) The control system identifies the quantity and model of the lower sand core 7.3 currently located on the top layer of the pallet 12 based on the photo, and calculates the coordinate position of the product. The depalletizing robot adjusts the gripping posture according to the model and coordinate position of the lower sand core 7.3 and performs the operation of gripping the lower sand core 7.3.

[0096] (3) First, determine whether there is a lower sand core 7.3 product on the positioning table 4. If there is a lower sand core 7.3 product, determine whether the lower sand core 7.3 needs to be positioned according to the model of the lower sand core 7.3, that is, determine whether there is a support boss 4.13 on the lower sand core 7.3. If there is a support boss 4.13 on the lower sand core 7.3, then position and blow clean the sand core. If there is no support boss 4.13 on the lower sand core 7.3, then only blow clean the product. After blowing clean and / or positioning, the transfer robot 11 grabs the product from the positioning table 4 and flips it. First, determine whether there is a product on the flipping table 9. If there is a product, wait for the flipping table 9 to be empty. If there is no product, then move the grabbed product to the flipping table 9.

[0097] (4) After the core-lowering robot 5 is started, it first determines whether there is a core-lowering product 7.3 on the flipping table 9. If there is no core-lowering product 7.3, it continues to wait; if there is a core-lowering product 7.3, it adjusts the gripping posture and accurately grabs the core-lowering product 7.3 from the flipping table 9, and continues to step (5).

[0098] (5) After the sand box 8 is in place, the two second camera devices 3 respectively photograph the positioning parts 8.1 at both ends of the sand box 8. The control system calculates the coordinate information of each mold cavity 8.2 in the sand box 8 based on the photo information. The core-lowering robot 5 adjusts the core-lowering position based on the coordinate information of the mold cavity 8.2 and then accurately places the core-lowering sand 7.3 into the mold cavity 8.2 of the sand box 8.

[0099] (6) Determine whether the pad needs to be removed 6.5:

[0100] If it is necessary to remove the pad 6.5, the destacking robot adjusts its posture and uses the suction cup assembly 6.4 to pick up and transfer the pad 6.5;

[0101] If it is not necessary to remove the pad 6.5, determine whether the shaping is complete. If the shaping is complete, then end the core-setting operation.

[0102] Some sand cores are stacked together from bottom to top 12, especially those sand cores with supporting bosses 4.13 (see reference). Figure 16 To ensure the stability of stacking 12, some sand core products are separated by a 6.5mm spacer between each layer of sand cores during stacking (see reference). Figure 7 and Figure 8 Therefore, the destacking robot needs to remove the pad 6.5 before it can grab the sand core when destacking.

[0103] (7) If the shape is not completed, repeat steps (1) to (6) above until the shape is completed.

[0104] like Figures 20 to 21b As shown, the midstream core-laying system includes two positioning platforms 4, which are arranged on the upper and lower sides of the core-laying robot 5. When the sand box containing the core 7.3 is transported to the midstream station by the conveyor line 1, the core-laying method of the midstream core-laying system performs the following steps:

[0105] (1) The first camera device 2 takes a picture of the intermediate sand core 7.2 stacked 12 and transmits the picture information to the control system;

[0106] (2) The control system identifies the quantity and model of the middle sand core 7.2 currently located on the top layer of the pallet 12 based on the photo, and calculates the coordinate position of the product. The depalletizing robot adjusts the gripping posture according to the product model and coordinate position of the middle sand core 7.2 and performs the operation of gripping the middle sand core 7.2.

[0107] (3) Select which positioning platform 4 to place the product on, place the gripped intermediate sand core 7.2 on the selected positioning platform 4, determine whether there is an intermediate sand core 7.2 on the positioning platform 4, if there is an intermediate sand core 7.2, determine whether the product needs to be positioned according to the model of the intermediate sand core 7.2, if positioning is required, then position and blow the sand core, if positioning is not required, then only blow the product.

[0108] (4) After the sand box 8 is in place, the second camera device 3 takes a picture of the positioning part 8.1 of the sand box 8. The control system calculates the coordinate information of each mold cavity 8.2 in the sand box 8 based on the picture information. The core-lowering robot 5 adjusts the core-lowering position based on the coordinate information of the mold cavity 8.2 and then accurately places the middle sand core 7.2 on the positioning table 4 into the mold cavity 8.2 of the sand box 8.

[0109] (5) Determine whether the pad 6.5 needs to be removed: If the pad 6.5 needs to be removed, the destacking robot adjusts its posture and uses the suction cup assembly 6.4 to adsorb and transfer the pad 6.5; if the pad 6.5 does not need to be removed, determine whether the shaping is complete. If the shaping is complete, the core-laying operation ends.

[0110] (6) If the shape is not completed, repeat steps (1) to (6) above until the shape is completed.

[0111] like Figures 22 to 23b As shown, the downstream core-setting system includes two positioning platforms 4, which are arranged on the upper and lower sides of the core-setting robot 5. When the sand box containing the lower sand core 7.3 and the intermediate sand core 7.2 is transported to the downstream station by the conveyor line 1, the core-setting method of the downstream core-setting system performs the following steps:

[0112] (1) The first camera device 2 takes a picture of the stacking 12 of the upper sand core 7.1 and transmits the picture information to the control system;

[0113] (2) The control system identifies the quantity and model of the top sand core 7.1 product currently located on the top layer of the stacking 12 based on the photo, and calculates the coordinate position of the top sand core 7.1. The destacking robot adjusts the gripping posture according to the model and coordinate position of the top sand core 7.1 and performs the operation of gripping the top sand core 7.1.

[0114] (3) After the destacking robot is started, it first determines whether the fixture needs to be replaced. If the destacking robot needs to replace the fixture, it moves to the fixture library to automatically replace the fixture before continuing to step (4). If the fixture does not need to be replaced, it continues to step (4). It can automatically switch models according to the product model to adapt to the shape of different product models. In this embodiment, such as Figure 17As shown, the upper sand core 7.1 and the lower sand core 7.3 have the same structure, and the unstacking robot gripper 6.6 of the upstream lower core system is the same as the robot gripper of the downstream lower core system.

[0115] (4) Select which positioning table 4 to place the product on, place the gripped upper sand core 7.1 on the selected positioning table 4, determine whether there is an upper sand core 7.1 on the positioning table 4, if there is an upper sand core 7.1, determine whether the upper sand core 7.1 needs to be positioned according to the model of the upper sand core 7.1, if positioning is required, then position and blow the sand core, if positioning is not required, then only blow the product;

[0116] (5) After the core-feeding robot 5 is started, it first determines whether the fixture needs to be replaced according to the product model. If the fixture needs to be replaced, the core-feeding robot 5 moves to the fixture library and automatically replaces the fixture before continuing step (6). If the fixture does not need to be replaced, then continue step (6).

[0117] (6) After the sand box 8 is in place, the second camera device 3 takes a picture of the positioning part 8.1 of the sand box 8. The control system calculates the coordinate information of each mold cavity 8.2 in the sand box 8 based on the picture information. The lower core robot 5 adjusts the lower core position according to the coordinate information of the mold cavity 8.2 and then accurately places the upper sand core 7.1 into the mold cavity 8.2 of the sand box 8.

[0118] (7) Determine whether the pad 6.5 needs to be removed: If the pad 6.5 needs to be removed, the destacking robot adjusts its posture and uses the suction cup assembly 6.4 to adsorb and transfer the pad 6.5; if the pad 6.5 does not need to be removed, determine whether the shaping is complete. If the shaping is complete, the core-laying operation ends.

[0119] (8) If the shape is not completed, repeat the above steps (1) to (7) until the shape is completed.

[0120] It should be noted that the control system can also choose to start or not start any of the core-laying systems. When only one sand core needs to be arranged in a single layer in a mold cavity 8.2, it can choose to start only one of the core-laying systems. Of course, it can also choose to start all the core-laying systems. In this case, all the core-laying systems will arrange the same sand core in the mold cavities 8.2 of different sand boxes 8, thereby improving the core-laying efficiency.

[0121] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An automated core-setting method for static pressure wire molding, characterized in that, The system includes a conveyor line (1), a control system, and three sets of core-unloading systems arranged around the conveyor line (1). The core-unloading system includes a first camera device (2), a second camera device (3), a positioning platform (4), a core-unloading robot (5), and a destacking robot (6). The control system, the first camera device (2), the second camera device (3), the positioning platform (4), the core-unloading robot (5), and the destacking robot (6) are interconnected. The automated core-unloading method is as follows: (1) The first camera device (2) takes a picture of the stacking (12) and transmits the picture information to the control system; (2) The control system identifies the quantity and model of the sand cores currently located on the top layer of the stack (12) based on the photo, and calculates the coordinate position of the sand cores. The destacking robot (6) adjusts the gripping posture according to the sand core model and coordinate position and performs the operation of gripping the sand cores. (3) The destacking robot (6) places the grasped sand core onto the positioning table (4), and the positioning table (4) selects to blow and / or position the sand core according to the model of the sand core; (4) The core-lowering robot (5) adjusts the gripper posture according to the model of the sand core and then accurately grips the sand core; (5) After the sand box (8) is in place, the second camera device (3) takes pictures of the positioning parts (8.1) at both ends of the sand box (8). The control system calculates the coordinate information of each mold cavity (8.2) in the sand box (8) based on the photo information. The core-lowering robot (5) adjusts the core-lowering position according to the coordinate information of the mold cavity (8.2) and then accurately places the sand core into the mold cavity (8.2) of the sand box (8). (6) Determine whether the pad needs to be removed (6.5): If the pad needs to be removed (6.5), the destacking robot (6) adjusts its posture and uses the suction cup assembly (6.4) to adsorb and transfer the pad (6.5); if the pad does not need to be removed (6.5), determine whether the shaping is complete. If the shaping is complete, the core-laying operation ends. (7) If the shape is not complete, repeat steps (1) to (6) above until the shape is complete; The three sets of core-laying systems are arranged sequentially around the conveyor line (1) from upstream to downstream. The upstream core-laying system places the lower sand core (7.3) of the combined sand core (7) into the mold cavity (8.2) of the sand box (8). When the sand box (8) moves with the conveyor line (1) to the midstream core-laying system, the midstream core-laying system places the middle sand core (7.2) of the combined sand core (7) into the mold cavity (8.2) containing the lower sand core (7.3). When the sand box (8) moves with the conveyor line (1) to the downstream core-laying system, the downstream core-laying system places the upper sand core (7.1) of the combined sand core (7) into the mold cavity (8.2) containing the lower sand core (7.3) and the middle sand core (7.2).

2. The automated core-setting method for static pressure wire molding according to claim 1, characterized in that, Any set of the core-laying system includes two positioning stages (4), which are arranged on both sides of the core-laying robot (5).

3. The automated core-setting method for static pressure wire molding according to claim 2, characterized in that, When the core-laying system includes two positioning platforms (4), in step (3), the system first selects which positioning platform (4) the destacking robot (6) will place the sand core on, and then the destacking robot (6) places the grasped sand core on the selected positioning platform (4).

4. The automated core-setting method for static pressure wire molding according to claim 1, characterized in that, Any set of the core-setting system also includes a transfer robot (11) and a flipping table (9). The transfer robot (11) flips the sand core on the positioning table (4) and transfers it to the flipping table (9). The core-setting robot (5) grabs the core from the flipping table (9).

5. The automated core-setting method for static pressure wire molding according to claim 4, characterized in that, When the core-laying system also includes a transfer robot (11) and a flipping table (9), the core-laying method of the core-laying system first determines whether there is a sand core on the positioning table (4) in step (3). If there is a sand core, it determines whether the sand core needs to be positioned according to the model of the sand core. If positioning is required, the sand core is positioned and purged. If positioning is not required, the sand core is only purged. After purging and / or positioning, the transfer robot (11) grabs the sand core from the positioning table (4) and flips it. First, it determines whether there is a sand core on the flipping table (9). If there is a sand core, it waits until there is no sand core on the flipping table (9). If there is no sand core, it moves the grabbed sand core to the flipping table (9). In step (4), it first determines whether there is a sand core on the flipping table (9). If there is no sand core, it continues to stop and wait. If there is a sand core, it adjusts the gripping posture and accurately grabs the sand core from the flipping table (9) and continues to step (5).

6. The automated core-setting method for static pressure wire molding according to claim 1, characterized in that, The core-lowering system includes two second-level camera devices (3), which are respectively aligned with the positioning parts (8.1) at both ends of the sand box (8) on the conveyor line (1).

7. The automated core-setting method for static pressure wire molding according to any one of claims 1 to 6, characterized in that, The first camera device (2) and the second camera device (3) are 3D cameras or 2D cameras. The first camera device (2) is used to acquire information about the sand core on the pallet (12), and the second camera device (3) is used to identify the position information of the sand box (8) cavity (8.2) on the conveyor line (1).

8. The automated core-setting method for static pressure wire molding according to claim 1, characterized in that, The positioning stage (4) includes a frame (4.1), on which a worktable is provided. On the worktable are one or more turntables (4.2), a rotation mechanism (4.3) for driving the turntables (4.2) to rotate, and a laser sensor (4.4). Each turntable (4.2) has a laser sensor (4.4) on one side.

9. The automated core-setting method for static pressure wire molding according to claim 1, characterized in that, The destacking robot (6) includes a destacking robot gripper (6.6), which includes a main connecting plate (6.1), a connecting flange (6.2) for connecting with the robot, a workpiece clamping mechanism (6.3), and a suction cup assembly (6.4). The connecting flange (6.2) is installed on the upper end of the main connecting plate (6.1), the workpiece clamping mechanism (6.3) is installed on the lower end of the main connecting plate (6.1), and the workpiece clamping mechanism (6.3) is used to grip and transfer workpieces. The suction cup assembly (6.4) is installed on one side of the main connecting plate (6.1), and the suction cup assembly (6.4) is used to adsorb and transfer pads (6.5).

Images