A wet sand casting system for wind turbine housings

Abstract

This invention discloses a wet sand casting system for wind turbine housings, relating to the technical field of casting systems. The invention includes a sprue vertically positioned on one side of the casting; a flow channel horizontally connected to the lower end of the sprue; a main riser vertically connected to the outlet end of the flow channel; a top riser neck and a bottom riser neck arranged side-by-side from top to bottom on the sidewall of the main riser; the top riser neck connected to the circumferential sidewall of the upper flange of the casting; the bottom riser neck connected to the circumferential sidewall of the lower flange of the casting; an insulation block positioned between the top and bottom riser necks; the insulation block connected to the sidewall of the main riser; a flow channel horizontally connected to the bottom of the main riser; multiple bottom ingates arranged side-by-side on the flow channel; and all multiple bottom ingates connected to the circumferential sidewall of the lower flange of the casting. This invention employs a multi-layer casting structure (top, middle, and bottom) to achieve a balanced temperature field in the product, which is beneficial for product forming.

Description

Technical Field

[0001] This invention belongs to the technical field of casting system, and in particular relates to a wet sand casting system for wind turbine housings. Background Technology

[0002] The wind turbine housing is an important component of the gearbox of a wind turbine. It bears the force from the impeller and the reaction force generated during gear transmission. Therefore, the wind turbine housing must have sufficient rigidity to withstand the force and torque.

[0003] Existing wet sand casting systems for wind turbine housings are complex and cumbersome due to the large number of risers and chills used. While some systems incorporate risers within the inner circumference of the wind turbine housing, the large riser necks make separation from the formed housing difficult. Therefore, there is an urgent need to develop a new wet sand casting system for wind turbine housings to address these issues. Summary of the Invention

[0004] The present invention provides a wet sand casting system for wind turbine housings, the purpose of which is to solve the technical problems mentioned in the background art.

[0005] To solve the above-mentioned technical problems, the present invention is achieved through the following technical solution:

[0006] This invention relates to a wet sand casting system for a wind turbine housing, comprising a sprue vertically arranged on one side of the casting; a flow channel horizontally connected to the lower end of the sprue; a main riser vertically connected to the outlet end of the flow channel; a top riser neck and a bottom riser neck arranged side-by-side from top to bottom on the sidewall of the main riser; the top riser neck connected to the circumferential sidewall of the upper flange of the casting; the bottom riser neck connected to the circumferential sidewall of the lower flange of the casting; an insulation block disposed between the top riser neck and the bottom riser neck; the insulation block connected to the sidewall of the main riser; a flow channel horizontally connected to the bottom of the main riser; multiple bottom ingates arranged side-by-side on the flow channel; each of the multiple bottom ingates connected to the circumferential sidewall of the lower flange of the casting; and a pair of vertically arranged waste liquid and gas discharge channels symmetrically connected to the circumferential sidewall of the upper flange of the casting.

[0007] As a preferred embodiment of the present invention, a filter screen is vertically installed inside the flow channel.

[0008] As a preferred embodiment of the present invention, the distance between the main riser and the two waste liquid and gas discharge channels is equal.

[0009] As a preferred embodiment of the present invention, a pair of arc-shaped chills are symmetrically installed on the lower part of the upper flange of the casting; both chills are located on the side of the waste liquid and gas discharge channel away from the main riser; the distance between the two chills and the main riser is equal.

[0010] The present invention has the following beneficial effects:

[0011] 1. This invention delivers molten iron into a slow-flow channel via a direct gating system, reducing the flow rate of the molten iron into the main riser. The molten iron then passes through the top and bottom riser necks of the main riser and enters the mold cavity of the casting. Simultaneously, the molten iron flows into the slow-flow transverse gating system from the bottom of the main riser, and then enters the bottom of the mold cavity of the casting through multiple bottom ingates. This enables the wet sand casting pouring operation of the wind turbine housing, which not only results in a low flow rate of molten iron entering the mold cavity and stable filling, but also allows for sequential solidification of the wind turbine housing casting, resulting in high-quality wind turbine housings with high surface quality and no internal defects.

[0012] 2. This invention introduces an insulation block at the main riser position to insulate the feeding channel, which not only opens up the feeding channel at the flange position of the casting and realizes the sequential solidification of the bottom flange of the casting, but also solves the problems of premature solidification of the feeding channel at the flange position and flange shrinkage defects in wind turbine box applications caused by traditional processes. At the same time, it reduces the difficulty of removing the gating system and grinding the casting. Furthermore, by designing a sand core heating self-feeding structure, it can also solve the problem of long-distance feeding of annular flanges with a single riser.

[0013] 3. This invention designs a multi-feeding channel riser and sets a top-level riser neck and a bottom-level riser neck distributed vertically on the main riser. The top-level riser neck and the bottom-level riser neck are merged into the main riser, and a single riser is used to achieve feeding of the upper and lower flanges. This not only improves the riser feeding capacity, but also simplifies the sand core process.

[0014] 4. The present invention adopts a multi-layer casting structure with upper, middle and lower layers. By horizontally connecting the bottom of the main riser to the slow-flow horizontal runner, and setting multiple bottom layer ingates side by side on the slow-flow horizontal runner, the multiple bottom layer ingates are all connected to the circumferential side wall of the lower flange of the casting. This can not only effectively reduce the flow rate of molten iron and reduce surface sand holes and surface quality problems caused by sand flushing, but also achieve a uniform temperature field of the product, which is beneficial to product forming.

[0015] 5. By installing a filter screen inside the slow flow channel, the present invention can filter the molten iron, reduce the impurity content in the molten iron entering the mold cavity, improve the purity of the molten iron entering the mold cavity, which is conducive to improving the flow performance and appearance quality of the casting, and ensures the casting quality of the wind turbine box.

[0016] 6. By setting chills on the side of the waste liquid and gas discharge channel away from the main riser, this invention can solve problems such as insufficient feeding distance of the upper flange riser of the casting, realize the sequential solidification of the casting, and effectively eliminate internal defects of the wind turbine box.

[0017] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the wet sand casting system for a wind turbine housing according to the present invention.

[0020] Figure 2 for Figure 1 Top view of the structure.

[0021] Figure 3 This is a schematic diagram of the connection between the straight gating system, the main riser, and the slow-flow horizontal gating system of the present invention.

[0022] Figure 4 This is a schematic diagram showing the relative positions of the main riser, the slow-flow horizontal runner, and the casting in this invention.

[0023] Figure 5 This is a schematic diagram of the connection between the direct gating system and the main riser of the present invention.

[0024] Figure 6 This is a schematic diagram showing the relative positions of the chill and the casting in this invention.

[0025] Figure 7 for Figure 6 The structural front view.

[0026] The attached diagram lists the components represented by each number as follows:

[0027] 1-Casting, 2-Straight sprue, 3-Slow flow channel, 4-Main riser, 5-Top riser neck, 6-Bottom riser neck, 7-Insulation block, 8-Slow flow horizontal sprue, 9-Bottom ingate, 10-Waste liquid and gas discharge channel, 11-Filter screen, 12-Chiller. Detailed Implementation

[0028] 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 embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Specific Implementation Example 1:

[0030] Please see Figure 1-5 As shown, this invention is a wet sand casting system for a wind turbine housing, including a sprue 2 vertically arranged on one side of the casting 1; a flow channel 3 horizontally connected to the lower end of the sprue 2; a main riser 4 vertically connected to the outlet end of the flow channel 3; a top riser neck 5 and a bottom riser neck 6 arranged side by side from top to bottom on the sidewall of the main riser 4; the top riser neck 5 connected to the circumferential sidewall of the upper flange of the casting 1; the bottom riser neck 6 connected to the circumferential sidewall of the lower flange of the casting 1; the top riser neck 5 and the bottom riser neck 6... A heat-insulating block 7 is provided between the riser neck 6; the heat-insulating block 7 is connected to the side wall of the main riser 4; the bottom of the main riser 4 is horizontally connected to a slow-flow transverse runner 8 with an arc structure; multiple bottom ingates 9 are arranged side by side on the slow-flow transverse runner 8; the multiple bottom ingates 9 are all connected to the circumferential side wall of the lower flange of the casting 1; a pair of vertically arranged waste liquid and gas discharge channels 10 are symmetrically connected to the circumferential side wall of the upper flange of the casting 1; the distance between the main riser 4 and the two waste liquid and gas discharge channels 10 is equal. In use, molten iron is fed into the slow-flow channel 3 through the sprue 2, which reduces the flow rate of the molten iron into the main riser 4. Then, the molten iron enters the cavity of the casting 1 through the top riser neck 5 and the bottom riser neck 6 of the main riser 4. At the same time, the molten iron flows into the slow-flow horizontal sprue 8 through the lower part of the main riser 4 (the flow rate of the molten iron in the slow-flow horizontal sprue 8 is less than that in the slow-flow channel 3). Then, the molten iron enters the bottom of the cavity of the casting 1 through multiple bottom ingates 9, thereby realizing the wet sand casting pouring operation of the wind turbine housing. This not only makes the flow rate of the molten iron entering the cavity low and the filling stable, but also enables the sequential solidification of the wind turbine housing casting, resulting in a high-quality wind turbine housing with high surface quality and no internal defects.

[0031] Among them, such as Figure 3 and Figure 5 As shown, a conventional filter screen 11 is vertically installed inside the flow channel 3. By installing the filter screen 11 inside the flow channel 3, the molten iron can be filtered, which can reduce the impurity content in the molten iron entering the mold cavity, improve the purity of the molten iron entering the mold cavity, and improve the flow performance and appearance quality of the casting, thus ensuring the casting quality of the wind turbine housing. Specific Implementation Example 2:

[0033] Based on specific embodiment one, 4 and Figure 6-7As shown, a pair of arc-shaped chills 12 are symmetrically installed on the lower part of the upper flange of casting 1; both chills 12 are located on the side of the waste liquid and gas discharge channel 10 away from the main riser 4; the distance between the two chills 12 and the main riser 4 is equal. In use, by setting chills on the side of the waste liquid and gas discharge channel 10 away from the main riser 4, the problem of insufficient feeding distance of the upper flange riser of casting 1 can be solved, realizing the sequential solidification of casting 1 and effectively eliminating internal defects of the wind turbine housing.

[0034] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A green sand foundry gating system for a windmill box, characterized in that, Including the vertical setting in the casting (1) one side of the sprue (2);The lower end of the sprue (2) is horizontally connected with the buffer channel (3);The outlet end of the buffer channel (3) is vertically connected with the main riser (4); The side wall of the main riser (4) is provided with top layer riser neck (5) and bottom layer riser neck (6) from top to bottom side by side;The top layer riser neck (5) is connected to the upper flange circumferential side wall of the casting (1);The bottom layer riser neck (6) is connected to the lower flange circumferential side wall of the casting (1);The top layer riser neck (5) and bottom layer riser neck (6) are provided with heat preservation block (7);The heat preservation block (7) is connected to the side wall of the main riser (4); The bottom of the main riser (4) is horizontally connected with the buffer cross runner (8);The buffer cross runner (8) is provided with a plurality of bottom layer inner gate (9) side by side;A plurality of bottom layer inner gate (9) are connected to the lower flange circumferential side wall of the casting (1);The upper flange circumferential side wall of the casting (1) is symmetrically connected with a pair of vertical waste liquid and gas discharge channel (10); The lower part of the upper flange of the casting (1) is symmetrically provided with a pair of cold iron (12) with arc structure; Two cold iron (12) are arranged on the side of the waste liquid and gas discharge channel (10) away from the main riser (4).

2. A wet sand casting gating system for a windmill box according to claim 1, characterized in that The inside of the buffer channel (3) is vertically provided with filter screen (11).

3. A wet sand casting gating system for a wind power nacelle according to claim 1 or 2, characterized in that, The distance between the main riser (4) and two waste liquid and gas discharge channel (10) is equal.

4. A wet sand casting gating system for a windmill housing according to claim 1, characterized in that The distance between two cold iron (12) and the main riser (4) is equal.

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