An automatic control method for lost foam production line

Abstract

The application discloses a kind of automatic control methods of lost foam production line, it is related to the field of lost foam production, solve the technical problem that existing lost foam casting adjustment method change type advantage is small, flexibility is low and efficiency is low.The method is, set material number, the sand box on current process production line is assigned to the material number, and the material number is checked by material number circulation mistake-proof checking mechanism;When judging material number is normal value, then carry out material number circulation process;When process production line or sand box appears failure and needs to change material number, trigger material number temporary change mechanism;When sand box completes box turning action, the material number corresponding to sand box is output to subsequent process production line and the material number corresponding to sand box on current process production line is emptied.The application solves the technical problem that existing lost foam production line has no actual material number to track sand box, improves the flexibility and work efficiency of operation, reduces the probability of processing process problem.

Description

Technical Field

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

[0002] Lost foam casting is a casting technique in which a refractory material is coated on the surface of a white foam mold, dried to become a yellow mold, and then the yellow mold is placed in a sand box, filled with molding sand and vibrated to compact it. The casting process is carried out under vacuum conditions in the sand box, followed by pressure holding and cooling to form the final shape.

[0003] The lost foam casting process can be divided into three areas: white pattern forming (white zone), coating application (yellow zone), and boxing, casting, and unpacking (black zone). The black zone is a crucial production area in the lost foam casting process. Besides auxiliary equipment such as sand treatment, dust removal, and cooling, the core of the black zone is the automated production line. This technical solution outlines the operational control technology for the various equipment on the automated production line in the black zone.

[0004] As shown in the diagram below, the lost foam casting automated production line includes: a #1 turning molding line, a #2 casting line, a #3 casting line (each with 10 casting stations), and a #4 cooling line. Sand boxes are transferred via #1-#3 shuttle cars and pushing / receiving mechanisms in the directions indicated by the arrows.

[0005] Bottom sand: Add a certain amount of bottom sand to the empty sand box and compact it.

[0006] Mold installation: Place one or more sets of yellow molds into the sand box and fix them in place with molding sand.

[0007] Vibration compaction: The molding sand is filled and vibrated to compact it.

[0008] Covering: Install the pouring cup and cover it with a sealing film.

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

[0010] Casting: While vacuuming, the molten alloy is manually cast by an automated casting robot; then the process is switched to pressure holding vacuum for a certain period of time to allow the product to solidify and take shape.

[0011] Cooling: The product is allowed to cool naturally in the sand box to the opening temperature.

[0012] Turning over the box: The product and molding sand are poured out and separated to obtain the product casting.

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

[0014] The biggest advantage of lost foam casting is its ability to produce multiple products simultaneously on a mixed production line with zero changeover time. However, when changing models or when different products are simultaneously introduced, each workstation on the line has different process parameters corresponding to the actual product. This requires each workstation to adjust the appropriate process parameters in real time based on the product model at that workstation to ensure correct production. Existing automatic control systems for lost foam production lines lack data on the actual part numbers flowing between workstations and a process database for all products at each workstation for retrieval and querying. Generally, manual settings or selections are required only when a product flows to the current workstation. Existing process adjustment methods significantly diminish the advantages of lost foam casting for model changes; reduce flexibility and efficiency; and easily lead to a series of process errors such as incorrect sand addition, under- or over-vibration, pouring the wrong molten iron grade, and insufficient pressure holding and cooling. Summary of the Invention

[0015] The technical problem to be solved by the present invention is to provide an automatic control method for lost foam casting production lines, which addresses the shortcomings of existing lost foam casting adjustment methods, such as limited advantages in mold changing, low flexibility, and low efficiency.

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

[0017] When the process production line or sand box malfunctions and a change of part number is required, the temporary part number change mechanism is triggered.

[0018] After the sand box completes the flipping action, the part number is output to the subsequent process production line, and the part number corresponding to the sand box on the current process production line is cleared.

[0019] As a further improvement, the part number transfer process is as follows: the carrying status and position of two adjacent transfer cars are obtained. The adjacent transfer cars are marked as the previous transfer car and the next transfer car respectively along the flow direction of the lost foam production line. When the previous transfer car is located on the first process production line and there is a part number on the previous transfer car, and the next transfer car is located on the first process production line and there is no part number on the next transfer car, a push box is completed on the process production line. The part number on the previous transfer car is moved to the first process production line. The part number on the first process production line is moved one position in sequence along the direction of the next transfer car. The part number that is closest to the next transfer car on the first process production line is moved to the next transfer car.

[0020] Furthermore, the part number transfer error prevention and verification mechanism is as follows: obtain the total number of sand boxes on the process production line and the total number of part numbers corresponding to the sand boxes, obtain the number of sand boxes placed on the transition car on the process production line, and when the total number of sand boxes is equal to the sum of the total number of part numbers and the number of sand boxes placed on the transition car, then the total number of part numbers is a normal value.

[0021] 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 in the transfer vehicle, an alarm will be triggered for an abnormal total number of material numbers.

[0022] After a box push is completed on the production line, the material number at the box flipping position and the material number at the loading position are obtained. When the box flipping material number is equal to the material loading material number, it is determined that both material numbers are normal values.

[0023] When the flipping part number is not equal to the loading part number, the loading part number and the flipping part number in the previous cycle are obtained. When the loading part number is equal to the loading part number in the previous cycle plus one and the flipping part number is equal to the loading part number in the previous cycle minus one, it is determined that the part numbers are both normal values. Otherwise, it is determined that the part numbers are abnormal.

[0024] Furthermore, when the process production line or sand box malfunctions and the part number needs to be changed, the part number can be changed to the target part number via the touch screen, so that the sand box can be transferred to the process production line corresponding to the target part number for production.

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

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

[0027] Furthermore, production is carried out by querying the corresponding process parameters in the process database based on the part number.

[0028] Beneficial effects

[0029] The advantages of this invention are:

[0030] 1. This invention sets a part number and assigns it to the sand box on the current process production line for part number transfer. After the sand box completes the flipping action, the part number corresponding to the sand box is output to the subsequent process production line, and the part number corresponding to the sand box on the current process production line is cleared. The corresponding process parameters in the process database can be queried through the part number to carry out production. It can record and intuitively present the product's online transfer process in real time, solve the technical problem of existing lost foam production lines that do not have actual part numbers to track sand boxes, improve operational flexibility and work efficiency, and reduce the probability of processing problems.

[0031] 2. This invention verifies part numbers by setting up a part number flow error prevention and verification mechanism, thereby reducing the error rate in setting and operating part numbers and improving work efficiency.

[0032] 3. This invention enables timely changes to part numbers when a malfunction occurs in the production line or sand box, thereby improving work efficiency and operational flexibility and preventing production line chaos when part numbers cannot be changed in a timely manner. Attached Figure Description

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

[0034] Figure 2 This is a schematic diagram of the material number arrangement before the push box of the present invention;

[0035] Figure 3 This is a schematic diagram of the material number arrangement after the box is pushed open according to the present invention;

[0036] Figure 4 This is a flowchart of the part number transfer process of the present invention;

[0037] Figure 5 This is a schematic diagram illustrating the part number data update of the present invention;

[0038] Figure 6 This is a schematic diagram of the part number transfer error prevention and verification mechanism of the present invention. Detailed Implementation

[0039] The present invention will be further described below with reference to embodiments, but this does not constitute any limitation on the present invention. Any limited modifications made by any person within the scope of the claims of the present invention are still within the scope of the claims of the present invention.

[0040] See Figures 2-6 The present invention discloses an automatic control method for a lost foam casting production line. The method comprises setting a material number and assigning the material number to the sand box on the current process production line. The material number is transferred in as follows: each sand box on the process production line serves as a container for a material number. After setting the current material number, at the entrance (bottom sand) station of the production line, before production begins at the bottom sand station, the material number is assigned to the sand box at the bottom sand station.

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

[0042] The part number is verified through a part number flow error prevention and verification mechanism.

[0043] The part number transfer error prevention and verification mechanism is as follows: obtain the total number of sand boxes on the process production line and the total number of part numbers corresponding to the sand boxes, and obtain the number of sand boxes placed on the transition car on the process production line. When the total number of sand boxes is equal to the sum of the total number of part numbers and the number of sand boxes placed on the transition car, the total number of part numbers is the normal value.

[0044] When the total number of sand boxes is not equal to the sum of the total number of part numbers and the number of sand boxes placed in the transfer vehicle, an alarm will be triggered for an abnormal total number of part numbers.

[0045] After a box is pushed on the production line, the box number at the box-flipping position and the loading position are obtained. If the box-flipping number is equal to the loading number, then both numbers are considered to be normal values.

[0046] When the part number of the flipped box is not equal to the part number of the loading box, obtain the loading box part number and the flipped box part number of the previous cycle. If the loading box part number is equal to the loading box part number of the previous cycle plus one and the flipped box part number is equal to the flipped box part number of the previous cycle minus one, then the part numbers are judged to be normal values. Otherwise, the part numbers are judged to be abnormal.

[0047] like Figure 2-3 As shown, the transfer (progression) of part numbers between workstations is achieved through the pushing action. Taking the No. 1 box-turning molding line as an example, after one box push is completed, the system pushes the part number of the No. 3 transfer car into the No. 1 line, and the part numbers of each sand box on the line move towards the workstation. Figure 2 Move one sand box to the right and move the rightmost sand box part number from line #1 to the transfer car #1. Transfer between lines is achieved by the transfer car moving the sand boxes on the car to another line end, thus completing the part number transfer for the entire automated production line together with lines #1-#4.

[0048] If all part numbers are determined to be within the normal range, then the part number transfer process will proceed.

[0049] The part number transfer process is as follows: obtain the carrying status and position of two adjacent transfer cars. The adjacent transfer cars are marked as the previous transfer car and the next transfer car respectively along the flow direction of the lost foam production line. When the previous transfer car is located on the first process production line and there is a part number on the previous transfer car, and the next transfer car is located on the first process production line and there is no part number on the next transfer car, complete one push box on the process production line, move the part number on the previous transfer car to the first process production line, and the part number on the first process production line moves one position in sequence along the direction of the next transfer car. The part number that is closest to the next transfer car on the first process production line is moved to the next transfer car.

[0050] In actual production, situations requiring changes to material numbers, such as incorrect material loading, temporary process changes, or temporarily removing a specific sand box material number to halt its circulation, can be addressed using the following methods:

[0051] When a process production line or sand box malfunctions and requires a change of part number, the touchscreen is used to change the part number to the target part number, allowing the sand box to be transferred to the process production line corresponding to the target part number. When a sand box needs to be removed for transfer production, the touchscreen is used to set the part number corresponding to the sand box to zero, so that the sand box enters the subsequent process production line without any processing.

[0052] After the sand box completes the flipping process, the corresponding part number of the sand box is output to the subsequent process production line, and the part number of the sand box on the current process production line is cleared. Part number transfer: When the sand box flows to the outlet (flipping) station and completes the flipping, the system outputs the part number of the sand box at the flipping station to the subsequent equipment and clears the sand box part number.

[0053] Production is carried out by querying the corresponding process parameters in the process database based on the part number. The part number at each workstation is consistent with the actual product flow. The workstation equipment can automatically retrieve the corresponding process parameters from the process database based on this part number to carry out production. By selecting the part number to be viewed or edited in the process database, the specific process data of each workstation under it can be set.

[0054] The above description is only a preferred embodiment of the present invention. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention, and these will not affect the effectiveness of the implementation of the present invention or the practicality of the patent.

Claims

1. An automatic control method for a lost foam casting production line, characterized in that, The method involves setting a part number, assigning the part number to the sand box on the current process production line, and verifying the part number through a part number transfer error prevention and verification mechanism. When it is determined that all the part numbers are normal values, the part number transfer process is then initiated. After the sand box completes the flipping action, the part number corresponding to the sand box is output to the subsequent process production line and the part number corresponding to the sand box on the current process production line is cleared. The part number transfer error prevention and verification mechanism is as follows: obtain the total number of sand boxes on the process production line and the total number of part numbers corresponding to the sand boxes, obtain the number of sand boxes placed on the transition car on the process production line, and when the total number of sand boxes is equal to the sum of the total number of part numbers and the number of sand boxes placed on the transition car, the total number of part numbers is a normal value. 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 in the transfer vehicle, an alarm will be triggered for an abnormal total number of material numbers. After a box push is completed on the production line, the box flipping number and the loading number are obtained from the box flipping position and the loading position. When the box flipping number is equal to the loading number, it is determined that the number is a normal value. When the flipping part number is not equal to the loading part number, obtain the loading part number and the flipping part number in the previous cycle. When the loading part number is equal to the loading part number in the previous cycle plus one and the flipping part number is equal to the flipping part number in the previous cycle minus one, it is determined that the part numbers are both normal values. Otherwise, it is determined that the part numbers are abnormal. Production is carried out by querying the corresponding process parameters in the preset process database based on the part number.

2. The automatic control method for a lost foam casting production line according to claim 1, characterized in that, The material number transfer process is as follows: the carrying status and position of two adjacent transfer cars are obtained. The adjacent transfer cars are marked as the previous transfer car and the next transfer car respectively along the flow direction of the lost foam production line. When the previous transfer car is located on the first process production line and there is a material number on the previous transfer car, and the next transfer car is located on the first process production line and there is no material number on the next transfer car, a push box is completed, and the material number on the previous transfer car is moved to the first process production line. The material number on the first process production line moves one position in sequence along the direction of the next transfer car. The material number that is closest to the next transfer car on the first process production line is moved to the next transfer car.

3. The automatic control method for a lost foam casting production line according to claim 1, characterized in that, When the process production line or sand box malfunctions and the part number needs to be changed, the part number can be changed to the target part number via the touch screen so that the sand box can be transferred to the process production line corresponding to the target part number.

4. The automatic control method for a lost foam casting production line according to claim 3, characterized in that, When the sand box needs to be removed for transfer production, the material number corresponding to the sand box is set to zero via the touch screen so that the sand box enters the subsequent process production line without any processing.

5. The automatic control method for a lost foam casting 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 material number is set.

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