A rotor aluminum casting device with automatic liquid adding function

Abstract

The invention discloses a rotor aluminum casting device with an automatic liquid adding function, which relates to the field of rotor manufacturing technology. Its technical points include an aluminum liquid storage tank and an aluminum casting mold. The top of the aluminum liquid storage tank is provided with an automatic liquid adding mechanism, a PLC controller is fixedly installed on the tripod of the aluminum liquid storage tank, and an exhaust mechanism is provided on the top of the aluminum casting mold. The automatic liquid adding mechanism includes a kinetic energy component, an aluminum liquid conveying component and an aluminum liquid dispersion component. The kinetic energy component includes a high-precision metering pump fixedly installed on the top of the aluminum liquid storage tank. The invention realizes the comprehensive automation, precision and safety of the rotor aluminum casting process by integrating the automatic liquid adding mechanism, the heating and heat preservation system, the exhaust mechanism and the PLC automatic control system. It not only significantly improves the production efficiency and reduces the errors and safety risks caused by manual operation, but also provides strong support for the high-quality production of rotors, and opens up a new way to improve the casting quality and production efficiency of rotors.

Description

Technical Field

[0001] The invention relates to the technical field of rotor manufacturing, in particular to a rotor aluminum casting device with an automatic liquid adding function. Background Art

[0002] In the production process of rotors, aluminum casting is a core process that directly affects the performance and quality of the rotors. This step not only requires that the aluminum liquid is evenly filled in the rotor slots, but also requires ensuring the accuracy and consistency of each aluminum casting to achieve the best physical and mechanical properties.

[0003] At present, many traditional rotor aluminum casting devices still rely on manual operation in the liquid adding process. This method is not only difficult to accurately control the amount of liquid added each time, but also highly dependent on the operator's experience and feel, resulting in a low level of automation and uneven quality of rotor aluminum casting between batches, which seriously affects the stability and reliability of the product. In addition, direct contact with high-temperature aluminum liquid also greatly threatens the safety of operators, and the risk of scalding remains high. Therefore, we propose a new type of rotor aluminum casting device with automatic liquid adding function. Summary of the invention

[0004] In view of the deficiencies in the prior art, the present invention provides a rotor aluminum casting device with an automatic liquid adding function, which solves the problems of low precision, poor consistency and safety hazards to operators caused by reliance on manual operation in the liquid adding link of traditional rotor aluminum casting devices.

[0005] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: a rotor aluminum casting device with automatic liquid adding function, comprising an aluminum liquid storage tank and an aluminum casting mold, the top of the aluminum liquid storage tank is provided with an automatic liquid adding mechanism, a PLC controller is fixedly installed on the tripod of the aluminum liquid storage tank, and the top of the aluminum casting mold is provided with an exhaust mechanism.

[0006] The automatic liquid adding mechanism comprises a kinetic energy component, an aluminum liquid conveying component and an aluminum liquid dispersing component.

[0007] The kinetic energy component comprises a high-precision metering pump fixedly mounted on the top of the aluminum liquid storage tank, and a connecting pipe is fixedly mounted on the output end of the high-precision metering pump.

[0008] The aluminum liquid conveying assembly includes an outer tube connected by a flange to the liquid outlet end of the connecting tube, an inner tube coaxial with the outer tube is fixedly installed in the inner cavity of the outer tube, a heating wire in contact with the inner tube and located on the inner circular surface of the outer tube is wound around the outer side of the inner tube, and a temperature sensor is fixedly installed on the outer circular surface of the inner tube.

[0009] The aluminum liquid dispersion component includes a liquid separation main pipe fixedly installed at the liquid outlet end of the outer pipe, a diverter plate connected to the inner cavity of the liquid separation main pipe is fixedly installed at the liquid outlet end of the liquid separation main pipe, a plurality of diverter branches connected to the inner cavity of the diverter plate are fixedly installed on the outer circumferential surface of the diverter plate, a diverter ring pipe connected to the inner cavity of the diverter branch pipe is fixedly installed at the liquid outlet end of the diverter branch pipe, and a nozzle connected to the inner cavity of the diverter ring pipe is fixedly installed on the outer circumferential surface of the diverter ring pipe.

[0010] Preferably, the outer tube is made of thermal insulation material; the inner tube is made of heat conductive insulation material.

[0011] Preferably, the heating wire is in a spiral shape as a whole, and the heating wire is located between the outer tube and the inner tube.

[0012] Preferably, the exhaust mechanism comprises a sealing cover, an inert gas generating assembly and an exhaust assembly.

[0013] The inert gas generating assembly comprises a mounting piece fixedly mounted on the outer circumferential surface of the sealing cover, an inert gas generator is fixedly mounted on the top of the mounting piece, and a gas guide elbow penetrating the sealing cover is fixedly mounted on the output end of the inert gas generator.

[0014] The exhaust assembly comprises an exhaust pipe fixedly mounted on the sealing cover and connected to the inner cavity of the sealing cover, and a one-way valve is fixedly mounted on the air outlet end of the exhaust pipe.

[0015] Preferably, the sealing cover is matched with the aluminum casting mold, wherein the sealing cover and the aluminum casting mold are connected by bolts, and the sealing property of the joint between the sealing cover and the aluminum casting mold is good.

[0016] Preferably, the liquid separation main pipe passes through the sealing cover, wherein the liquid inlet end of the liquid separation main pipe is located at the top of the sealing cover, and the liquid outlet end of the liquid separation main pipe is located in the inner cavity of the sealing cover.

[0017] Preferably, the high-precision metering pump, temperature sensor and inert gas generator are electrically connected to a PLC controller.

[0018] Compared with the prior art, the present invention provides a method having the following beneficial effects: 1. The present invention provides stable and accurate power for the delivery of molten aluminum by setting a kinetic energy component. After being accurately extracted by a high-precision metering pump, the molten aluminum is delivered to the molten aluminum delivery component through a connecting pipe. This process is fully automated and does not require manual intervention. This design solves the problems of inaccurate liquid addition and uneven quality between batches caused by manual operation in traditional rotor aluminum casting devices, improves the accuracy and consistency of casting, and thus ensures the best physical and mechanical properties of the rotor.

[0019] 2. The present invention realizes heating and heat preservation of aluminum liquid during transportation by setting heating wire and temperature sensor. The temperature sensor monitors the temperature of aluminum liquid in the inner tube in real time and feeds back the data to the PLC controller. The PLC controller quickly adjusts the heating power of the heating wire according to the received temperature data to ensure that the aluminum liquid is maintained within the optimal temperature range. This measure effectively prevents the solidification or reduction of fluidity of aluminum liquid due to temperature drop, and provides reliable guarantee for subsequent uniform filling.

[0020] 3. The present invention realizes fine dispersion and uniform filling of aluminum liquid by setting up an aluminum liquid dispersion component. After being heated and heat-insulated by the aluminum liquid conveying component, the aluminum liquid is conveyed to the aluminum liquid dispersion component. The aluminum liquid passes through the liquid separation main pipe, the diversion plate, the diversion branch pipe and the diversion ring pipe, and is finally evenly distributed to each nozzle, and is accurately sprayed into the rotor slot of the aluminum casting mold in the form of mist or thin stream. This dispersion method not only ensures the uniform filling of aluminum liquid, but also greatly improves the filling efficiency, and further improves the casting quality and production efficiency of the rotor.

[0021] 4. The present invention effectively solves the influence of air on casting quality in the traditional rotor aluminum casting device by setting up an exhaust mechanism. Before the aluminum liquid is filled, the PLC controller instructs the inert gas generator to start, and the generated inert gas is introduced into the aluminum casting mold through the gas guide elbow, and the air in the mold is squeezed out from the exhaust pipe. The one-way valve ensures that the gas can only flow out of the mold in one direction, preventing the backflow of external air. This design avoids the reaction of aluminum liquid with oxygen in the air during the casting process, thereby ensuring the casting quality of the rotor. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a structural schematic diagram of the present invention; Figure 2 For the present invention Figure 1 Another perspective structural diagram of; Figure 3 It is a schematic diagram of the cross-sectional structure of the aluminum casting mold of the present invention; Figure 4 It is a schematic diagram of the structure of the aluminum liquid dispersion assembly of the present invention; Figure 5 It is a schematic diagram of the structure of the aluminum liquid conveying assembly of the present invention.

[0023] In the figure: 1. Aluminum liquid storage tank; 2. Cast aluminum mold; 3. Automatic liquid adding mechanism; 31. Kinetic energy component; 311. High-precision metering pump; 312. Connecting pipe; 32. Aluminum liquid conveying assembly; 321. Outer tube; 322. Inner tube; 323. Heating wire; 324. Temperature sensor; 33. Aluminum liquid dispersion assembly; 331. Liquid distribution main pipe; 332. Diverter plate; 333. Diverter branch pipe; 334. Diverter ring pipe; 335. Nozzle; 4. PLC controller; 5. Exhaust mechanism; 51. Sealing cover; 52. Inert gas generating assembly; 521. Mounting piece; 522. Inert gas generator; 523. Gas guide elbow; 53. Exhaust assembly; 531. Exhaust pipe; 532. One-way valve. DETAILED DESCRIPTION

[0024] In the present invention, unless otherwise specified, the directions used, such as "up" and "down", usually refer to the directions shown in the drawings, or to the vertical, perpendicular or gravity directions; similarly, for ease of understanding and description, "left" and "right" usually refer to the left and right shown in the drawings; "inside" and "outside" refer to the inside and outside relative to the outline of each component itself, but the above-mentioned directions are not used to limit the present invention.

[0025] The present invention provides a technical solution: See also Figures 1 to 5 A rotor aluminum casting device with automatic liquid adding function includes an aluminum liquid storage tank 1 and an aluminum casting mold 2. An automatic liquid adding mechanism 3 is arranged on the top of the aluminum liquid storage tank 1. A PLC controller 4 is fixedly installed on the tripod of the aluminum liquid storage tank 1. An exhaust mechanism 5 is arranged on the top of the aluminum casting mold 2.

[0026] The automatic liquid adding mechanism 3 includes a kinetic energy component 31, an aluminum liquid conveying component 32 and an aluminum liquid dispersion component 33. Through the coordinated action of the kinetic energy component 31, the aluminum liquid conveying component 32 and the aluminum liquid dispersion component 33, the automatic extraction, transportation, heating and insulation, and precise dispersion and filling of the aluminum liquid are realized, thereby solving the problems of the liquid adding link in the traditional rotor aluminum casting device relying on manual operation, inaccurate liquid addition amount, and low automation level.

[0027] The kinetic energy component 31 includes a high-precision metering pump 311 fixedly installed on the top of the aluminum liquid storage tank 1, and a connecting pipe 312 is fixedly installed on the output end of the high-precision metering pump 311. The aluminum liquid in the aluminum liquid storage tank 1 is accurately extracted through the high-precision metering pump 311 and the connecting pipe 312 in the kinetic energy component 31, and is transported to subsequent components, thereby realizing the automation and precise control of the aluminum liquid addition.

[0028] The aluminum liquid conveying component 32 includes an outer tube 321 which is flange-connected to the liquid outlet end of the connecting tube 312; an inner tube 322 which is coaxial with the outer tube 321 is fixedly installed in the inner cavity of the outer tube 321; a heating wire 323 which is in contact with the inner tube 322 and located on the inner circumferential surface of the outer tube 321 is wound around the outer side of the inner tube 322; a temperature sensor 324 is fixedly installed on the outer circumferential surface of the inner tube 322; through the outer tube 321, the inner tube 322, the heating wire 323 and the temperature sensor 324, precise temperature control of the aluminum liquid during the conveying process is achieved, the aluminum liquid is prevented from solidifying or reducing its fluidity, the optimal filling state of the aluminum liquid is guaranteed, and the casting quality of the rotor is improved.

[0029] The aluminum liquid dispersion component 33 includes a liquid separation main pipe 331 fixedly installed at the liquid outlet end of the outer tube 321, a diverter plate 332 connected to the inner cavity of the liquid separation main pipe 331 is fixedly installed at the liquid outlet end of the liquid separation main pipe 331, a plurality of diverter branches 333 connected to the inner cavity of the diverter plate 332 are fixedly installed on the outer circumferential surface of the diverter plate 332, a diverter ring pipe 334 connected to the inner cavity of the diverter branch pipe 333 is fixedly installed at the liquid outlet end of the diverter branch pipe 333, and a nozzle 335 connected to the inner cavity of the diverter ring pipe 334 is fixedly installed on the outer circumferential surface of the diverter ring pipe 334. Through the coordinated action of the liquid separation main pipe 331, the diverter plate 332, the diverter branch pipe 333, the diverter ring pipe 334 and the nozzle 335, the aluminum liquid is evenly dispersed and accurately sprayed onto the rotor slot in the aluminum casting mold 2, ensuring the uniformity and consistency of aluminum liquid filling and improving the rotor casting quality.

[0030] Furthermore, the outer tube 321 is made of thermal insulation material; the inner tube 322 is made of thermal conductive insulation material. The outer tube 321 uses thermal insulation material to reduce heat loss, and the inner tube 322 uses thermal conductive insulation material to efficiently transfer heat and prevent current from passing through. The use of these two materials ensures that the aluminum liquid maintains a suitable temperature during the transportation process, thereby improving energy utilization and casting quality.

[0031] Furthermore, the heating wire 323 is spirally shaped as a whole, and is located between the outer tube 321 and the inner tube 322. Since the heating wire 323 is spirally shaped and is located between the outer tube 321 and the inner tube 322, the heating wire can transfer heat to the aluminum liquid more evenly and efficiently, while ensuring a compact structure, improving space utilization and heating efficiency, and ensuring that the aluminum liquid maintains a suitable temperature.

[0032] Furthermore, the exhaust mechanism 5 includes a sealing cover 51, an inert gas generating assembly 52 and an exhaust assembly 53. The design of the sealing cover 51, the inert gas generating assembly 52 and the exhaust assembly 53 can ensure that the air in the mold is effectively discharged to prevent the aluminum liquid from being oxidized. At the same time, the one-way valve 532 prevents the backflow of external air, thereby ensuring the casting quality of the rotor and improving production efficiency and safety.

[0033] The inert gas generating assembly 52 includes a mounting piece 521 fixedly mounted on the outer cylindrical surface of the sealing cover 51, an inert gas generator 522 is fixedly mounted on the top of the mounting piece 521, and a gas guide elbow 523 penetrating the sealing cover 51 is fixedly mounted on the output end of the inert gas generator 522. The inert gas generating assembly 52 is fixed to the sealing cover 51 through the mounting piece 521 on the inert gas generating assembly 52. ​​The inert gas generator 522 on the top thereof uses the gas guide elbow 523 to introduce the inert gas into the mold, effectively displacing and discharging the air in the mold, preventing the aluminum liquid from oxidizing, and ensuring the casting quality of the rotor.

[0034] The exhaust assembly 53 includes an exhaust pipe 531 fixedly mounted on the sealing cover 51 and connected to the inner cavity of the sealing cover 51. A one-way valve 532 is fixedly mounted on the gas outlet end of the exhaust pipe 531, which is connected to the inner cavity of the sealing cover 51 through the exhaust pipe 531. The one-way valve 532 ensures one-way outflow of gas, prevents backflow of external air, effectively exhausts air in the mold, and avoids oxidation of aluminum liquid.

[0035] Furthermore, the sealing cover 51 is adapted to the aluminum casting mold 2, wherein the sealing cover 51 and the aluminum casting mold 2 are connected by bolts, and the sealing cover 51 and the aluminum casting mold 2 have good sealing properties at the joint. The sealing cover 51 and the aluminum casting mold 2 are connected by bolts and have good sealing properties, thereby ensuring that gas and aluminum liquid do not leak during exhaust and liquid addition, maintaining the stability of the internal environment of the device, and ensuring the smooth progress of the casting process and the quality of the rotor.

[0036] Furthermore, the liquid separation main pipe 331 passes through the sealing cover 51, wherein the liquid inlet end of the liquid separation main pipe 331 is located at the top of the sealing cover 51, and the liquid outlet end of the liquid separation main pipe 331 is located in the inner cavity of the sealing cover 51. The design of the liquid separation main pipe 331 allows the aluminum liquid to smoothly enter the sealing cover 51 from the top and directly reach its inner cavity, ensuring that the aluminum liquid is evenly sprayed into the aluminum casting mold 2 through the dispersion component, maintaining the simplicity and efficiency of the liquid addition path, and helping to improve the accuracy and production efficiency of rotor aluminum casting.

[0037] Furthermore, the high-precision metering pump 311, the temperature sensor 324 and the inert gas generator 522 are electrically connected to the PLC controller 4. By electrically connecting the high-precision metering pump 311, the temperature sensor 324 and the inert gas generator 522 to the PLC controller 4, it is convenient to use the PLC controller 4 to achieve precise control and automated operation, ensure the accurate extraction of molten aluminum, real-time monitoring of temperature and effective filling of inert gas, and improve production efficiency and rotor casting quality.

[0038] When used specifically, the working principle of the present invention is as follows: When using the rotor aluminum casting device with automatic liquid addition function, first, the device is powered on and started. Before the aluminum liquid is filled, a key pretreatment step is exhaust. This step is achieved by the PLC controller 4 accurately commanding the inert gas generator 522 to start. The inert gas generator 522 quickly generates inert gas, which is then introduced into the aluminum casting mold 2 through the gas guide elbow 523. As the inert gas is continuously filled, they gradually accumulate at the bottom of the mold cavity to form a protective layer, effectively squeezing out the original air in the mold from the exhaust pipe 531 of the exhaust component 53. In this process, the one-way valve 532 plays a vital role. It ensures that the gas can only flow out of the mold in one direction, effectively preventing the backflow of external air after exhaust, thereby avoiding the reaction of aluminum liquid with oxygen in the air during the casting process, and ensuring that the quality of the rotor is not affected.

[0039] Next, the PLC controller 4 continues to play its core control role, and it instructs the high-precision metering pump 311 to start working according to the preset program parameters. The high-precision metering pump 311 accurately extracts a preset amount of aluminum liquid from the aluminum liquid storage tank 1. This process completely avoids the error of manual operation and ensures the accuracy and consistency of the amount of aluminum liquid in each casting process.

[0040] The extracted aluminum liquid then enters the aluminum liquid conveying assembly 32 through the connecting pipe 312. Here, the temperature sensor 324 monitors the temperature of the aluminum liquid in the inner tube 322 in real time and feeds back the real-time data to the PLC controller 4. According to the received temperature data, the PLC controller 4 quickly adjusts the heating power of the heating wire 323 to ensure that the aluminum liquid is maintained in an optimal temperature range during the conveying process. This heating and heat preservation measure effectively prevents the aluminum liquid from solidifying or reducing its fluidity due to the drop in temperature, and provides a strong guarantee for subsequent uniform filling.

[0041] After being heated and insulated by the aluminum liquid conveying assembly 32, the aluminum liquid is conveyed to the aluminum liquid dispersing assembly 33. Here, the aluminum liquid first enters the liquid distributing main pipe 331, and then is evenly distributed to the diversion ring pipe 334 through the diversion plate 332 and a plurality of diversion branches 333. Finally, the aluminum liquid is accurately sprayed into the rotor slot of the aluminum casting mold 2 in the form of mist or fine stream from the nozzles 335 evenly distributed on the diversion ring pipe 334. This fine dispersion method not only ensures the uniform filling of the aluminum liquid, but also greatly improves the filling efficiency, further improving the casting quality of the rotor.

[0042] The entire process of adding liquid and casting is completed automatically under the precise control of the PLC controller 4. From the filling of inert gas, the precise extraction and heating of aluminum liquid, to the uniform dispersion and filling of aluminum liquid, each step has been carefully designed and optimized. This highly automated operation method not only significantly improves production efficiency, but also effectively reduces the errors and safety risks caused by manual operation, providing strong support for the high-quality production of rotors.

[0043] In summary, the present invention realizes the comprehensive automation, precision and safety of the rotor aluminum casting process by integrating the automatic liquid adding mechanism, the heating and insulation system, the exhaust mechanism and the PLC automatic control system, opening up a new way to improve the rotor casting quality and production efficiency.

[0044] The above are only specific embodiments of the present invention, but the technical features of the present invention are not limited thereto. Any simple changes, equivalent replacements or modifications made based on the present invention to solve basically the same technical problems and achieve basically the same technical effects are all included in the protection scope of the present invention.

Claims

1. A rotor aluminum casting device with an automatic liquid adding function, comprising an aluminum liquid storage tank (1) and an aluminum casting mold (2), characterized in that: An automatic liquid adding mechanism (3) is provided on the top of the aluminum liquid storage tank (1), a PLC controller (4) is fixedly mounted on the tripod of the aluminum liquid storage tank (1), and an exhaust mechanism (5) is provided on the top of the aluminum casting mold (2); The automatic liquid adding mechanism (3) comprises a kinetic energy component (31), an aluminum liquid conveying component (32) and an aluminum liquid dispersing component (33); The kinetic energy component (31) comprises a high-precision metering pump (311) fixedly mounted on the top of the aluminum liquid storage tank (1), and a connecting pipe (312) is fixedly mounted on the output end of the high-precision metering pump (311); The aluminum liquid conveying assembly (32) comprises an outer tube (321) connected by a flange to a liquid outlet end of a connecting tube (312); an inner tube (322) coaxial with the outer tube (321) is fixedly mounted in the inner cavity of the outer tube (321); a heating wire (323) in contact with the inner tube (322) and located on the inner circumferential surface of the outer tube (321) is wound around the outer side of the inner tube (322); and a temperature sensor (324) is fixedly mounted on the outer circumferential surface of the inner tube (322); The aluminum liquid dispersion assembly (33) comprises a liquid separation main pipe (331) fixedly mounted on the liquid outlet end of the outer pipe (321); a flow distribution plate (332) in communication with the inner cavity of the liquid separation main pipe (331) is fixedly mounted on the liquid outlet end of the liquid separation main pipe (331); a plurality of flow distribution branches (333) in communication with the inner cavity of the flow distribution plate (332) are fixedly mounted on the outer circumferential surface of the flow distribution plate (332); a flow distribution ring pipe (334) in communication with the inner cavity of the flow distribution branch pipe (333) is fixedly mounted on the liquid outlet end of the flow distribution branch pipe (333); and a nozzle (335) in communication with the inner cavity of the flow distribution ring pipe (334) is fixedly mounted on the outer circumferential surface of the flow distribution ring pipe (334).

2. The rotor aluminum casting device with automatic liquid adding function according to claim 1, characterized in that: The outer tube (321) is made of thermal insulation material; the inner tube (322) is made of thermal conductive insulation material.

3. The rotor aluminum casting device with automatic liquid adding function according to claim 1, characterized in that: The heating wire (323) is in a spiral shape as a whole, and the heating wire (323) is located between the outer tube (321) and the inner tube (322).

4. The rotor aluminum casting device with automatic liquid adding function according to claim 1, characterized in that: The exhaust mechanism (5) comprises a sealing cover (51), an inert gas generating assembly (52) and an exhaust assembly (53); The inert gas generating assembly (52) comprises a mounting member (521) fixedly mounted on the outer circumferential surface of the sealing cover (51); an inert gas generator (522) is fixedly mounted on the top of the mounting member (521); and a gas guide elbow (523) penetrating the sealing cover (51) is fixedly mounted on the output end of the inert gas generator (522); The exhaust assembly (53) comprises an exhaust pipe (531) fixedly mounted on the sealing cover (51) and connected to the inner cavity of the sealing cover (51); a one-way valve (532) is fixedly mounted on the exhaust end of the exhaust pipe (531).

5. The rotor aluminum casting device with automatic liquid adding function according to claim 4 is characterized in that: The sealing cover (51) is adapted to the aluminum casting mold (2), wherein the sealing cover (51) and the aluminum casting mold (2) are connected by bolts, and the sealing performance of the joint between the sealing cover (51) and the aluminum casting mold (2) is good.

6. The rotor aluminum casting device with automatic liquid adding function according to claim 4, characterized in that: The liquid separation main pipe (331) passes through the sealing cover (51), wherein the liquid inlet end of the liquid separation main pipe (331) is located at the top of the sealing cover (51), and the liquid outlet end of the liquid separation main pipe (331) is located in the inner cavity of the sealing cover (51).

7. The rotor aluminum casting device with automatic liquid adding function according to claim 4 is characterized in that: The high-precision metering pump (311), the temperature sensor (324), and the inert gas generator (522) are electrically connected to the PLC controller (4).

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