Grinding ball centrifugal casting method and production line thereof

Abstract

The invention relates to the technical field of centrifugal casting, in particular to a grinding ball centrifugal casting method and a grinding ball centrifugal casting production line. The technical problems that an existing iron mold sand coating grinding ball production line is low in molten iron utilization rate, harmful carcinogenic gas is inevitably generated in the sand coating process, environmental protection is not facilitated, the body health of field personnel is damaged, the wear resistance of products is difficult to improve, and the overall use performance is reduced exist. According to the technical scheme, the grinding ball centrifugal pouring method and the grinding ball centrifugal pouring production line comprise the following procedures that the grinding ball centrifugal pouring production line is composed of a plurality of machine tables and mainly comprises a pouring station, a plurality of cooling stations, a mold stripping station and a cleaning and spraying station, and all the stations are connected in series through a mold circulating system to form the complete production line; according to the method, a composite die of cast iron and a heat-resistant material is adopted for direct pouring, so that the purposes of reducing the production cost, eliminating harmful gas emission and improving the wear resistance and impact toughness of the product are achieved.

Description

Technical Field

[0001] The invention relates to the technical field of centrifugal casting, in particular to a grinding ball centrifugal casting method and a production line thereof. Background Art

[0002] Centrifugal casting technology has been around for decades. Under the guidance of users' increasing demands, with the development of technology and the continuous innovation of manufacturers, more and more products are applicable. So far, there is no production line that uses centrifugal casting technology to produce grinding balls.

[0003] The widely used iron film coated sand grinding ball production process is the most advanced technology so far. It has the highest level of automation and is widely used by various manufacturers. However, its inherent defects hinder further improvement of economic benefits. The utilization rate of molten iron is low. Harmful carcinogenic gases are inevitably produced during the iron mold coating process, which is not conducive to environmental protection and harms the health of on-site personnel. In addition, the wear resistance of the product is difficult to improve, which reduces the overall performance.

[0004] Therefore, in view of the above-mentioned shortcomings, namely, low utilization rate of molten iron, the inevitable generation of harmful carcinogenic gases in the production process, which is not conducive to environmental protection, harms the health of on-site personnel, and it is difficult to improve the wear resistance of the product; a grinding ball centrifugal casting production line is set up to solve the above-mentioned problems. Summary of the invention

[0005] In order to overcome the low utilization rate of molten iron in the existing iron mold coated sand grinding ball production line, harmful carcinogenic gases are inevitably produced during the production process, which is not conducive to environmental protection, damages the health of on-site personnel, and the wear resistance of the product is difficult to improve, affecting the further improvement of economic benefits.

[0006] The technical solution of the present invention is: a method for centrifugal casting of grinding balls, which adopts cast iron and refractory composite mold casting, and uses centrifugal molding casting technology, cooperates with intelligent quantitative casting machine to complete the product casting process, and peripherally supports corresponding circulation equipment, demoulding device, cooling and spraying device to realize intelligent continuous production.

[0007] A grinding ball centrifugal casting production line includes the following steps:

[0008] S1: The grinding ball centrifugal casting production line consists of several machines, casting stations, several cooling stations, demoulding stations and cleaning and spraying stations. The above stations are connected in series through the mold circulation system to form a complete production line;

[0009] S2: The pouring station is equipped with an intelligent quantitative pouring machine, which can accurately control the pouring weight according to the current mold needs, maximize the utilization rate of molten iron, and eliminate the appearance of material shortage and waste. The pouring curve can be set, and only manual loading and unloading is required. The rest of the work is automatically completed by PLC control, reducing the impact of human factors on product quality. After the mold is moved to the pouring station, the mold and the mold car descend along the track, the mold and the centrifugal rotating disk are connected, and the safety cover descends at the same time to close the pouring space, and the pouring runner is in place. After the control system detects that it is correct, the mold begins to rotate, and the pouring machine pours the quantitative molten iron according to the set process and returns to its original position. When the mold rotation time reaches the set time, the molten iron solidifies, the mold stops rotating, and the positioning stops. Then the lifting track carries the mold car, the mold and the safety cover to the original position, completing the pouring and waiting for the next mold to be in place. The poured mold enters the cooling station. The cooling station can be equipped with an air cooling and water cooling system to accelerate mold cooling, reduce the number of molds used, and shorten the length of the production line;

[0010] S3: The mold car track of the demoulding station is fixed on the flap, and there is a flip shaft under the flap. After the mold is in place, the mold lifting mechanism moves to lift the upper mold assembly, and then the clamping cylinder moves to fix the mold car, the lower mold assembly and the mold car track together. Then the motor drives the flap and the lower mold to flip through the reducer, and the grinding balls are poured into the ball drop grid. After the platform flips 180 degrees, if it is detected that there is a product that has not been demoulded, it will vibrate repeatedly until the mold is clean, the flap and the lower mold are reversed, the lower mold assembly is reset, and the upper mold assembly descends to close the mold, waiting to move to the next station;

[0011] S4: After the mold cart brings the mold into the cleaning and spraying station, the nozzle lifting mechanism drives the spray head down to the vicinity of the mold gap, and the nozzle sprays the release agent. When the set time comes, the spray head resets, and the mold waits to enter the pouring station to start a new cycle.

[0012] Preferably, the mold circulation system includes a fixed rail, an electric cylinder, a transfer rail, a mold cart, a mold, a transfer cart, a lifting rail and a flipping rail. The lifting rail and the flipping rail correspond to the pouring station and the demolding station respectively. The fixed rails are six groups arranged in parallel in pairs. Multiple groups of mold carts are provided on the fixed rails, and the mold carts carry molds.

[0013] Preferably, transfer tracks are provided at both ends of the fixed track, and transfer vehicles are provided on the transfer tracks.

[0014] Preferably, the demolding station includes a flipping mechanism and a mold lifting mechanism. The flipping mechanism includes a mold cart track, a flip plate, a positioning device, a flip axis, a first reducer, a motor, and a flip support frame. A movable mold cart is provided on the mold cart track, and the mold cart carries an upper mold assembly and a lower mold assembly.

[0015] Preferably, a mold car track is fixed on the flap, and positioning devices are installed on both sides of the mold car track. The positioning hooks of the positioning device are controlled by the clamping cylinder. A flip shaft is provided at the bottom of the flap, and the flip shaft is installed in the bearing of the support frame. A first reducer is provided at one end of the flip shaft, and a motor is provided at one end of the first reducer. The mold lifting mechanism is located at the upper part of the demolding station, and a ball drop grid is provided below the demolding station.

[0016] Preferably, a mold lifting mechanism is provided on the upper part of the demoulding station, a first lifting cylinder is provided above the lifting frame of the mold lifting mechanism, and a lifting hook is installed at the end of the first lifting cylinder.

[0017] Preferably, the spraying station includes a nozzle lifting mechanism and a mold cart. A spray head is provided below the nozzle lifting mechanism, a second lifting cylinder is provided on the top of the spray head, a grinding ball mold is provided correspondingly below the spray head, and a mold cart is provided below the grinding ball mold.

[0018] Preferably, the pouring and casting station is provided with a centrifugal rotating mechanism, an intelligent quantitative pouring machine and a track lifting mechanism. A safety cover is installed on the periphery of the centrifugal rotating mechanism. The bottoms of the centrifugal rotating mechanism, the track lifting mechanism and the safety cover use a common mounting base. A coupling and a rotating disk are arranged inside the centrifugal rotating mechanism. A reducer adapter, a second reducer and a servo motor are fixedly installed in the center below the base. The servo motor finally drives the rotating disk to rotate through the second reducer and the coupling. A track is fixed on the track frame of the lifting mechanism, and a guide rod is installed under the track frame. Track lifting cylinders are fixed on both sides of the mounting base. The track frame is connected to the cylinder rod. The track frame, the track and the safety cover connected to them are driven up and down by the third lifting cylinder, and the mold car and the mold on the track are lifted and lowered accordingly, thereby realizing the engagement and separation between the mold and the rotating disk.

[0019] Beneficial effects of the present invention:

[0020] 1. Use cast iron and refractory composite mold casting to achieve the purpose of reducing production costs and eliminating harmful gas emissions. Use centrifugal casting process to reduce pouring and riser. Centrifugal casting is conducive to the discharge of bubbles and slag. The strong centrifugal force makes the casting structure denser. Composite mold casting has a shorter production process, a smaller footprint, intelligent production, less on-site labor, low pouring temperature, better adaptability, more than 92% molten iron utilization, less waste, and a PLC control system that can better control the production line. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 What is shown is the overall schematic diagram of the centrifugal casting production line of the present invention;

[0022] Figure 2 Shown is a schematic diagram of a mold circulation system of a centrifugal casting production line of the present invention;

[0023] Figure 3 Shown is a side view schematic diagram of the centrifugal casting production line of the present invention;

[0024] Figure 4 Shown is a schematic diagram of a demoulding station of a centrifugal casting production line of the present invention;

[0025] Figure 5 Shown is a schematic diagram of a cleaning and spraying station of a centrifugal casting production line of the present invention;

[0026] Figure 6 Shown is a schematic diagram of a casting station of a centrifugal casting production line of the present invention;

[0027] Figure 7 Shown is a schematic side view of a mold circulation system of a centrifugal casting production line of the present invention.

[0028] Description of reference numerals: 1. mold circulation system; 2. intelligent quantitative pouring machine; 3. demoulding station; 4. cleaning and spraying station; 5. pouring station; 101. fixed track; 102. electric cylinder; 103. mold; 104. transfer track; 105. conveying track; 106. transfer vehicle; 31. flip mechanism; 32. positioning device; 33. mold lifting mechanism; 301. upper mold assembly; 302. lower mold assembly; 304. lower mold; 305. ball drop grid; 307. mold vehicle track; 311. flap; 312. flip shaft; 313. first reducer; 314. motor; 315. flip support frame; 3 21. Clamping cylinder; 322. Cylinder seat; 323. Connecting rod; 324. Bearing; 325. Positioning hook; 331. First lifting cylinder; 332. Lifting frame; 333. Lifting hook; 401. Second lifting cylinder; 402. Spray head lifting mechanism; 403. Spraying head; 404. Grinding ball and grinding tool; 500. Base seat; 51. Centrifugal rotating mechanism; 52. Track lifting mechanism; 53. Safety cover; 511. Rotating disk; 512. Reducer adapter; 513. Second reducer; 514. Servo motor; 521. Third lifting cylinder; 522. Guide rod; 523. Track frame; 524. Track. DETAILED DESCRIPTION

[0029] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0030] See also Figure 1-7 The present invention provides an embodiment: a grinding ball centrifugal casting method, which is characterized by using a cast iron and refractory composite mold for casting, and a centrifugal molding casting process, cooperating with an intelligent quantitative casting machine to complete the product casting process, and peripherally supporting corresponding circulation equipment, demoulding devices, cooling and spraying devices to realize intelligent continuous production.

[0031] A grinding ball centrifugal casting production line includes the following steps:

[0032] S1: The grinding ball centrifugal casting production line consists of several machines, a casting station 5, several cooling stations, a demoulding station 3 and a cleaning and spraying station 4 connected in series through a mold circulation system 1 to form a complete production line;

[0033] S2: The pouring station 5 is equipped with an intelligent quantitative pouring machine 2, which can accurately control the pouring weight according to the current mold 103, maximize the utilization rate of molten iron, and prevent the occurrence of material shortage and waste. The pouring curve can be set, and only manual loading and unloading is required. The rest of the work is completed by PLC control, reducing the impact of human factors on product quality. After the mold 103 is moved to the pouring station 5, the mold 103 and the mold car are lowered along the track 524, and the mold 103 is connected to the centrifugal rotating disk 511. At the same time, the safety cover is lowered to close the pouring space, and the pouring runner is in place. After the control system detects that it is correct, the motor 314 The rotating disk 511 and the mold 103 start to rotate driven by the reducer. The pouring machine returns to its original position after pouring a predetermined amount of molten iron according to the set process. When the rotation time of the mold 103 reaches the set time and the molten iron solidifies, the mold 103 stops rotating and stops positioning. Then the lifting track brings the mold car, the mold 103 and the safety cover up to the original position, the pouring is completed, and the next mold 103 is waiting to be put into place. The poured mold 103 enters the cooling station. The cooling station can be equipped with an air cooling or water cooling system to accelerate the cooling of the mold 103, reduce the number of molds 103 used, and shorten the length of the production line.

[0034] S3: The mold car track 307 in the demoulding station 3 is fixed on the flap 311, and there is a flip shaft 312 below. After the mold 103 is in place, the mold 103 lifting mechanism is actuated to lift the upper mold assembly 301 in the mold 103, and then the clamping cylinder 321 is actuated to fix the mold car, the lower mold assembly 302 and the mold car track 307 together. Then the motor 314 drives the flap 311 and the lower mold assembly 302 to flip through the first reducer 313, and pours the grinding balls into the ball drop grid 305. After the lower mold assembly 302 is flipped, if it is detected that there is a product that has not been released from the mold, it will vibrate repeatedly until the product is completely ejected, and the flap 311 will reverse the lower mold assembly. After the lower mold assembly 302 is reset, the upper mold descends to close the mold and waits to move to the next station;

[0035] S4: After the mold cart carries the mold 103 into the cleaning and spraying station 4, the nozzle lifting mechanism 402 drives the spray head 403 to descend to the vicinity of the mold gap, and the nozzle sprays the release agent. When the set time comes, the spray head 403 is reset, and the mold 103 waits to enter the pouring station 5 to start a new cycle.

[0036] See also Figure 1-3In this embodiment, the mold circulation system 1 includes a fixed rail 101, an electric cylinder 102, a transfer rail 104, a conveying rail 105, a mold cart, a mold 103, a transfer cart 106, a lifting rail and a reversing rail. The lifting rail and the reversing rail correspond to the pouring station 5 and the demolding station 3 respectively. The fixed rail 101 is arranged in six groups in parallel. Multiple groups of mold carts are arranged on the fixed rail 101. The mold 103 is carried on the top of the mold cart. A transfer rail 104 is arranged on the outer side of the fixed rail 101, and a transfer cart 106 is arranged on the transfer rail 104.

[0037] See also Figure 2-4 In this embodiment, the demolding station 3 is provided with a flipping mechanism 31, a clamping positioning device 32 and a mold 103 lifting mechanism. A ball drop grid 305 is provided below the demolding station 3. The flipping mechanism 31 includes a flap 311 and a flip shaft 312 fixed below the flap 311. One end of the flip shaft 312 is connected to a first reducer 313. The first reducer 313 is fixed on a flip support frame 315 and is directly connected to a motor 314. A mold car track 307 is fixed on the flap 311. When the flap 311 is in the original position, the mold 103 track 524 is connected to the fixed track 101 of the circulation system. The mold car can walk on the mold car track 307. The mold car carries an upper mold assembly 301 and a lower mold assembly 302. A clamping and positioning device 32 is also installed on 311. The positioning device 32 is composed of a positioning hook 325, a bearing 324, a connecting rod 323, a cylinder seat 322, a clamping cylinder 321 and a fisheye joint. When the clamping cylinder 321 is actuated, the positioning hook 325 is driven to open and close through the connecting rod 323 to loosen or fix the lower mold assembly 302. A mold 103 lifting mechanism is provided above the demoulding station 3, which is composed of a first lifting cylinder 331, a lifting frame 332 and a lifting assembly; when the mold 103 moves, the lifting assembly is in the lower position. After the mold 103 is positioned, the first lifting cylinder 331 is actuated to lift the upper mold assembly 301 to the upper position, and the flipping mechanism 31 flips the lower mold assembly 302 to release the product from the mold 103.

[0038] See also Figure 4-7In this embodiment, the cleaning and spraying station 4 includes a second lifting cylinder 401, a nozzle lifting mechanism 402 and a mold car. A spray head 403 is provided below the nozzle lifting mechanism 402, and a second lifting cylinder 401 is provided on the top of the spray head 403. A grinding ball mold 404 is correspondingly provided below the spray head 403, and the grinding ball mold 404 is fixed on the mold car. The pouring station 5 includes a centrifugal rotating mechanism 51, an intelligent quantitative pouring machine 2 and a track lifting mechanism 52. A common mounting base is provided at the bottom of the track lifting mechanism 52 and the centrifugal rotating mechanism 51. A rotatable rotating disk 511 is installed on the mounting base of the centrifugal rotating mechanism 51, and a safety cover 53 is installed on the periphery of the rotating disk 511. The track lifting mechanism 52 is on the outside of the centrifugal rotating mechanism 51, and a second reducer 513 is provided below. A servo motor 514 is provided at the bottom of the second reducer 513, and a driving cylinder of the track lifting mechanism 52 is also installed under the base.

[0039] The embodiments of the present invention are described in detail above with reference to the accompanying drawings, but the present invention is not limited to the above embodiments, and various changes can be made within the knowledge scope of those skilled in the art without departing from the spirit of the present invention.

Claims

1. A method for producing grinding balls, characterized in that The casting process is completed by using a composite mold of cast iron and refractory materials and a centrifugal casting process, in conjunction with an intelligent quantitative pouring machine. The corresponding peripheral circulation equipment, demoulding device, cooling and spraying device are used to realize intelligent continuous production.

2. A grinding ball centrifugal casting production line, characterized in that: The following steps are included: S1: The grinding ball centrifugal casting production line is composed of a plurality of machines, wherein a casting station (5), a plurality of cooling stations, a demoulding station (3) and a cleaning and spraying station (4) are connected in series through a mold circulation system (1) to form a complete production line; S2: The pouring station (5) is equipped with an intelligent quantitative pouring machine (2), which can accurately control the pouring weight according to the current mold, maximize the utilization rate of molten iron, and prevent the occurrence of material shortage and waste. The pouring curve can be set, and only manual loading and unloading is required. The rest of the work is completed by PLC control, reducing the impact of human factors on product quality. After the mold is moved to the pouring station, the mold and the mold car are lowered along the track, the mold is connected to the centrifugal rotating disk, and the safety cover is lowered at the same time to close the pouring space and put the pouring runner in place. After the control system detects that it is correct, the mold starts to rotate, and the pouring machine pours the quantitative molten iron according to the set process and then stops pouring. When the mold rotation time reaches the set time, the molten iron solidifies, and the mold stops rotating. Then the lifting track brings the mold car, the mold and the safety cover up to the original position, completing the pouring, waiting for the next mold to be put in place, and the poured mold enters the cooling station. The cooling station can be equipped with an air cooling and (or) water cooling system to accelerate mold cooling, reduce the number of molds used, and shorten the length of the production line; S3: The mold cart track at the demoulding station (3) is fixed on the flap, and there is a flip shaft under the flap. After the mold is in place, the mold lifting mechanism (33) is activated to lift the upper mold assembly (301) of the mold, and then the clamping cylinder (321) is activated to fix the mold cart, the lower mold assembly (302) and the mold cart track (307) together. Then the motor drives the platform and the lower mold (304) to flip through the first reducer (313), and the grinding balls are poured into the ball drop grid (305). After the lower mold assembly (302) is flipped 180 degrees, if it is detected that there is a product that has not been demoulded, it will vibrate repeatedly until the mold is clean, and the flap (311) will reverse the lower mold assembly (302). After the lower mold assembly (302) is reset, the upper mold assembly (301) descends to close the mold and waits to move to the next station; S4: After the mold cart brings the mold into the cleaning and spraying station (4), the spray head lifting mechanism (402) drives the spray head to descend to the vicinity of the mold gap, and the spray head sprays the release agent. After the set time, the spray head (403) is reset, and the mold waits to enter the casting station to start a new cycle.

3. The grinding ball centrifugal casting production line according to claim 2, characterized in that: The mold circulation system (1) in S1 includes a fixed track (101), an electric cylinder (102), a transfer track (104), a conveying track (105), a mold cart, a mold (103), a transfer cart (106), a lifting track and a turning track, wherein the lifting track and the turning track correspond to the pouring station and the demoulding station respectively, the fixed track (101) is arranged in six groups in parallel, and a plurality of mold carts are arranged on the fixed track (101), and the mold carts carry the mold (103).

4. The grinding ball centrifugal casting production line according to claim 3, characterized in that: A transfer track (104) is arranged outside the fixed track (101), and a transfer vehicle (106) is arranged on the transfer track (104).

5. The grinding ball centrifugal casting production line according to claim 2, characterized in that: The demoulding station (3) in S2 includes a flipping mechanism (31) and a mold lifting mechanism (33). The flipping mechanism includes a mold car track (307), a flip plate (311), a positioning device (32), a flip shaft (312), a first reducer (313), a motor (314), and a flip support frame (315). A movable mold car is provided on the mold car track (307), and the mold car carries an upper mold assembly (301) and a lower mold assembly (302).

6. A grinding ball centrifugal casting production line according to claim 5, characterized in that: A mold vehicle track (307) is fixed on the flap (311), and positioning devices (32) are installed on both sides of the mold vehicle track (307). The positioning hooks (325) of the positioning device (32) are controlled by the clamping cylinder (321). A turning shaft (312) is provided at the bottom of the flap (311), and the turning shaft (312) is installed in the bearing of the support frame (315). A first reducer (313) is provided at one end of the turning shaft, and a motor (314) is provided at one end of the first reducer (313). The mold lifting mechanism (33) is located at the upper part of the demoulding station (3), and a ball drop grid (305) is provided below the demoulding station (3).

7. The grinding ball centrifugal casting production line according to claim 5, characterized in that: A mold lifting mechanism (33) is provided on the upper part of the demoulding station (3), a first lifting cylinder (331) is provided above the lifting frame (332) of the mold lifting mechanism (33), and a lifting hook (333) is installed at the end of the first lifting cylinder (331).

8. The grinding ball centrifugal casting production line according to claim 2, characterized in that: The cleaning and spraying station (4) in S3 includes a nozzle lifting mechanism (402) and a mold cart. A spray head (403) is provided below the nozzle lifting mechanism (402). A second lifting cylinder (401) is provided on the top of the spray head (403). A grinding ball mold (404) is provided below the spray head (403). A mold cart is provided below the grinding ball mold (404).

9. The grinding ball centrifugal casting production line according to claim 2, characterized in that: The pouring station (5) in S4 is provided with a centrifugal rotating mechanism (51), an intelligent quantitative pouring machine (2) and a track lifting mechanism (52). A safety cover (53) is installed on the periphery of the centrifugal rotating mechanism (51). The bottoms of the centrifugal rotating mechanism (51), the track lifting mechanism (52) and the safety cover (53) use a common mounting base (500). A coupling and a rotating disk (511) are provided in the centrifugal rotating mechanism (51). A reducer adapter (512), a second reducer (513) and a servo motor (514) are fixedly installed in the center below the base (500). The servo motor (514) drives the rotating disk (511) to rotate through the second speed reducer (513) and the coupling. The track (524) is fixed on the track frame (523) of the lifting mechanism (52). A guide rod (522) is installed under the track frame (523). Track lifting cylinders (521) are fixed on both sides of the installation base (500). The track frame (523) and the cylinder rod are connected. The third lifting cylinder (521) drives the track frame (523), the track (524) and the safety cover connected to them to move up and down, and the mold car and the mold (103) on the track are lifted and lowered accordingly.

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