Low-carbon development green casting application demonstration center

Abstract

The application provides a low-carbon development green casting application demonstration center, which comprises a molding sand storage area for storing various molding sands used in processing; a negative pressure blank preparation area provided with an automatic sand mixing device, a vibration compaction device and a negative pressure molding device, which is used for preparing frozen sand blanks with a set water-sand mixing ratio and an outer shape size; a frozen processing area provided with a vertical cutting forming equipment for frozen sand molds, a horizontal cutting forming equipment for frozen sand molds and a printing forming equipment for frozen sand molds, which are used for processing frozen sand molds (cores); a cryogenic storage area provided with a cryogenic refrigerator and a partition gradient refrigerator; a smelting and pouring area provided with a negative pressure pouring device; a material transfer channel, which is a special channel planned for an AGV carrier; and a central control system for monitoring and controlling the states of various regional modules and coordinating and planning the actions of each region. The application adopts digital and intelligent equipment, has high production efficiency, high precision and quality of obtained castings, and sand drop can be recycled and reused, and the processing process is green, clean and pollution-free.

Description

TECHNICAL FIELD

[0001] The application relates to a system integration and application demonstration center for digital processing of each process in the field of freeze casting, in particular to a low-carbon development green casting application demonstration center. BACKGROUND

[0002] Casting is widely used in various industries as a basic industry of mechanical manufacturing, but the traditional casting industry has problems such as backward technology, high labor intensity, poor working environment, long production cycle, serious pollution, and difficulty in manufacturing large and complex castings and difficulty in ensuring size accuracy. With the development of technology, new technologies such as sand extrusion forming, sand cutting forming, sand 3D printing forming, and freeze casting forming have emerged, and certain achievements have been made in rapid manufacturing and green manufacturing, and the manufacturing process is more flexible and flexible, with higher size accuracy and significantly shorter development cycle. Some enterprises have introduced the above technologies, but the technologies are independent of each other, there is no supporting digital equipment for pre-processing and post-processing, and a complete digital production line is formed. There is still a lot of room for improvement in production efficiency, cost savings, greenness, digitization, and networking. The Mechanical Science Research Institute has proposed a digital moldless casting island, forming a complete sand digital processing production line. However, the sand mold produced by the casting island still uses traditional binder types, which inevitably pollutes the environment and harms the human body during printing, cutting, sintering, and after pouring. The sand is difficult to collapse, the parts are difficult to remove, and there is no sand recycling function, resulting in sand waste and the need for professional means to handle waste sand.

[0003] Therefore, based on the freeze sand mold rapid manufacturing technology and the concept of digital production line, a digital freeze sand mold green casting system is built to realize digital and intelligent production of large, complex and high-precision freeze sand molds (cores), improve sand mold quality and reduce production cycle. And the freeze sand mold uses water as the binder, the whole production process is clean and pollution-free, the sand collapses naturally after pouring, the sand falls easily, and there is a sand falling recycling function, realizing the recycling of sand, saving resources. SUMMARY

[0004] To solve the above problems, the application discloses a low-carbon development green casting application demonstration center, which is an integration of all digital equipment based on freeze sand mold rapid manufacturing technology, can realize full-process manufacturing of large and complex freeze sand molds (cores), and realize closed loop from material supply to waste recycling. The problems of high energy consumption, low production efficiency, long processing cycle, large sand waste and serious environmental pollution in the current casting industry are solved.

[0005] The technical scheme adopted by the application to achieve the above purpose is:

[0006] A low-carbon development green casting application demonstration center, comprising: a molding sand storage area for storing various molding sands used for processing; a negative pressure blank making area, which is divided into an automatic sand mixing area, a vibration compaction area and a negative pressure molding area, for mixing water and molding sand in a set proportion and making frozen sand blanks; a frozen processing area, which is divided into a frozen sand mold vertical cutting forming area, a frozen sand mold horizontal cutting forming area and a frozen sand mold printing forming area, for cutting processing frozen sand blanks or directly printing forming frozen sand molds (cores); a cryogenic storage area, which is provided with a cryogenic freezer and a partition gradient freezer, for further freezing and strengthening the processed frozen sand molds, and for coating, assembling and storing; a smelting and pouring area, which is divided into a negative pressure pouring area and a cleaning and sand removal area, for smelting various materials, negative pressure pouring and sand cleaning and recycling; a material transfer channel specially planned for AGV carriers; AGV carriers for realizing material transfer; and a central control system for monitoring and controlling the state of each area module and coordinating the action of each area.

[0007] Further, the molding sand storage area is further divided into multiple areas according to the types and mesh numbers of the molding sands, and is identified by codes, so as to facilitate the identification and automatic transfer of the molding sands; and the raw sands are stored separately and identified by codes, so as to facilitate the storage and access.

[0008] Further, multiple automatic sand mixing devices are placed in the negative pressure blank making area, each of which is responsible for only one type of molding sand, so as to realize the mixing of molding sand and water in any proportion; and the raw materials can be pretreated in time.

[0009] Further, multiple vibration compaction devices are placed in the vibration compaction area, multiple size cavity molds are provided, and the vibration compaction of mixed water molding sand is realized to form a precast sand blank.

[0010] Further, multiple negative pressure molding devices are placed in the negative pressure molding area, liquid nitrogen cooling method is adopted to rapidly cool the precast sand blank, the sand blank can be cooled to-40 DEG C at the lowest, and a frozen sand blank is formed.

[0011] Further, multiple frozen sand mold printing forming devices are placed in the frozen sand mold printing forming area, the printing device adopts inkjet printing method, uses water as a binder, and realizes the rapid forming of single material or multi-material frozen sand molds (cores) through layer-by-layer printing and freezing forming; the molding sand in the non-printing area is collected and recycled; the sand in all processing processes can be recycled; the printing method is different, and there are vertical cutting and horizontal cutting two choices, which are suitable for different situations.

[0012] Further, the horizontal cutting forming area of the frozen sand mold is placed with multiple types of horizontal cutting forming devices of the frozen sand mold, the horizontal cutting forming of the frozen sand blank is carried out, the sand is easily discharged in the cutting process, and the horizontal cutting forming device is generally used for the machining of the frozen sand mold with complex structure and relatively complex operation.

[0013] Further, the vertical cutting forming area of the frozen sand mold is placed with multiple types of vertical cutting forming devices of the frozen sand mold, the vertical cutting forming of the frozen sand blank is carried out, the sand is discharged in the cutting process, and the vertical cutting forming device is generally used for the machining of the frozen sand mold with simple structure and simple operation.

[0014] Further, the lowest temperature of the deep cooling refrigerator can reach-40 DEG C and is dry, the automatic coating equipment of the sand mold (core) and the sand mold storage rack are arranged in the deep cooling refrigerator, the automatic coating of the frozen sand mold (core) is carried out, and the frozen sand mold (core) is arranged.

[0015] Further, the lowest temperature of the deep cooling refrigerator can reach-40 DEG C and is dry, the automatic coating equipment of the sand mold (core) and the sand mold storage rack are arranged in the deep cooling refrigerator, the automatic coating of the frozen sand mold (core) is carried out, and the frozen sand mold (core) is arranged.

[0016] Further, multiple negative pressure pouring devices are placed in the negative pressure pouring area, and the melting and pouring of multiple metals can be realized.

[0017] Further, the sand cleaning device is arranged in the sand cleaning area, and the collapsed sand can be quickly collected.

[0018] Further, the material running channel only allows the AGV carrier to travel in one direction according to the mark in the normal working state, and does not allow people or other articles to occupy the channel.

[0019] Further, the AGV carrier is provided with a mechanical arm, and the functions of automatic route searching, code identification, material loading and unloading and the like can be realized.

[0020] Advantages of the application

[0021] The low-carbon development green casting application demonstration center provided by the application can realize the automatic production of the frozen sand mold, does not need to make a mold, has high production efficiency, greatly shortens the production cycle, and the machining, assembly and monitoring processes of the frozen sand mold are all completed by the automatic equipment, so that the product quality is high and the consistency is good.

[0022] The frozen sand mold is made by using water as the binder in the application, the whole production process is clean and pollution-free, and does not cause any harm to the human body. After pouring is completed, the frozen sand mold is automatically collapsed, the cleaning of the shakeout is easy, recycling is convenient, the waste sand recycling rate is high, recycling can be realized, and resources can be saved. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 It is a schematic diagram of the overall arrangement structure of the application;

[0024] Figure 2 It is a schematic diagram of the relationship between the regions of the application;

[0025] Figure 3 It is a schematic diagram of the frozen casting process of the application;

[0026] Illustration mark:

[0027] 1 - sand storage area, 2 - negative pressure molding area, 201 - automatic sand mixing area, 202 - vibration compaction area, 203 - negative pressure molding area, 3 - frozen processing area, 301 - frozen sand mold printing forming area, 302 - horizontal cutting forming area of frozen sand mold, 303 - vertical cutting forming area of frozen sand mold, 4 - cryogenic storage area, 401 - cryogenic freezer, 402 - partition gradient freezer, 5 - melting and pouring area, 501 - negative pressure pouring area, 502 - cleaning and shakeout area, 6 - material transfer channel, 7 - AGV carrier, 8 - central control system. DETAILED DESCRIPTION

[0028] The application will be further illustrated below in combination with the drawings and specific embodiments, and it should be understood that the following specific embodiments are only used to illustrate the application and are not used to limit the scope of the application. It should be noted that the words "front", "back", "left", "right", "up" and "down" used in the following description refer to the directions in the drawings, and the words "in" and "out" refer to the directions towards or away from the geometric center of a particular component.

[0029] Figure 1 And Figure 2 It is a structure layout diagram and a region relationship diagram of a low-carbon development green casting application demonstration center of the application. Mainly includes: sand storage area 1, negative pressure molding area 2, automatic sand mixing area 201, vibration compaction area 202, negative pressure molding area 203, frozen processing area 3, frozen sand mold printing forming area 301, horizontal cutting forming area of frozen sand mold 302, vertical cutting forming area of frozen sand mold 303, cryogenic storage area 4, cryogenic freezer 401, partition gradient freezer 402, melting and pouring area 5, negative pressure pouring area 501, cleaning and shakeout area 502, material transfer channel 6, AGV carrier 7, central control system 8.

[0030] The molding sand storage area is divided into multiple sections to store molding sand of different types and mesh sizes.

[0031] The negative pressure molding zone is further divided into an automatic sand mixing zone, a vibration compaction zone, and a negative pressure molding zone. It is used to mix water and molding sand in a set ratio and to make the mixed molding sand into frozen sand blanks.

[0032] The cryogenic processing area is further divided into a cryogenic sand mold printing and forming area, a cryogenic sand mold horizontal cutting and forming area, and a cryogenic sand mold vertical cutting and forming area. The cryogenic sand mold (core) is directly printed using a cryogenic sand mold printing and forming device, or the cryogenic sand mold vertical cutting and forming device or the cryogenic sand mold horizontal cutting and forming device is used to cut and process the cryogenic sand blank to make a cryogenic sand mold.

[0033] The cryogenic storage area is equipped with cryogenic cold storage and zoned gradient cold storage to further freeze and strengthen the processed frozen sand molds, and to carry out coating, assembly, dimensional measurement and storage.

[0034] The smelting and casting area is further divided into a negative pressure casting area and a cleaning and sand removal area. It is used to smelt metal, perform negative pressure casting of frozen sand molds, clean and collect the collapsed molding sand after casting, and take out the casting.

[0035] Material transfer channel, a channel specifically designed for AGV transport vehicles.

[0036] AGV (Automated Guided Vehicle) transport vehicles are used to transport materials.

[0037] The central control system monitors and controls the status of each regional module and coordinates and plans the actions of each region.

[0038] Combination Figure 3 The illustrated process uses the fabrication of a complex mold requiring assembly and containing both a sand mold and a sand core as an example. It explains the use of a cryogenic sand mold printing and forming device to create the sand core, and a cryogenic sand mold horizontal cutting and forming device to create the sand mold. First, the 3D model of the casting is used to inversely calculate the 3D shape of the sand mold and sand core. Based on this, the dimensions of the cryogenic sand billet, the control programs for the cryogenic sand mold printing and forming device, and the cryogenic sand mold horizontal cutting device are output. According to the process plan, the appropriate type and mesh size of molding sand are selected. After the above steps are completed, the central control system 8 begins to coordinate the work in each area.

[0039] AGV 7 from the sand storage area 1 loaded with a predetermined amount of sand to the frozen sand print forming area 301, through the frozen sand print forming device layer by layer printing to make the frozen sand core, after printing is completed, the non-printing area of the sand cleaning collection, take out the printed sand core through the AGV 7 transport to the deep freezer 401 storage and generate code identification. At the same time, another AGV 7 from the sand storage area 1 loaded with a predetermined amount of sand to the automatic sand mixing area 201, the automatic sand mixing device according to the set water and sand ratio automatic sand mixing a certain time; the mixed sand is transferred to the vibration compaction area 202, the vibration compaction device according to the size of the frozen sand in the mold sand compaction, forming a prefabricated sand; the prefabricated sand is transferred to the negative pressure molding area 203, the negative pressure molding device using liquid nitrogen gas cooling method, the prefabricated sand is rapidly cooled to-40 DEG C, forming a frozen sand; AGV 7 will make the frozen sand core to the frozen sand horizontal cutting forming area 302, the frozen sand horizontal cutting device according to the control program to the clamping area of the frozen sand core local temperature control, ensure the strength of the frozen sand core while cutting forming, AGV 7 will be processed to the frozen sand mold storage and coding identification, the cut off sand will be collected for recycling.

[0040] According to the coding of the finished frozen sand mold and the frozen sand core in the deep freezer 401 respectively taken out for spraying, using automatic spraying equipment on the sand core, sand core surface uniform spraying a layer of paint. AGV 7 will be sprayed to the sand core, sand core transport to the partition gradient freezer 402. The sand core is transported to the partition gradient freezer 402 and placed on the assembly platform, assembled by the automatic assembly equipment and the size and precision measurement of the cavity, to ensure the size accuracy of the mold. AGV car will be transported to the negative pressure pouring area 501.

[0041] The negative pressure pouring area 501 according to the progress of the mold, will be ahead of the metal smelting, when the mold is transported to the negative pressure pouring area 501, can be poured. After pouring and cooling, the sand is cleaned in the cleaning area 502, and the casting is taken out, and the sand is recycled.

[0042] The technical means disclosed in the scheme of the application is not limited to the technical means disclosed in the above embodiment, but also includes the technical scheme composed of any combination of the above technical features.

Claims

1. A low carbon development green foundry application demonstration center, characterized in that, The application relates to a sand storage area (1), a negative pressure blank making area (2), a frozen processing area (3), a deep cooling storage area (4), a smelting and pouring area (5), a material transfer channel (6), an AGV carrier (7) and a central control system (8); the sand storage area (1) is internally provided with multiple subareas for storing different types and mesh numbers of sands; the negative pressure blank making area (2) is sequentially provided with an automatic sand mixing area (201), a vibration compaction area (202) and a negative pressure molding area (203); the frozen processing area (3) is sequentially provided with a frozen sand mold printing forming area (301), a horizontal frozen sand mold cutting forming area (302) and a vertical frozen sand mold cutting forming area (303); the deep cooling storage area (4) is internally sequentially provided with a deep cooling refrigerator (401) and a subarea gradient cooling refrigerator (402); the smelting and pouring area (5) is internally sequentially provided with a negative pressure pouring area (501) and a sand cleaning area (502); the material transfer channel (6) is a special channel planned for the AGV carrier (7); and the central control system (8) is used for monitoring and controlling the states of the various modules and coordinating the actions of each module.

2. The low carbon development green foundry application demonstration center according to claim 1, characterized in that: The subareas in the sand storage area (1) are allocated with different codes according to the types and mesh numbers of the sands, so that the sand storage and access and automatic carrying are facilitated.

3. The low carbon development green foundry application demonstration center according to claim 1, characterized in that: The automatic sand mixing area (201) is internally provided with multiple automatic sand mixing devices, each of which is responsible for mixing one type of sand with water in any proportion; the vibration compaction area (202) is internally provided with multiple vibration compaction devices, which provide multiple size cavity molds and vibrate and compact the sand mixed with water to form prefabricated sand blanks; and the negative pressure molding area (203) is internally provided with multiple negative pressure molding devices, which adopt liquid nitrogen cooling method to cool the prefabricated sand blanks to a minimum temperature of-40 DEG C, so that the frozen sand blanks are manufactured.

4. The low carbon development green foundry application demonstration center according to claim 1, characterized in that: The frozen sand mold printing forming area (301) is internally provided with multiple types of frozen sand mold printing forming devices, which directly perform inkjet 3D printing forming on the sand from the sand storage area (1) and adopt water as a binder to realize the rapid forming of single material or multi-material frozen sand molds or sand cores; the sand in a non-printing area is collected and recycled; the horizontal frozen sand mold cutting forming area (302) is internally provided with multiple types of horizontal frozen sand mold cutting forming devices, which perform horizontal cutting forming on the frozen sand blanks; the clamping sand mold area has a local temperature control function to ensure the sand mold strength; and the cut sand is collected and recycled; and the vertical frozen sand mold cutting forming area (303) is internally provided with multiple types of vertical frozen sand mold cutting forming devices, which perform vertical cutting forming on the frozen sand blanks.

5. The low carbon development green foundry application demonstration center according to claim 1, characterized in that: The deep cooling refrigerator (401) has a minimum temperature of-40 DEG C and is dry, is internally provided with a sand mold or sand core automatic coating equipment and a sand mold storage rack, is used for automatically spraying and storing the frozen sand mold coating, automatically generates a code when the sand mold storage rack stores the frozen sand mold, and facilitates identification and subsequent processing.

6. The low carbon development green foundry application demonstration center according to claim 1, characterized in that: The lowest temperature of the partition gradient refrigerator (402) can reach -20 DEG C and is dry, and a sand mold or sand core assembly platform, automatic assembly equipment and a storage rack are arranged inside, and are used for freezing assembly and size precision measurement of the sand mold or sand core.

7. The low carbon development green foundry application demonstration center according to claim 1, characterized in that: Multiple negative pressure pouring devices are placed in the negative pressure pouring area (501), and melting and pouring of multiple metals can be realized; the shakeout cleaning and recycling device in the shakeout cleaning area (502) can quickly collect the collapsed sand.

8. The low carbon development green foundry application demonstration center according to claim 1, characterized in that: The material transfer channel (6) only allows the AGV carrier (7) to travel in one direction according to the mark in normal operation, and does not allow people or other objects to occupy the channel.

9. The low carbon development green foundry application demonstration center according to claim 1, characterized in that: The AGV carrier (7) is provided with a mechanical arm.

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