Filter screen assembly and method and apparatus for making same

Abstract

This invention relates to a filter assembly and its manufacturing method and apparatus. The method includes assembling at least two filter screens, wherein the at least two filter screens have the same structure, size, and mesh count, and the filter screens have a centrally symmetrical structure. The manufacturing method includes: fixing a first filter screen at a first angle; fixing a second filter screen at a second angle; placing a support member on the second filter screen fixed at the second angle; translating the first filter screen placed at the first angle onto the support member, so that the first filter screen, support member, and second filter screen are stacked sequentially; and fixing the stacked first filter screen, support member, and second filter screen together to form a filter assembly. The angle is the angle of rotation of the filter screen around its center, and the first angle and the second angle are different. The purpose is to obtain a stacked filter assembly with consistent porosity. This invention solves the technical problem of poor quality consistency of the formed castings caused by inconsistent porosity.

Description

Technical Field

[0001] This invention relates to the field of casting technology, and in particular to a filter screen assembly and its manufacturing method and apparatus. Background Technology

[0002] During the casting process of aluminum alloy compressor housings, a filter screen (placed at the sand core inlet of the pouring cup) must be used to filter the oxide slag in the molten aluminum; otherwise, slag porosity will appear in the casting, leading to scrap. Conventional filter screens include two types: one is a fiber filter screen, usually in sheet form, which has poor filtration efficiency when used as a single layer but is lower in cost; the other is a ceramic filter screen, usually in block form, which has a longer flow path and residence time, resulting in better spatial filtration, but is more expensive.

[0003] For fiber filters, to achieve better filtration results, at least two filters are typically randomly stacked together before being placed into the pouring cup core. See also Figure 1 This diagram illustrates a structure in the prior art where three fiber filter screens 1 are randomly stacked together. The problem with this randomly stacked structure is that, due to the random stacking, the pore size of the filter screens used in each casting is inconsistent, leading to poor quality consistency in the formed castings, i.e., poor product quality stability, with the slag rejection rate fluctuating between 5% and 10%. Furthermore, because each screen is a very thin sheet structure, the three fiber filter screens 1 stacked together only provide planar, one-time filtration, without forming a spatial structure; the spatial filtration effect is still much worse than that of ceramic filter screens. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a filter screen assembly and its manufacturing method and apparatus, with the aim of obtaining a superimposed filter screen assembly with consistent porosity, thereby solving the technical problem of poor quality consistency in the formed castings caused by inconsistent porosity.

[0005] The technical solution adopted in this invention is as follows:

[0006] This invention provides a method for manufacturing a filter assembly, comprising assembling at least two filter screens, wherein the at least two filter screens have the same structure, size, and mesh count, and the filter screens have a centrally symmetrical structure. The manufacturing method includes:

[0007] The first filter screen is fixed at a first angle;

[0008] The second filter screen is fixed at the second angle;

[0009] A support is placed on the second filter screen, which is fixed at the second angle;

[0010] The first filter screen, which is placed at the first angle, is moved to the support member, so that the first filter screen, the support member, and the second filter screen are stacked in sequence.

[0011] The first filter, the support, and the second filter are stacked sequentially and fixedly connected to form a filter assembly.

[0012] The angle is the angle at which the filter rotates around its center, and the first angle and the second angle are different.

[0013] The further technical solution is as follows:

[0014] The step of fixing the first filter screen at a first angle includes:

[0015] The mesh on the first filter screen is inserted and matched with the first set of positioning posts at preset positions, and the first filter screen is fixedly placed at a first angle.

[0016] The step of fixing the second filter at a second angle includes:

[0017] The mesh on the second filter screen is inserted and engaged with the second set of positioning posts at preset positions, thereby fixing the second filter screen at a second angle.

[0018] A support member is placed on the second filter screen, which is fixed at the second angle, including:

[0019] Place the support at the center of the filter screen so that the two are coaxial.

[0020] The step of moving the first filter screen, which is placed at the first angle, onto the support member, so that the first filter screen, the support member, and the second filter screen are stacked in sequence, includes:

[0021] By passing the connector through the center of the first filter placed at a first angle, the first filter is moved horizontally above the support. Then, the connector passes through the support and the second filter from the center, so that the three are coaxially connected on the connector and stacked in sequence into a whole.

[0022] Remove the entire assembly from the connector and attach it to form a filter assembly.

[0023] The present invention also provides a filter assembly, manufactured according to the method for manufacturing the filter assembly, comprising at least two filter screens and at least one support body;

[0024] A support member is sandwiched between two adjacent filter screens and fixedly connected to form a stacked structure;

[0025] In the stacked structure, adjacent filter screens are separated by supports so that they do not come into contact.

[0026] In the stacked structure, the first filter is placed at a first angle, and the second filter is set at a second angle.

[0027] As a further improvement to the above technical solution:

[0028] The thickness of the filter screen may be the same as or different from the thickness of the support; the filter screen is a fiber filter screen; the support is an asbestos gasket.

[0029] The present invention also provides an apparatus for manufacturing a filter assembly, comprising:

[0030] The positioning part has at least two positioning slots. The first positioning slot is provided with a first positioning post for placing the first filter screen at a first angle, and the second positioning slot is provided with a second positioning post for placing the second filter screen at a second angle.

[0031] The pick-and-place unit includes a handle, a guide sleeve, a connecting rod, and a spring. The lower end face of the handle is provided with a needle. The handle is fitted into the guide sleeve and can slide along it, so that the needle can extend out of the opening at the lower part of the guide sleeve. The connecting rod is respectively disposed on the guide sleeve and the handle. The two ends of the spring are respectively connected to the connecting rod located on the guide sleeve and the handle. The spring is used to provide preload and restoring force, so that the needle retracts into the guide sleeve.

[0032] The further technical solution is as follows:

[0033] The positioning groove is also provided with a clearance hole to provide clearance when the needle penetrates the filter screen.

[0034] The beneficial effects of this invention are as follows:

[0035] This application uses filter screens stacked together at a specific angle and fixedly connected to form a filter screen assembly, resulting in stable pores and consistent casting quality. Supports are placed between adjacent filter screens to separate them, forming a spatial structure along the stacking direction. When liquid flows through this structure, each layer of filter screen ensures effective filtration, expanding the contact area and increasing residence time, thereby significantly improving filtration performance.

[0036] Other features and advantages of the invention will be set forth in the following description or may be learned by practicing the invention. Attached Figure Description

[0037] Figure 1 This is a schematic diagram of the superimposed structure of fiber filter screens in the prior art.

[0038] Figure 2 This is a flowchart illustrating the manufacturing method of Embodiment 1 of the present invention.

[0039] Figure 3 This is a schematic diagram of the structure of the first filter assembly manufactured according to Embodiment 1 of the present invention.

[0040] Figure 4This is a flowchart illustrating the manufacturing method of Embodiment 2 of the present invention.

[0041] Figure 5 This is a schematic diagram of the structure of the second filter assembly manufactured according to Embodiment 2 of the present invention.

[0042] Figure 6 This is a schematic diagram of the positioning part of the manufacturing device in Embodiment 3 of the present invention.

[0043] Figure 7 This is a schematic diagram of the positioning part of the manufacturing device in the working state of Embodiment 3 of the present invention.

[0044] Figure 8 for Figure 7 Enlarged view of section A.

[0045] Figure 9 This is a schematic diagram of the pick-and-place section of the manufacturing device in Embodiment 3 of the present invention.

[0046] Figure 10 This is a flowchart of the process of taking and placing the filter screen (assembly) in the device for manufacturing embodiment 3 of the present invention.

[0047] Figure 11 This is a schematic diagram showing the cooperation state between the positioning part and the picking and placing part of the manufacturing device in Embodiment 3 of the present invention.

[0048] In the diagram: 1. Fiber filter screen; 2. Support component; 4. Clearance hole; 5. First set of positioning posts; 6. Guide hole; 7. Handle; 8. Spring; 9. Guide sleeve; 10. First filter screen; 11. Guide post; 12. Second set of positioning posts; 13. Third set of positioning posts; 14. Needle; 20. Second filter screen; 30. Third filter screen; 31. First positioning groove; 32. Second positioning groove; 33. Third positioning groove; 34. Component placement groove; 201. First support component; 202. Second support component; 100. First filter screen assembly; 200. Second filter screen assembly. Detailed Implementation

[0049] The specific embodiments of the present invention are described below with reference to the accompanying drawings.

[0050] Example 1

[0051] See Figure 2 This embodiment provides a method for manufacturing a filter assembly, which involves assembling two filter screens. The two filter screens have the same structure, size, and mesh count, and the filter screens have a centrally symmetrical structure. The manufacturing method includes:

[0052] The first filter 10 is fixed at a first angle;

[0053] The second filter 20 is fixed at the second angle;

[0054] A support member 2 is placed on the second filter screen 20, which is fixed at a second angle;

[0055] The first filter 10, which is placed at the first angle, is moved to the support 2, so that the first filter 10, the support 2, and the second filter 20 are stacked in sequence.

[0056] The first filter screen 10, the support member 2, and the second filter screen 20, stacked sequentially, are fixedly connected to form the first filter screen assembly 100, such as... Figure 3 As shown;

[0057] The angle is the angle at which the filter rotates around its center; the first angle and the second angle are different.

[0058] Specifically, fixing the first filter at a first angle includes:

[0059] The mesh on the first filter screen is inserted and matched with the first set of positioning posts at preset positions, and the first filter screen is fixedly placed at a first angle.

[0060] The step of fixing the second filter at a second angle includes:

[0061] The mesh on the second filter screen is inserted and engaged with the second set of positioning posts at preset positions, thereby fixing the second filter screen at a second angle.

[0062] A support member is placed on the second filter screen, which is fixed at a second angle, including:

[0063] Place the support at the center of the filter screen so that the two are coaxial.

[0064] The first filter screen, positioned at a first angle, is moved horizontally onto the support, so that the first filter screen, the support, and the second filter screen are stacked sequentially, including:

[0065] The first filter is moved to the top of the support by passing through the center of the first filter placed at the first angle with the connecting piece. Then, the connecting piece passes through the support and the second filter from the center position, so that the three are coaxially connected on the connecting piece and stacked into a whole.

[0066] Remove the entire assembly from the connector and staple it (using a stapler) into a filter assembly.

[0067] Example 2

[0068] See Figure 4 This embodiment provides a method for manufacturing a filter assembly. The difference from Embodiment 1 is that three filter screens are assembled. The three filter screens have the same structure, size, and mesh count, and the filter screens have a centrally symmetrical structure. The manufacturing method includes:

[0069] The first filter 10 is fixed at a first angle;

[0070] The second filter 20 is fixed at the second angle;

[0071] The third filter 30 is fixed at a third angle;

[0072] A first support member 201 is placed on a second filter screen 20 that is fixed at a second angle;

[0073] A second support 202 is placed on the third filter screen 30, which is fixed at a third angle;

[0074] The first filter 10, which is placed at the first angle, is moved to the first support 201, so that the first filter 10, the first support 201, and the second filter 20 are stacked in sequence to form a first assembly.

[0075] The first assembly is moved onto the second support 202, so that the first filter 10, the first support 201, the second filter 20, the second support 202, and the third filter 30 are stacked in sequence to form the second assembly;

[0076] The second assembly is fixedly connected to form the second filter assembly 200, such as Figure 5 As shown;

[0077] Here, the angle is the angle at which the filter rotates around its center. The first angle is different from the second angle, and the third angle is different from the second angle, but can be the same as the first angle. That is, the angles of two adjacent filters in the stacked structure are different.

[0078] As can be seen from Examples 1 and 2, if the number of filters is increased, the corresponding filter components can be obtained by repeatedly stacking and fixing them according to the above rules.

[0079] The filter assembly prepared according to Examples 1 and 2 includes at least two filter screens and at least one support.

[0080] A support member is sandwiched between two adjacent filter screens and fixedly connected to form a stacked structure;

[0081] In the stacked structure, adjacent filter screens are separated by supports so that they do not come into contact;

[0082] In the stacked structure, the first filter is placed at a first angle, and the second filter is set at a second angle.

[0083] Specifically, the thickness of the filter screen may be the same as or different from the thickness of the support component;

[0084] Specifically, the filter is a fiber filter;

[0085] Preferably, the support is an asbestos gasket.

[0086] Example 3

[0087] See Figures 6 to 9 The apparatus for manufacturing the filter assembly in this embodiment includes:

[0088] Positioning part, such as Figures 6 to 8 As shown, it has at least two positioning slots. The first positioning slot 31 is provided with a first set of positioning posts 5 for placing the first filter screen 10 at a first angle. The second positioning slot 32 is provided with a second set of positioning posts 12 for placing the second filter screen 20 at a second angle. The third positioning slot 33 is provided with a third set of positioning posts 13 for placing the third filter screen 30 at a third angle.

[0089] Take-out section, such as Figure 9 As shown, the device includes a handle 7, a guide sleeve 9, a connecting rod, and a spring 8. The lower end face of the handle 7 is provided with a needle 14. The handle 7 is fitted in the guide sleeve 9 and can slide along it, so that the needle 14 can extend out of the opening at the lower part of the guide sleeve 9. The connecting rod is respectively set on the guide sleeve 9 and the handle 7. The two ends of the spring 8 are respectively connected to the connecting rod located on the guide sleeve 9 and the handle 7. The spring 8 is used to provide preload and restoring force, so that the needle 14 retracts into the guide sleeve.

[0090] The positioning posts are fixed in place to limit the angle of the filter, ensuring that the filter is always placed at the same angle. See details below. Figure 6 The first set of positioning posts 5 includes two first posts, symmetrically arranged around the center of the positioning groove. The straight line connecting the two first posts is called the first straight line, and its angle is named 0°. The corresponding first filter screen is placed at the first angle, i.e., 0°. The second set of positioning posts 12 includes two second posts, symmetrically arranged around the center of the positioning groove. The straight line connecting the two second posts is called the second straight line, with an angle of 30° relative to the first straight line. The corresponding second filter screen is placed at the second angle, i.e., 30°. The third set of positioning posts 13 includes two third posts, symmetrically arranged around the center of the positioning groove. The straight line connecting the two third posts is called the third straight line, with an angle of 0° relative to the first straight line. The corresponding third filter screen is placed at the third angle, i.e., 0°. By setting a fixed angle each time and superimposing the angles sequentially, a filter screen assembly with a fixed porosity can be obtained.

[0091] In use, the manufacturing apparatus involves the pick-and-place unit taking and placing the filter screen and support components from the positioning slot of the positioning unit. The process of the pick-and-place unit taking and placing the filter screen is as follows: Figure 10As shown, the needle acts as a connector, inserting downwards into the mesh of the first filter 10 to fix the first filter 10 in the first positioning groove onto the needle 14. Then, the first filter 10 is moved to the second positioning groove and inserted downwards, sequentially connecting the first support member 201 and the second filter 20. It continues to move to the third positioning groove and inserts downwards, sequentially connecting the first support member 201, the second filter 20, the second support member 202, and the third filter 30. When the handle 7 returns to its original position under the action of the spring, the guide sleeve 9 is pushed downwards relative to the handle 7, and the needle 14 retracts, allowing the assembled filter assembly to be removed from the needle 10.

[0092] The structure of the fabrication device in use in this embodiment is shown in the figure. Figure 11 The positioning part can also be provided with a component placement slot 34 for placing the filter component removed from the needle, and then the filter component is fixed by stapler.

[0093] The positioning groove is also provided with a clearance hole 4 to provide clearance when the needle 14 penetrates the filter screen.

[0094] Preferably, guide posts 11 are provided on both sides of the positioning groove, and guide holes 6 are provided on both sides of the take-up and put-down part guide sleeve 9 for cooperating with the guide posts 11. The guide sleeve 9 moves on the guide posts 11 through the guide holes 6, restricting the movement trajectory when taking up and putting down the fiber filter screen, so that the needle can penetrate into the center of the filter screen every time it is taken up and put down.

[0095] This invention effectively improves filtration performance and, compared to ceramic filters, reduces costs by using fiber filters.

[0096] It will be understood by those skilled in the art that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. 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. A method of making a filter screen assembly, comprising: At least two filter screens are assembled, wherein the at least two filter screens have the same structure, size, and mesh count, and the filter screens have a centrally symmetrical structure. The manufacturing method includes: The first filter screen is fixed at a first angle, comprising: The mesh on the first filter screen is inserted and matched with the first set of positioning posts at the preset position, and the first filter screen is fixed at the first angle. The second filter screen is fixed at a second angle, which includes: The mesh on the second filter screen is inserted and engaged with the second set of positioning posts at the preset positions, thereby fixing the second filter screen at the second angle. Placing a support member on the second filter screen, which is fixed at the second angle, includes: placing the support member at the center of the second filter screen so that the two are coaxially arranged. The first filter screen, positioned at the first angle, is moved horizontally onto the support member, such that the first filter screen, the support member, and the second filter screen are stacked sequentially, comprising: The first filter is moved horizontally above the support by passing the connector through the center of the first filter placed at the first angle. Then, the connector passes through the support and the second filter from the center position, so that the three are coaxially connected on the connector and stacked into a whole. The first filter, support member and second filter are stacked in sequence and fixedly connected to form a filter assembly, which includes removing the whole from the connecting member and fixing it into a filter assembly; Adjacent filter screens are separated by supports so that they do not come into contact; The angle is the angle at which the filter rotates around its center, and the first angle and the second angle are different.

2. The manufacturing method according to claim 1, characterized in that, The filter assembly produced by the manufacturing method comprises at least two filter screens and at least one support. A support member is sandwiched between two adjacent filter screens and fixedly connected to form a stacked structure; In the stacked structure, adjacent filter screens are separated by supports so that they do not come into contact. In the stacked structure, the first filter is placed at a first angle, and the second filter is set at a second angle.

3. The manufacturing method according to claim 1, characterized in that, The thickness of the filter screen may be the same as or different from the thickness of the support; the filter screen is a fiber filter screen; the support is an asbestos gasket.

4. A manufacturing apparatus for performing the manufacturing method according to any one of claims 1-3, characterized in that, include: The positioning part has at least two positioning slots. The first positioning slot is provided with a first set of positioning posts for placing the first filter screen at a first angle, and the second positioning slot is provided with a second set of positioning posts for placing the second filter screen at a second angle. The pick-and-place unit includes a handle, a guide sleeve, a connecting rod, and a spring. The lower end face of the handle is provided with a needle. The handle is fitted into the guide sleeve and can slide along it, so that the needle can extend out of the opening at the lower part of the guide sleeve. The connecting rod is respectively disposed on the guide sleeve and the handle. The two ends of the spring are respectively connected to the connecting rod located on the guide sleeve and the handle. The spring is used to provide preload and restoring force, so that the needle retracts into the guide sleeve.

5. The manufacturing apparatus according to claim 4, characterized in that, The positioning groove is also provided with a clearance hole to provide clearance when the needle penetrates the filter screen.

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