Automatic control method for evanescent mode production line

Abstract

The invention discloses an automatic control method for an evanescent mode production line, relates to the field of evanescent mode production, and solves the technical problems that an existing evanescent mode casting adjustment method is small in model changing advantage, low in flexibility and low in efficiency. The method comprises the steps that a material number is set, the material number is assigned to a sand box on a current process production line, and the material number is verified through a material number circulation mistake-proofing verification mechanism; when it is judged that the material numbers are all normal values, the material number circulation process is carried out; when a process production line or a sand box breaks down and the material number needs to be changed, a temporary material number changing mechanism is triggered; and after the sand box is turned over, the material number corresponding to the sand box is output to a subsequent process production line, and the material number corresponding to the sand box on the current process production line is emptied. The technical problem that an existing evanescent mode production line has no actual material number to track the sand box is solved, the operation flexibility and the working efficiency are improved, and the probability of occurrence of machining process problems is reduced.

Description

Technical Field

[0001] The invention relates to the field of lost foam production, and more specifically, to an automatic control method for a lost foam production line. Background Art

[0002] Lost foam casting is a casting technology in which refractory materials are coated on the surface of the formed foam white mold, which is dried to become a yellow mold. The yellow mold is then placed in a sand box, filled with molding sand and vibrated to compact it. The casting and pressure-maintaining and cooling molding are carried out under the condition of vacuuming the sand box.

[0003] The production process of lost foam can be divided into three production areas: white mold forming (white area), coating (yellow area) and box casting (black area). The black area is an important production area in the lost foam casting process. In addition to auxiliary equipment such as sand treatment, dust removal, cooling, etc., the core of the black area is the automatic production line. This technical solution is a technical solution for the operation control process of each equipment of the automatic production line in the black area.

[0004] As shown in the figure below, the lost foam automatic production line includes: 1# box turning molding line, 2# casting line, 3# casting line with 10 casting stations each, and 4# cooling line. The sand box is circulated in the direction indicated by the arrow through the 1#-3# shuttle bus and the box pusher and box welcomer mechanism.

[0005] Bottom sand: Add a certain height of bottom sand into the empty sand box and vibrate it.

[0006] Moulding: Place one or more sets of yellow moulds into the sand box and initially fix them with moulding sand.

[0007] Vibration: The molding sand is filled and vibrated.

[0008] Laminating: Install the pouring cup and cover with sealing film.

[0009] Surface sand: Add top molding sand to fix the film.

[0010] Casting: While vacuuming, the molten alloy fluid is manually cast by an automatic pouring robot; then it is switched to pressure-maintaining vacuum for a certain period of time to maintain pressure and cool down so that the product can solidify and take shape.

[0011] Cooling: The product is naturally cooled to the unpacking temperature in the sand box.

[0012] Turning over the box: dumping and separating the product and the molding sand to obtain the product casting.

[0013] In actual production, the above-mentioned workstations need to execute different process parameters according to different products to achieve the best product quality.

[0014] The biggest advantage of lost foam casting is that multiple varieties can be mixed online and produced in zero mold change time. However, when changing molds or different products are online at the same time, each station equipment on the line has different process parameters corresponding to the actual products. This requires each station to adjust the appropriate process parameters in real time according to the product model at the station in order to carry out correct production. The existing automatic control system of the lost foam production line does not have the actual material number in the station flow data, and there is no process database corresponding to all products in each station for retrieval, query and call. Generally, it is necessary to manually set or select a certain product when it flows to the current station. The existing process adjustment method greatly weakens the advantages of lost foam mold change; reduces flexibility and efficiency; and easily causes a series of process errors such as sand addition errors, under-compaction or over-compaction, pouring the wrong iron brand, insufficient pressure holding and cooling, etc. Summary of the invention

[0015] The technical problem to be solved by the present invention is to provide an automatic control method for a lost foam production line in view of the deficiencies in the prior art, so as to solve the technical problems of the existing lost foam casting adjustment method having small mold change advantage, low flexibility and low efficiency.

[0016] The invention discloses an automatic control method for a lost foam production line, which includes setting a material number, assigning the material number to a sand box on a current process production line, and verifying the material number through a material number flow error prevention verification mechanism;

[0017] When the process production line fails or the sand box fails and the material number needs to be changed, the temporary material number change mechanism is triggered;

[0018] When the sand box completes the box turning action, the material number is output to the subsequent process production line and the material number corresponding to the sand box on the current process production line is cleared.

[0019] As a further improvement, the material number circulation process is to obtain the transportation status and position of two adjacent transition vehicles, and the adjacent transition vehicles are respectively marked as the previous transition vehicle and the next transition vehicle along the circulation direction of the lost foam production line. When the previous transition vehicle is located at the first process production line and there is a material number on the previous transition vehicle and the next transition vehicle is located at the first process production line and there is no material number on the next transition vehicle, a box pushing on the process production line is completed, and the material number on the previous transition vehicle is moved to the first process production line, and the material number on the first process production line is moved one position in turn along the direction of the next transition vehicle, and the material number closest to the next transition vehicle on the first process production line is moved to the next transition vehicle.

[0020] Furthermore, the material number flow error prevention verification mechanism is to obtain the total number of sand boxes on the process production line and the total number of material numbers corresponding to the sand boxes, and obtain the number of sand boxes placed on the transition vehicle on the process production line. When the total number of sand boxes is equal to the sum of the total number of material numbers and the number of sand boxes placed on the transition vehicle, the total number of material numbers is a normal value;

[0021] When the total number of the sand boxes is not equal to the sum of the total number of material numbers and the number of sand boxes placed on the transition vehicle, an abnormal alarm for the total number of material numbers is issued;

[0022] After completing a box push on the process production line, the material number on the box turning position and the material number of the loading position are obtained. When the box turning material number is equal to the material number of the loading position, it is determined that the material numbers are both normal values;

[0023] When the box-turning material number is not equal to the loading material number, obtain the loading material number in the previous cycle and the box-turning material number in the previous cycle. When the loading material number is equal to the loading material number in the previous cycle plus one and the box-turning material number is equal to the loading material number in the previous cycle minus one, it is judged that the material numbers are normal values. Otherwise, it is judged that the material numbers are operating abnormally.

[0024] Furthermore, when the process production line or the sand box fails and the material number needs to be changed, the material number is changed to the target material number through the touch screen so that the sand box can be circulated and produced with the process production line corresponding to the target material number.

[0025] Furthermore, when the sand box needs to be drawn out for circulation production, the material number corresponding to the sand box is set to zero through the touch screen, so that the sand box enters the subsequent process production line without any processing action.

[0026] Furthermore, a production cycle is set, and when the production cycle ends and the product in the sand box is changed, a new loading material number is set.

[0027] Furthermore, the corresponding process parameters in the process database are queried according to the material number to carry out production.

[0028] Beneficial Effects

[0029] The advantages of the present invention are:

[0030] 1. The present invention sets a material number, assigns the material number to the sand box on the current process production line, and performs a material number circulation process; when the sand box completes the box turning action, the material number corresponding to the sand box is output to the subsequent process production line and the material number corresponding to the sand box on the current process production line is cleared, and the corresponding process parameters in the process database can be queried through the material number to carry out production, and the product circulation process online can be recorded and intuitively presented in real time, solving the technical problem that the existing lost foam production line has no actual material number to track the sand box, thereby improving the flexibility and work efficiency of operation and reducing the probability of processing technology problems.

[0031] 2. The present invention verifies the material number by setting up a material number flow error prevention verification mechanism, thereby reducing the error rate in the material number setting and material number operation process and improving work efficiency.

[0032] 3. The present invention sets up a temporary material number change mechanism to achieve timely change of material numbers when a process production line or sand box fails, thereby improving work efficiency and operational flexibility and preventing chaos in the production line when the material number cannot be changed in time. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a schematic diagram of the overall structure of the existing lost foam automatic production line;

[0034] Figure 2 This is a schematic diagram of the arrangement of material numbers in front of the push box of the present invention;

[0035] Figure 3 This is a schematic diagram of the arrangement of material numbers after the push box of the present invention;

[0036] Figure 4 It is a flow chart of the material number transfer process of the present invention;

[0037] Figure 5 It is a schematic diagram of updating the material number data of the present invention;

[0038] Figure 6 Schematic diagram of the material number flow error prevention verification mechanism of the present invention. DETAILED DESCRIPTION

[0039] The present invention will be further described below in conjunction with the embodiments, but it does not constitute any limitation to the present invention. Any limited number of modifications made by anyone within the scope of the claims of the present invention are still within the scope of the claims of the present invention.

[0040] See also Figure 2-Figure 6 The present invention provides an automatic control method for a lost foam production line. The method comprises the following steps: setting a material number and assigning the material number to a sand box on the current process production line; transferring the material number: each sand box on the process production line is used as a container for a material number. After the current loading material number is set, at the entrance (bottom sand) station of the production line, before the bottom sand station starts production, the material number is assigned to the sand box of the bottom sand station.

[0041] Set a production cycle. When the production cycle ends and the product in the sand box changes, set a new loading material number to realize the change of material number transfer.

[0042] The material number is verified through the material number flow error prevention verification mechanism.

[0043] The material number flow error prevention verification mechanism is to obtain the total number of sand boxes on the process production line and the total number of material numbers corresponding to the sand boxes, and obtain the number of sand boxes placed on the transition vehicle on the process production line. When the total number of sand boxes is equal to the sum of the total number of material numbers and the number of sand boxes placed on the transition vehicle, the total number of material numbers is a normal value.

[0044] When the total number of sand boxes is not equal to the sum of the total number of material numbers and the number of sand boxes placed on the transition vehicle, an abnormal alarm for the total number of material numbers will be issued.

[0045] After completing a box push on the process production line, obtain the box turning material number on the box turning position and the loading material number on the loading position. When the box turning material number is equal to the loading material number, it is judged that the material numbers are normal values.

[0046] When the box turning material number is not equal to the loading material number, obtain the loading material number and the box turning material number in the previous cycle. When the loading material number is equal to the loading material number in the previous cycle plus one and the box turning material number is equal to the box turning material number in the previous cycle minus one, it is judged that the material numbers are normal values. Otherwise, the material numbers are judged to be abnormal.

[0047] like Figure 2-3 As shown in the figure, the material number is transferred (progressively) between the workstations by pushing the box. Taking the 1# box turning molding line as an example, after completing one box pushing, the system pushes the material number of the 3# transition car into the 1# line, and the material number boxes of each sand box on the line move to Figure 2 Move a sand box position to the right of the 1# line, and move the material number of the sand box on the far right of the 1# line to the 1# ferry car. The transfer between the lines is realized by moving the sand box on the car to another line end, and together with the 1#-4# lines, the material number transfer of the entire automatic production line is completed.

[0048] When it is determined that the material numbers are all normal values, the material number circulation process is carried out.

[0049] The material number circulation process is to obtain the transportation status and position of two adjacent transition vehicles. The adjacent transition vehicles are marked as the previous transition vehicle and the next transition vehicle along the circulation direction of the lost foam production line. When the previous transition vehicle is located at the first process production line and there is a material number on the previous transition vehicle and the next transition vehicle is located at the first process production line and there is no material number on the next transition vehicle, a box push on the process production line is completed, and the material number on the previous transition vehicle is moved to the first process production line. The material number on the first process production line is moved one position in the direction of the next transition vehicle, and the material number on the first process production line closest to the next transition vehicle is moved to the next transition vehicle.

[0050] In actual production, if the material number needs to be changed due to loading the wrong material, temporarily changing the process, temporarily withdrawing a sand box material number to stop its circulation, etc., the following methods can be used to achieve this:

[0051] When a process line or sand box fails and the material number needs to be changed, the material number is changed to the target material number through the touch screen so that the sand box can be circulated and produced in the process line corresponding to the target material number. When the sand box needs to be pulled out for circulation production, the material number corresponding to the sand box is set to zero through the touch screen so that the sand box can enter the subsequent process line without processing.

[0052] When the sand box is turned over, the material number of the sand box is output to the subsequent process production line and the material number of the sand box on the current process production line is cleared. Material number transfer: When the sand box flows to the exit (turning box) station and the turning is completed, the system outputs the sand box material number of the turning box station to the subsequent equipment and clears the sand box material number.

[0053] According to the material number, the corresponding process parameters in the process database are queried for production. The material number on each workstation is consistent with the actual product flow. The workstation equipment can automatically retrieve the corresponding process parameters from the process database for production based on this material number. Select the material number to be browsed or edited in the process database, and you can set the specific process data of each subordinate workstation.

[0054] The above is only a preferred embodiment of the present invention. It should be pointed out that for those skilled in the art, several modifications and improvements can be made without departing from the structure of the present invention, which will not affect the effect of the implementation of the present invention and the practicality of the patent.

Claims

1. A method for automatic control of a lost foam production line, characterized in that: The method is to set a material number, assign the material number to a sand box on the current process production line, and verify the material number through a material number flow error prevention verification mechanism; When it is determined that the material numbers are all normal values, the material number circulation process is carried out; When the sand box completes the box turning action, the material number corresponding to the sand box is output to the subsequent process production line and the material number corresponding to the sand box on the current process production line is cleared.

2. The automatic control method of a lost foam production line according to claim 1, characterized in that: The material number circulation process is to obtain the transportation status and position of two adjacent transition vehicles, and the adjacent transition vehicles are respectively marked as the previous transition vehicle and the next transition vehicle along the circulation direction of the lost foam production line. When the previous transition vehicle is located at the first process production line and there is a material number on the previous transition vehicle and the next transition vehicle is located at the first process production line and there is no material number on the next transition vehicle, a box push is completed to move the material number on the previous transition vehicle to the first process production line, and the material number on the first process production line is moved one position in turn along the direction of the next transition vehicle, and the material number on the first process production line closest to the next transition vehicle is moved to the next transition vehicle.

3. The automatic control method of a lost foam production line according to claim 2 is characterized in that: The material number flow error prevention verification mechanism is to obtain the total number of sand boxes on the process production line and the total number of material numbers corresponding to the sand boxes, and obtain the number of sand boxes placed on the transition vehicle on the process production line. When the total number of sand boxes is equal to the sum of the total number of material numbers and the number of sand boxes placed on the transition vehicle, the total number of material numbers is a normal value; When the total number of the sand boxes is not equal to the sum of the total number of material numbers and the number of sand boxes placed on the transition vehicle, an abnormal alarm for the total number of material numbers is issued; After completing a box push on the process production line, the box turning material number on the box turning position and the material loading material number on the material loading position are obtained. When the box turning material number is equal to the material loading material number, it is determined that the material numbers are both normal values; When the box-turning material number is not equal to the loading material number, obtain the loading material number in the previous cycle and the box-turning material number in the previous cycle. When the loading material number is equal to the loading material number in the previous cycle plus one and the box-turning material number is equal to the box-turning material number in the previous cycle minus one, it is judged that the material numbers are normal values. Otherwise, the material numbers are judged to be abnormal.

4. The automatic control method of a lost foam production line according to claim 1, characterized in that: When the process production line or the sand box fails and the material number needs to be changed, the material number is changed to the target material number through the touch screen so that the sand box can be circulated and produced with the process production line corresponding to the target material number.

5. The automatic control method of a lost foam production line according to claim 4, characterized in that: When the sand box needs to be drawn out for circulation production, the material number corresponding to the sand box is set to zero through the touch screen, so that the sand box enters the subsequent process production line without any processing action.

6. The automatic control method of a lost foam production line according to claim 1, characterized in that: A production cycle is set, and when the production cycle ends and the product in the sand box is changed, a new loading material number is set.

7. The automatic control method of a lost foam production line according to claim 1, characterized in that: The corresponding process parameters in the preset process database are queried according to the material number to carry out production.

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