A vertical composite brake drum centrifugal casting device and method

Abstract

This invention relates to a vertical composite brake drum centrifugal casting device and method, comprising a base plate and a top plate, which are connected and fixed by four guide pillars. Protective plates are provided around the base plate and top plate. A base is located at the center of the base plate, and a rotating unit is rotatably connected within the base. The rotating unit is coupled to an inner mold and an outer mold unit. A casting removal channel is provided on the top plate. This invention is scientifically and rationally designed. The centrifugal motion of the casting liquid within the cavity enables the casting of the brake drum from the outside in, thus allowing the casting of a composite brake drum with a steel outer layer and a cast iron inner layer, resulting in a denser microstructure and improved quality and performance. Simultaneously, the movable plate drives the vertical movement and horizontal sliding of the flat outer mold to achieve mold opening and casting, enabling the casting of special-shaped brake drums with spiral or reinforcing ribs on the outer surface and similar rotating parts.

Description

Technical Field

[0001] This invention belongs to the field of casting equipment technology, specifically relating to a vertical composite brake drum centrifugal casting device and method. Background Technology

[0002] Brake drums are the friction pairs of drum brakes. In addition to having the strength and rigidity required as components, they should also have the highest and most stable coefficient of friction, as well as high wear resistance, heat resistance, and heat dissipation. Brake drums are widely used in heavy-duty trucks.

[0003] Brake drums were originally made using clay sand casting, a method that not only produces a lot of dust and fumes, but also consumes a lot of electricity, has high resource costs, and is environmentally unfriendly. Composite brake drums are now produced using a steel plate spinning shell and centrifugal casting of the inner layer, a technology that results in high equipment costs, a long production process, and a low yield rate. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a vertical composite brake drum centrifugal casting device and method.

[0005] The technical problem solved by this invention is achieved through the following technical solution:

[0006] A vertical composite brake drum centrifugal casting device is characterized in that: it includes a base plate and a top plate, the base plate and the top plate are connected and fixed by four guide columns, both sides of the base plate and the top plate are provided with protective plates, a base is provided at the center of the base plate, a rotating unit is rotatably connected in the base, the rotating unit is connected with an inner mold and an outer mold unit, and a casting removal channel is provided on the top plate.

[0007] Furthermore, the rotating unit includes a main shaft, a rotating disk, and an inner mold. Both ends of the main shaft are rotatably connected to the base via bearing seats and end face bearings. The rotating disk is fixedly mounted on the upper end of the main shaft, and the inner mold is fixedly mounted on the rotating disk. A guide cap is provided at the top of the inner mold. A fixing ring connecting rod is fixedly mounted on the bearing seat at the lower end of the base. The lower end of the fixing ring connecting rod is connected to a rotating joint fixing ring. A cooling water pipe seat is fixedly connected to the bottom end of the main shaft. A cooling water pipe is coaxially fitted inside the cooling water pipe seat. The upper end of the cooling water pipe extends into the inner mold. Several water outlet holes are provided at the upper end of the cooling water pipe. A water pipe elbow is connected to the lower end of the cooling water pipe. A synchronous pulley is fitted on the lower part of the main shaft. A motor is mounted on the base plate via a motor seat. A synchronous pulley is fitted on the motor shaft of the motor, and the main shaft is driven to rotate by the synchronous belt.

[0008] Furthermore, the inner and outer mold unit includes a movable plate and an outer mold mounting plate that slides left and right on the movable plate, as well as a flat outer mold. Both the outer mold mounting plate and the flat outer mold are composed of two symmetrical parts. The movable plate is connected to the guide post through a guide sleeve. Lifting cylinder connectors are provided on both sides below the movable plate. A lifting cylinder is installed on the bottom plate. The cylinder rod of the lifting cylinder drives the movable plate to move up and down along the guide post through the cylinder connector. Two sliding pads are arranged parallel to each other on the movable plate. The outer mold mounting plate is slidably installed on the sliding pads. The flat outer mold is installed on the outer mold mounting plate. The flat outer mold cooperates with the inner mold of the rotating unit. A mold closing ring is installed at the top of the flat outer mold. Mold opening cylinder seats are fixedly installed at both ends of the top plate. Mold opening cylinders are installed on the mold opening cylinder seats. The cylinder rod end of the mold opening cylinder is connected to the mold opening cylinder connector. Mold opening grooves are provided on both sides of the outer mold mounting plate. The mold opening cylinder connector is engaged with the mold opening groove.

[0009] A casting method for a vertical composite brake drum centrifugal casting device, characterized in that the method comprises the following steps:

[0010] S1. Mold Closing: The mold opening cylinder pushes the outer mold to move towards the center, and the two halves of the outer mold close and are positioned. The lifting cylinder installed on the base plate moves downward, driving the movable plate and the flat outer mold to move downward, so that the flat outer mold cooperates with the inner mold on the rotating plate, completing the mold closing of the flat outer mold and the inner mold. The movable plate continues to descend, and the mold separates from the movable plate.

[0011] S2. Centrifugal casting: Start the motor and drive the main shaft to rotate through the synchronous belt, thereby driving the rotating disk and mold to rotate, pour in the molten metal, and the molten metal moves outward under the action of centrifugal force to achieve casting from the inside to the outside;

[0012] S3, Casting cooling: Cold water is introduced into the lower end of the water pipe elbow, and the cold water is sprayed into the inner mold through the water outlet on the cooling water pipe to cool the inner mold.

[0013] S4. Mold Opening: After casting is completed, the lifting cylinder is activated to drive the movable plate upward, which in turn drives the outer mold to move upward. The casting rises along with the outer mold and separates from the inner mold. When the movable plate reaches the set position, the lifting cylinder stops. The mold opening cylinder connector at the end of the mold opening cylinder engages with the mold opening groove on the outer mold mounting plate. Then, the mold closing ring on the outer mold is removed. After the robotic arm clamps the casting, the mold opening cylinder moves outward, causing the outer mold mounting plate and the two parts of the outer mold to separate from each other on the movable plate along the sliding pad, thus completing the mold opening and part removal.

[0014] The advantages and beneficial effects of this invention are as follows:

[0015] 1. The vertical composite brake drum centrifugal casting device of the present invention can cast composite brake drums by first casting molten steel and then casting molten iron, thereby producing brake drums with higher strength and lighter weight.

[0016] 2. The vertical composite brake drum centrifugal casting device of the present invention realizes the mold opening and removal of the casting by driving the horizontal movement and horizontal sliding of the flat outer mold through the movable plate. It is convenient to operate and has a high degree of automation. The mold opening and removal of the casting is completed by the horizontal mold opening method, which can cast special brake drums with spiral or reinforcing ribs on the outer surface.

[0017] 3. The vertical composite brake drum centrifugal casting device of the present invention rotates the rotating disk and inner mold evenly and smoothly under the drive of the main shaft, and the guide cap above the inner mold can play a guiding role, protecting the mold from erosion and making casting smoother. Attached Figure Description

[0018] Figure 1 This is the front view of the invention (with the front protective plate removed);

[0019] Figure 2 for Figure 1 The right view;

[0020] Figure 3 for Figure 1 Sectional view along axis AA;

[0021] Figure 4 for Figure 2 BB-direction sectional view;

[0022] Figure 5 This is a schematic diagram of the structure of the present invention (with the front end guard plate removed);

[0023] Figure 6 This is a schematic diagram of the half-section structure of the present invention.

[0024] Explanation of reference numerals in the attached figures

[0025] 1-Top plate, 2-Guard plate, 3-Guide pillar, 4-Bottom plate, 5-Base, 6-Movable plate, 7-Casting removal channel, 8-Guide sleeve, 9-Lifting cylinder, 10-Mold closing ring, 11-Splash shield, 12-Sliding pad, 13-Mold opening probe rod, 14-Mold opening cylinder, 15-Mold opening cylinder connector, 16-Mold opening groove, 17-Flow guide cap, 18-Inner mold, 19-Rotating disc, 20-Motor, 21-Synchronous belt, 22-Synchronous belt pulley, 23-Main shaft, 24-Cooling water pipe seat, 25-Cooling water pipe, 26-Water pipe elbow, 27-Rotary joint fixing ring, 28-Fixing ring connecting rod, 29-Bearing seat, 30-Lifting cylinder connector, 31-Mold opening cylinder seat, 32-Outer mold mounting plate, 33-Flat outer mold, 34-Water outlet. Detailed Implementation

[0026] The present invention will be further described in detail below through specific embodiments. The following embodiments are merely descriptive and not limiting, and should not be used to limit the scope of protection of the present invention.

[0027] An innovative feature of a vertical composite brake drum centrifugal casting device is that it includes a base plate 4 and a top plate 1, which are connected and fixed by four guide columns 3. Both sides of the base plate and the top plate are provided with guard plates 2. A base 5 is provided at the center of the base plate. A rotating unit is rotatably connected inside the base. The rotating unit is connected to an inner mold and an outer mold unit. A casting removal channel 7 is provided on the top plate.

[0028] The rotating unit includes a main shaft 23, a rotating disk 19, and an inner mold 18. Both ends of the main shaft are rotatably connected to the base via bearing seats 29 and end face bearings. The rotating disk is fixedly mounted on the upper end of the main shaft, and the inner mold is fixedly mounted on the rotating disk. A guide cap 17 is provided at the top of the inner mold. A fixing ring connecting rod 28 is fixedly mounted on the bearing seat at the lower end of the base. The lower end of the fixing ring connecting rod is connected to a rotary joint fixing ring 27. There are three fixing ring connecting rods, which are evenly distributed on the rotary joint fixing ring. A cooling water pipe seat 24 is fixedly connected to the bottom end of the main shaft. A cooling water pipe 25 is coaxially installed in the cooling water pipe seat. The upper end of the cooling water pipe extends into the inner mold. Several water outlet holes 34 are provided at the upper end of the cooling water pipe. A water pipe elbow 26 is connected to the lower end of the cooling water pipe. A synchronous pulley 22 is installed on the lower part of the main shaft. A motor 20 is mounted on the base plate via a motor seat. A synchronous pulley 21 is installed on the motor shaft of the motor, and the main shaft is driven to rotate by a synchronous belt.

[0029] The inner and outer mold unit includes a movable plate 6 and an outer mold mounting plate 32 and a flat outer mold 33 that slide left and right on the movable plate. Both the outer mold mounting plate and the flat outer mold are composed of two symmetrical parts. The movable plate is connected to the guide post via a guide sleeve 8. Lifting cylinder connectors 30 are provided on both sides below the movable plate. A lifting cylinder 9 is installed on the base plate. The cylinder rod of the lifting cylinder drives the movable plate to move up and down along the guide post via the cylinder connector. Two sliding pads 12 are arranged parallel to each other on the movable plate, and the inner and outer mold units are slidably mounted on the sliding pads. The outer mold mounting plate is equipped with a hinged outer mold, and a splash guard 11 is installed on the hinged outer mold to prevent the casting liquid from splashing out and causing injury to personnel. The hinged outer mold cooperates with the inner mold of the rotating unit, and a mold closing ring 10 is installed at the top of the hinged outer mold. Mold opening cylinder seats 31 are fixedly installed at both ends of the top plate, and mold opening cylinders 14 are installed on the mold opening cylinder seats. The cylinder rod end of the mold opening cylinder is connected to the mold opening cylinder connector 15. Mold opening grooves 16 are provided on both sides of the outer mold mounting plate, and the mold opening cylinder connector is engaged with the mold opening groove.

[0030] The guard plate is located above the mold opening cylinder and is equipped with a probe rod mounting seat. The mold opening probe rod 13 is installed on the probe rod mounting seat. The mold opening probe rod can accurately detect the position of the movable plate and position and stop the movable plate in time to facilitate mold opening.

[0031] An innovative method for casting a vertical composite brake drum centrifugal casting device is described, with the following steps:

[0032] S1. Mold Closing: The mold opening cylinder pushes the outer mold to move towards the center, and the two halves of the outer mold close and are positioned. The lifting cylinder installed on the base plate moves downward, driving the movable plate and the flat outer mold to move downward, so that the flat outer mold cooperates with the inner mold on the rotating plate, completing the mold closing of the flat outer mold and the inner mold. The movable plate continues to descend, and the mold separates from the movable plate.

[0033] S2. Centrifugal casting: Start the motor and drive the main shaft to rotate through the synchronous belt, thereby driving the rotating disk and mold to rotate, pour in the molten metal, and the molten metal moves outward under the action of centrifugal force to achieve casting from the inside to the outside;

[0034] S3, Casting cooling: Cold water is introduced into the lower end of the water pipe elbow, and the cold water is sprayed into the inner mold through the water outlet on the cooling water pipe to cool the inner mold.

[0035] S4. Mold Opening: After casting is completed, the lifting cylinder is activated to drive the movable plate upward, which in turn drives the outer mold to move upward. The casting rises along with the outer mold and separates from the inner mold. When the movable plate reaches the set position, the lifting cylinder stops. The mold opening cylinder connector at the end of the mold opening cylinder engages with the mold opening groove on the outer mold mounting plate. Then, the mold closing ring on the outer mold is removed. After the robotic arm clamps the casting, the mold opening cylinder moves outward, causing the outer mold mounting plate and the two parts of the outer mold to separate from each other on the movable plate along the sliding pad, thus completing the mold opening and part removal.

[0036] This invention is scientifically and rationally designed. It achieves the casting of the brake drum from the outside to the inside through the centrifugal motion of the casting liquid in the cavity, thereby casting a composite brake drum with a steel outer layer and a cast iron inner layer, and obtaining a denser microstructure, thus improving the quality and performance of the brake drum. At the same time, the mold opening and part removal of the casting is achieved by the up-and-down movement and horizontal sliding of the flat outer mold driven by the movable plate, which can cast special brake drums with spiral or reinforcing ribs on the outer surface and similar rotating parts.

[0037] This invention achieves centrifugal casting of the brake drum through the centrifugal motion of the casting liquid inside the mold, thereby improving the quality and performance of the brake drum. At the same time, the mold opening and part removal of the casting is achieved by the up-and-down movement and horizontal sliding of the outer mold driven by the movable plate. The operation is convenient and highly automated.

[0038] The rotating unit of this invention is firmly connected, and the rotation of the rotating disk and inner mold is uniform and stable under the drive of the main shaft. The guide cap above the inner mold can play a guiding role, protecting the mold from erosion and making the casting smoother.

[0039] The inner and outer mold unit structure of this invention is ingeniously designed. The casting is opened and removed by horizontal mold opening, which is convenient and quick and avoids damage to the casting during the removal process.

[0040] In this invention, the movement of the motor, lifting cylinder, and mold opening cylinder are all controlled by switches installed on the guard plate.

[0041] Although embodiments and drawings of the present invention have been disclosed for illustrative purposes, those skilled in the art will understand that various substitutions, variations and modifications are possible without departing from the spirit and scope of the present invention and the appended claims. Therefore, the scope of the present invention is not limited to the contents disclosed in the embodiments and drawings.

Claims

1. A method for centrifugal casting of a vertical composite brake drum, characterized in that: The casting device used in the casting method includes a bottom plate and a top plate. The bottom plate and the top plate are connected and fixed by four guide columns. Protective plates are provided on both sides of the bottom plate and the top plate. A base is provided at the center of the bottom plate. A rotating unit is rotatably connected inside the base. The rotating unit is connected to an inner mold and an outer mold unit. A casting removal channel is provided on the top plate. The rotating unit includes a main shaft, a rotating disk, and an inner mold. Both ends of the main shaft are rotatably connected to the base via bearing seats and end face bearings. The rotating disk is fixedly mounted on the upper end of the main shaft, and the inner mold is fixedly mounted on the rotating disk. A guide cap is provided at the top of the inner mold. A fixing ring connecting rod is fixedly mounted on the bearing seat at the lower end of the base. The lower end of the fixing ring connecting rod is connected to a rotary joint fixing ring. A cooling water pipe seat is fixedly connected to the bottom end of the main shaft. A cooling water pipe is coaxially fitted inside the cooling water pipe seat. The upper end of the cooling water pipe extends into the inner mold. Several water outlet holes are provided at the upper end of the cooling water pipe. A water pipe elbow is connected to the lower end of the cooling water pipe. A synchronous pulley is fitted on the lower part of the main shaft. A motor is mounted on the base plate via a motor seat. A synchronous pulley is fitted on the motor shaft of the motor, and the main shaft is driven to rotate by a synchronous belt. The inner and outer mold unit includes a movable plate and an outer mold mounting plate that slides left and right on the movable plate, and a flat outer mold. The outer mold mounting plate and the flat outer mold are both composed of two symmetrical parts. The movable plate is connected to the guide post through a guide sleeve. Lifting cylinder joints are provided on both sides below the movable plate. A lifting cylinder is installed on the bottom plate. The cylinder rod of the lifting cylinder drives the movable plate to move up and down along the guide post through the cylinder joint. Two sliding pads are arranged parallel to each other on the movable plate. The outer mold mounting plate is slidably installed on the sliding pads. The flat outer mold is installed on the outer mold mounting plate. The flat outer mold cooperates with the inner mold of the rotating unit. A mold closing ring is installed at the top of the flat outer mold. Mold opening cylinder seats are fixedly installed at both ends of the top plate. Mold opening cylinders are installed on the mold opening cylinder seats. The cylinder rod end of the mold opening cylinder is connected to the mold opening cylinder joint. Mold opening grooves are provided on both sides of the outer mold mounting plate. The mold opening cylinder joints are engaged with the mold opening grooves. The steps of the method are as follows: S1. Mold Closing: The mold opening cylinder pushes the outer mold to move towards the center, and the two halves of the outer mold close and are positioned. The lifting cylinder installed on the base plate moves downward, driving the movable plate and the flat outer mold to move downward, so that the flat outer mold cooperates with the inner mold on the rotating plate, completing the mold closing of the flat outer mold and the inner mold. The movable plate continues to descend, and the mold separates from the movable plate. S2. Centrifugal casting: Start the motor and drive the main shaft to rotate through the synchronous belt, thereby driving the rotating disk and mold to rotate, pour in the molten metal, and the molten metal moves outward under the action of centrifugal force to achieve casting from the inside to the outside; S3, Casting cooling: Cold water is introduced into the lower end of the water pipe elbow, and the cold water is sprayed into the inner mold through the water outlet on the cooling water pipe to cool the inner mold. S4. Mold Opening: After casting is completed, the lifting cylinder is activated to drive the movable plate upward, which in turn drives the outer mold to move upward. The casting rises along with the outer mold and separates from the inner mold. When the movable plate reaches the set position, the lifting cylinder stops. The mold opening cylinder connector at the end of the mold opening cylinder engages with the mold opening groove on the outer mold mounting plate. Then, the mold closing ring on the outer mold is removed. After the robotic arm clamps the casting, the mold opening cylinder moves outward, causing the outer mold mounting plate and the two parts of the outer mold to separate from each other on the movable plate along the sliding pad, thus completing the mold opening and part removal.

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