Casting automatic sorting device

Abstract

The invention relates to the technical field of casting production, and discloses an automatic sorting device for castings. Comprising a vibration disc, a first conveyor is arranged at an output port of the vibration disc, a spacing mechanism is arranged at the joint of the first conveyor and the vibration disc, a turn-over detection mechanism is arranged on the first conveyor, a second conveyor is connected to the tail end of the first conveyor, and a sorting mechanism is arranged on the second conveyor. A discharging mechanism is arranged at the tail end of the second conveyor, and the sorting mechanism is connected with a conveying rail. A multi-angle industrial lens is adopted to realize six-surface omnibearing detection of the casting, and surface defects are ensured to be free of omission; the intelligent turn-over mechanism is matched with the anti-deviation design, so that the detection accuracy and consistency are remarkably improved; the spacing mechanism orderly separates the castings, so that stacking and overlapping are avoided, and optimal conditions are created for subsequent detection; and a closed-loop circulation detection mechanism is used for carrying out secondary reinspection on the suspicious casting, so that the misjudgment rate is greatly reduced, and the overall yield is remarkably improved.

Description

Technical Field

[0001] The present invention relates to the technical field of casting production, and specifically to an automatic sorting device for castings. Background Art

[0002] During the casting production process, surface quality inspection is a key link to ensure the product qualification rate. Traditional casting inspections mainly rely on manual visual inspection, which is not only inefficient but also prone to missed or misjudged inspections due to fatigue or subjective judgment. With the development of automation technology, some enterprises have begun to use mechanical sorting equipment to replace manual inspection, but the existing technologies still have the following problems:

[0003] The disordered arrangement of castings affects the inspection accuracy: During the conveying process, castings are prone to stacking or overlapping, resulting in the inspection mechanism being unable to accurately identify surface defects and reducing the sorting accuracy rate.

[0004] Insufficient flipping inspection: Existing equipment usually only takes photos and inspects one side or part of the angles of the casting, making it difficult to comprehensively cover all surfaces of the casting, resulting in some defects not being detected.

[0005] The misjudgment rate of the sorting mechanism is high: Due to incomplete inspection data or response delay of the sorting mechanism, some qualified castings may be wrongly rejected, or defective castings are not effectively intercepted, affecting the overall yield rate.

[0006] Secondary damage is easily caused during the blanking process: If qualified castings fall freely during blanking, they may be scratched or deformed on the surface due to collisions, reducing the quality of the final product.

[0007] The processing efficiency of defective castings is low: Some sorting systems only simply reject defective castings without setting up a cyclic re-inspection mechanism, resulting in some repairable or misjudged castings being directly discarded, increasing production costs.

[0008] In view of the above problems, there is an urgent need for an efficient, accurate and cyclic inspection-capable automatic sorting system for castings to improve the inspection efficiency, reduce the misjudgment rate, and ensure that the castings are not damaged during sorting and blanking. Summary of the Invention

[0009] Aiming at the deficiencies of the prior art, the present invention provides an automatic sorting device for castings, which solves the problems of inspection, sorting, blanking and inspection cycle in the traditional casting production process. Through an integrated design, the overall yield rate is increased, and a better and more efficient inspection efficiency is achieved, ensuring the yield rate of casting production and processing.

[0010] To achieve the above object, the present invention provides the following technical solution: A casting sorting system includes a vibrating bowl, a first conveyor is provided at the output port of the vibrating bowl, a spacing mechanism is provided at the connection between the first conveyor and the vibrating bowl, a turning detection mechanism is provided on the first conveyor, the end of the first conveyor is connected to a second conveyor, a sorting mechanism is provided on the second conveyor, a blanking mechanism is provided at the end of the second conveyor, the sorting mechanism is connected to a conveying rail, the end of the conveying rail is connected to a third conveyor, a leveling mechanism is provided at the end of the third conveyor, and a stepped loader is connected to the third conveyor and the vibrating bowl.

[0011] Further: The spacing mechanism includes a support frame, a first telescopic cylinder is fixed at the inclined end of the support frame, a connecting rod is fixed at the output end of the first telescopic cylinder, a spacing plate is fixed at the end of the connecting rod, the spacing plate is inclined at the connection between the vibrating bowl and the first conveyor, and the first telescopic cylinder drives the spacing plate to intermittently separate the castings through the connecting rod.

[0012] Further: The turning detection mechanism includes a first motor, the first motor is fixed on the side wall of the first conveyor, a rotating rod is fixed at the output end of the first motor, a connecting sleeve is fixed on the rotating rod, a turning rod is fixed on the side wall of the connecting sleeve, a connecting sliding rod slides on the turning rod, a screw is threadedly connected to the connecting sliding rod and abuts against the outer end face of the turning rod, a contact block is fixed at the end of the connecting sliding rod, a stop bar is fixed at the inner end of the first conveyor, a fixing frame is fixed on the other side wall of the first conveyor, an industrial camera is fixed at the lower end of the fixing frame, the contact block cooperates with the stop bar to turn the casting, and the industrial camera takes pictures and compares the castings.

[0013] Further: The sorting mechanism includes a sorting partition board, and the sorting partition board sorts defective castings to the conveying rail according to the detection data.

[0014] Further: The blanking mechanism includes a blanking rail, a buffer roller is provided at the turning point of the blanking rail, sliders are fixed at both ends of the buffer roller, a sliding rod is fixed outside the turning end of the blanking rail, a spring is sleeved on the sliding rod, a nut is threadedly connected to the sliding rod at the lower end of the slider, a blanking channel is fixed at the lower end of the blanking rail, inclined sliding plates are fixed in the blanking channel in a staggered manner, a receiving box is provided at the lower end of the blanking channel, a second motor is fixed in the receiving box, a disc is fixed at the output end of the second motor, a plurality of grooves are formed in the upper end of the disc, and sliding rollers are rotatably arranged in the grooves. The buffer roller adjusts the blanking gap, the inclined sliding plates slow down the blanking impact, and the disc disperses the castings to prevent accumulation.

[0015] Further: The leveling mechanism includes a support base fixed to the side wall of the third conveyor. An extension frame is fixed to the upper end of the support base, and symmetric second telescopic cylinders are fixed to the lower end of the extension frame. The output end of one of the second telescopic cylinders is fixed with an inclined plate, and the output end of the other second telescopic cylinder is fixed with a flat plate. The inclined plate and the flat plate adjust the placement angle of the casting.

[0016] Further: The stepped loader returns the leveled defective castings to the vibrating bowl for cyclic detection.

[0017] Further: The first conveyor, the second conveyor, the third conveyor, and the stepped loader are all electrically connected to the main controller.

[0018] Further: A number of anti-slip strips with equal spacing are fixed on the conveyor belt of the first conveyor. The anti-slip strips are arranged in an arrow shape and are arranged in the same direction as the conveying direction of the first conveyor.

[0019] Further: The upper end surface of the stop bar is inclined, and the inclination angle at the end close to the casting is an obtuse angle. The upper end of the stop bar is arranged as an arc surface.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] The present invention realizes the six-sided all-round detection of castings by using multi-angle industrial lenses to ensure no omission of surface defects; through the intelligent turning mechanism and anti-offset design, the detection accuracy and consistency are significantly improved; the spacing mechanism separates the castings in an orderly manner to avoid stacking and overlapping, creating the best conditions for subsequent detection; the closed-loop cyclic detection mechanism performs secondary re-inspection on suspicious castings, greatly reducing the misjudgment rate, and significantly improving the overall yield rate.

[0022] The present invention greatly reduces manual intervention through a fully automated operation mode, reducing labor costs; the modular design is convenient for maintenance, and the standardized components reduce the use cost; the cyclic detection mechanism minimizes material waste and improves resource utilization; the control system records production data throughout the process, providing a reliable basis for quality traceability and management decision-making; the compact and reasonable structure design ensures the stable operation of the system and meets the continuous production requirements.

[0023] The innovative buffer feeding system of the present invention effectively avoids surface damage of castings through multi-stage deceleration and dispersion design; the adaptive adjustment mechanism can be compatible with different specifications of products to ensure the safety and reliability of the processing process. The anti-piling device ensures neat and orderly feeding, avoiding secondary damage; each functional module operates in coordination, improving production efficiency while ensuring that the product quality is always in the best state. The system operates stably and reliably, providing all-round guarantee for product quality.

[0024] Other features and advantages of the present invention will be set forth in the following description, and in part will be obvious from the description, or may be learned by practice of the present invention. The objectives and other advantages of the present invention may be realized and attained by the structure particularly pointed out in the specification, claims as well as the drawings. Brief Description of the Drawings

[0025] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0026] Figure 2 It is a schematic diagram of the structure of the vibrating disk and the second conveyor of the present invention;

[0027] Figure 3 It is a schematic diagram of the structure of the part of the turning detection mechanism of the present invention;

[0028] Figure 4 It is a schematic diagram of the structure of the blanking mechanism of the present invention;

[0029] Figure 5 It is Figure 1 The enlarged schematic diagram of the structure at position A in

[0030] Figure 6 It is Figure 1 The enlarged schematic diagram of the structure at position B in

[0031] Figure 7 It is Figure 1 The enlarged schematic diagram of the structure at position C in

[0032] Figure 8 It is Figure 4 The enlarged schematic diagram of the structure at position D in

[0033] Figure 9 It is a schematic diagram of the structure of the part of the blanking mechanism of the present invention.

[0034] In the figure: 1, vibrating disk; 2, first conveyor; 3, anti-slip strip; 4, support frame; 5, first telescopic cylinder; 6, connecting rod; 7, spacer; 8, first motor; 9, rotating rod; 10, connecting sleeve; 11, turning rod; 12, connecting slide bar; 13, screw; 14, contact block; 15, stop bar; 16, fixing frame; 17, industrial lens; 18, second conveyor; 19, sorting partition; 20, conveying rail; 21, blanking rail; 22, buffer roller; 23, perforation; 24, slide bar; 25, spring; 26, slider; 27, nut; 28, blanking channel; 29, inclined slide plate; 30, receiving box; 31, second motor; 32, disk; 33, groove; 34, sliding roller; 35, third conveyor; 36, stepped loader; 37, support seat; 38, extension frame; 39, second telescopic cylinder; 41, flat plate; 42, inclined plate. Detailed Description of the Preferred Embodiments

[0035] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the technical field of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0036] The structure of an automatic sorting device for castings in the present invention is similar to that of an existing automatic sorting device for castings. The main improvement points of the present invention are as follows: through a turning detection mechanism, a sorting mechanism, a blanking mechanism, and a leveling mechanism, the castings are photographed and detected comprehensively, and the defective castings are effectively sorted and re-detected, which not only improves the detection quality of the castings, but also effectively improves the detection efficiency under the action of the leveling mechanism; the qualified castings can further increase the qualified rate through the blanking mechanism during blanking.

[0037] Please refer to Figures 1 - 9 ; The implementation steps in this embodiment are as follows: The castings are vibrated and fed orderly in the vibrating bowl 1. A first conveyor 2 is arranged at the output port of the vibrating bowl 1. An interval mechanism is arranged at the connection between the first conveyor 2 and the vibrating bowl 1. The castings are intermittently and orderly separated through the interval mechanism to prevent the castings from piling up on the first conveyor 2. A turning detection mechanism is arranged on the first conveyor 2. The castings are turned over and photographed through the turning detection mechanism, and the data is uploaded after the turning-over photographing and compared with the actual standard. A second conveyor 18 is arranged at the end of the first conveyor 2. A sorting mechanism is arranged at the upper end of the second conveyor 18. Through the comparison of the data after the turning-over photographing, the defective castings are sorted and blocked through the sorting mechanism. A blanking mechanism is arranged at the end of the second conveyor 18. The qualified castings enter the blanking mechanism through the transportation of the second conveyor 18. The blanking mechanism buffers the blanking of the castings and can prevent blanking accumulation. Among them, the defective castings sorted by the sorting mechanism are isolated and transported through the conveying rail 20 on the side of the second conveyor 18. A third conveyor 35 is arranged at the end of the conveying rail 20. The third conveyor 35 transports the defective castings for secondary detection, which can improve the qualified rate and avoid incorrect data comparison. A leveling mechanism is arranged on one side of the end of the third conveyor 35. The leveling mechanism arranges the defective castings horizontally. The horizontally arranged defective castings are transported to the stepped loader 36 at the end of the third conveyor 35. The loading end of the stepped loader 36 extends into the vibrating bowl 1. Therefore, through a complete set of processes, not only can the castings be sorted for defects, but also the passing rate of data comparison can be guaranteed, so that the defective castings can be circulated in the process for detection and sorting. The qualified castings can avoid piling up and damaging the surface due to too fast falling during blanking, and further improve the qualified rate.

[0038] Among them, the first conveyor 2, the second conveyor 18, the third conveyor 35, and the stepped loader 36 mentioned above can all be purchased on the market. They belong to mature technologies and have been fully disclosed. Therefore, they will not be repeated in the specification. The first conveyor 2, the second conveyor 18, the third conveyor 35, and the stepped loader 36 are equipped with power connection lines, and they are all electrically connected to the external main controller and the 220V single-phase voltage (or 380V line voltage) through the power lines. And the main controller can be a conventional known device such as a computer that plays a control role.

[0039] The spacing mechanism includes a support frame 4. The support frame 4 is fixed on the side wall of the first conveyor 2. A first telescopic cylinder 5 is fixed on the upper side wall of the support frame 4. The output end of the first telescopic cylinder 5 is fixedly connected with a connecting rod 6. The middle of the connecting rod 6 is rotatably connected to the side wall of the support frame 4. A spacing plate 7 is fixed at the lower end of the connecting rod 6. Through the intermittent telescopic movement of the first telescopic cylinder 5, the castings are spaced and isolated by the spacing plate 7, so that the castings on the first conveyor 2 can be spaced apart, facilitating the detection and flipping in the subsequent steps, and improving the detection efficiency and detection quality of the overall process.

[0040] The flipping detection mechanism includes a first motor 8 fixed to the side wall of the first conveyor 2, a rotating rod 9 is fixedly connected to the output end of the first motor 8, the other end of the rotating rod 9 is rotatably arranged with the outer wall of the first conveyor 2, a connecting sleeve 10 is fixed to the rotating rod 9, and a symmetrical flipping rod 11 is fixed to the side wall of the connecting sleeve 10, a connecting slide bar 12 is slidably arranged on the flipping rod 11, and a screw 13 is threadedly connected to the upper end of the connecting slide bar 12, and the screw 13 passes through the end of the connecting slide bar 12 and is arranged against the outer wall of the flipping rod 11, and a contact block 14 is fixedly connected to the inner side of the lower end of the connecting slide bar 12, and the end face of the contact block 14 is arranged in an arc shape. Driven by the first motor 8, the contact block 14 toggles the casting, and the position of the connecting slide bar 12 is adjusted according to the height of the casting. In order to facilitate flipping, a baffle 15 is fixedly connected to the inner wall of the first conveyor 2, and the upper end of the baffle 15 is inclined, and the top end is arc-shaped. When the casting is turned according to When the blocking bar 15 is used to resist on the left and right, the contact block 14 is used to push the upper end in the opposite direction to assist in the flipping. At the same time, an anti-skid strip 3 is fixedly connected to the conveyor belt of the first conveyor 2. The anti-skid strip 3 can provide reverse friction, thereby further improving the efficiency and success rate of the flipping. Four groups of contact blocks 14 are arranged on the outer wall of the first conveyor 2, and an industrial lens 17 is arranged between each pair of contact blocks 14. The upper end of the industrial lens 17 is connected to a fixed frame 16, and the fixed frame 16 is fixed to the outer end of the first conveyor 2. After the flipping, the end face of the casting is photographed vertically downward through the industrial lens 17, and data comparison is performed on the surface, thereby improving the yield rate of the casting. At the same time, data is transmitted for unqualified castings, and the data is recorded and transmitted according to the order of movement. A three-sided industrial lens 17 is arranged at the end of the first conveyor 2, and the six sides of the casting can be completely photographed and compared through the three-sided industrial lens 17.

[0041] The castings are transported by the first conveyor 2 to the second conveyor 18. The sorting mechanism on the second conveyor 18 includes sorting partitions 19. There are several sorting partitions 19, which are controlled to rotate by a controller and perform corresponding operations based on the transmission of photographed data to sort and isolate defective castings, and move the defective castings to the conveying rail 20, which are then transferred downward to the third conveyor 35 for cyclic transportation. The movement control of the sorting partitions 19 and the corresponding operations of data transmission are existing known technologies and will not be introduced in detail here.

[0042] The blanking mechanism includes a blanking rail 21 which is arranged obliquely downward. A buffer roller 22 is provided at the turning point of the blanking rail 21. The surface of the buffer roller 22 is smooth. Sliders 26 are fixed at both ends of the buffer roller 22. A perforation 23 is formed in the protruding part at the turning of the blanking rail 21, and the slider 26 is arranged through the perforation 23. A slide bar 24 is fixed on the outer side wall of the protruding end of the blanking rail 21. A spring 25 is sleeved on the slide bar 24. The upper end of the spring 25 is fixed to the outer end of the blanking rail 21, and the lower end of the spring 25 is fixedly arranged with the upper end of the slider 26. A nut 27 is threadedly connected to the slide bar 24 below the slider 26, and the gap between the buffer roller 22 and the blanking rail 21 is adjusted by the nut 27 and adjusted according to the size of the casting. A blanking channel 28 is fixed at the lower end of the blanking rail 21. An inclined slide plate 29 is fixedly connected in the blanking channel 28. The inclined slide plates 29 are arranged in relative dislocation. The castings slide left and right and cross in the blanking channel 28 to slow down the blanking impact force. A receiving box 30 is placed at the blanking end of the blanking channel 28. The receiving box 30 is rectangular. A second motor 31 is fixed in the receiving box 30. A disc 32 is fixed to the upper end of the output of the second motor 31. A number of grooves 33 with equal spacing are formed in the upper end of the disc 32. Slide rollers 34 are rotated in the grooves 33. The sizes of the slide rollers 34 are different and are arranged linearly from large to small. When the casting falls on the disc 32, it is swung to the periphery by rotation. Due to the different contact areas at different positions of the casting during blanking, the contact friction is different, so that the positions where the casting is thrown out on the disc 32 are different, avoiding the accumulation of castings during blanking in the receiving box 30.

[0043] The leveling mechanism includes a support seat 37 fixed on the side of the third conveyor 35. An extension frame 38 is fixed to the upper end of the support seat 37. Symmetrical second telescopic cylinders 39 are fixed to the lower end of the extension frame 38. An inclined plate 42 is fixed to the output end of the first second telescopic cylinder 39, and a flat plate 41 is fixed to the output end of the second second telescopic cylinder 39. When the defective casting meets the inclined plate 42 during transportation on the third conveyor 35, the placement angle of the defective casting is first set to be perpendicular to the side wall of the third conveyor 35 through the inclined plate 42, and then the defective casting in a nearly vertical state is leveled by the flat plate 41. In this way, it is convenient for the defective casting to be fed and transported when entering the stepped loader 36, providing more efficient feeding and transportation.

[0044] Obviously, the above-mentioned embodiments of the present invention are only examples for clearly explaining the present invention, and are not intended to limit the implementation manners of the present invention. For those of ordinary skill in the art in the technical field, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all the implementation manners here. Any modifications, equivalent replacements, and improvements made within the spirit and principle of the present invention should be included in the protection scope of the claims of the present invention.

Claims

1. A casting sorting system, comprising a vibrating bowl (1), characterized in that: A first conveyor (2) is provided at the output port of the vibrating bowl (1). An interval mechanism is provided at the connection between the first conveyor (2) and the vibrating bowl (1). A turning detection mechanism is provided on the first conveyor (2). The end of the first conveyor (2) is connected to a second conveyor (18). A sorting mechanism is provided on the second conveyor (18). A blanking mechanism is provided at the end of the second conveyor (18). The sorting mechanism is connected to a conveying rail (20). The end of the conveying rail (20) is connected to a third conveyor (35). A leveling mechanism is provided at the end of the third conveyor (35). The stepped loader (36) is connected to the third conveyor (35) and the vibrating bowl (1).

2. The casting sorting system according to claim 1, wherein: The interval mechanism includes a support frame (4). A first telescopic cylinder (5) is fixed to the inclined end of the support frame (4). The output end of the first telescopic cylinder (5) is fixed with a connecting rod (6). The end of the connecting rod (6) is fixed with a spacer plate (7). The spacer plate (7) is inclined and arranged at the connection between the vibrating bowl (1) and the first conveyor (2). The first telescopic cylinder (5) drives the spacer plate (7) to intermittently separate the castings through the connecting rod (6).

3. The casting sorting system according to claim 2, wherein: The turning detection mechanism includes a first motor (8). The first motor (8) is fixed on the side wall of the first conveyor (2). The output end of the first motor (8) is fixed with a rotating rod (9). A connecting sleeve (10) is fixed on the rotating rod (9). A turning rod (11) is fixed on the side wall of the connecting sleeve (10). A connecting slide rod (12) slides on the turning rod (11). A screw (13) is threadedly connected to the connecting slide rod (12) and abuts against the outer end face of the turning rod (11). A contact block (14) is fixed at the end of the connecting slide rod (12). A stop bar (15) is fixed at the inner end of the first conveyor (2). Another side wall of the first conveyor (2) is fixed with a fixing frame (16). An industrial camera lens (17) is fixed at the lower end of the fixing frame (16). The contact block (14) cooperates with the stop bar (15) to turn the castings, and the industrial camera lens (17) takes pictures of the castings for comparison.

4. A casting sorting system according to claim 2, characterized in that: The sorting mechanism includes a sorting partition plate (19). The sorting partition plate (19) sorts defective castings to the conveying rail (20) according to the detection data.

5. A casting sorting system according to claim 2, characterized in that: The blanking mechanism includes a blanking rail (21). A buffer roller (22) is provided at the turning point of the blanking rail (21). Sliders (26) are fixed at both ends of the buffer roller (22). A slide bar (24) is fixed outside the turning end of the blanking rail (21). A spring (25) is sleeved on the slide bar (24). A nut (27) is threadedly connected to the slide bar (24) at the lower end of the slider (26). A blanking channel (28) is fixed at the lower end of the blanking rail (21). Diagonal slide plates (29) that are offset relative to each other are fixed in the blanking channel (28). A receiving box (30) is provided at the lower end of the blanking channel (28). A second motor (31) is fixed inside the receiving box (30). A disc (32) is fixed to the output end of the second motor (31). A number of grooves (33) are formed in the upper end of the disc (32). Slide rollers (34) are rotatably arranged in the grooves (33). The buffer roller (22) adjusts the blanking gap. The diagonal slide plates (29) reduce the impact of the falling material. The disc (32) disperses the castings to prevent accumulation.

6. The casting sorting system according to claim 2, wherein: The leveling mechanism includes a support base (37). The support base (37) is fixed to the side wall of the third conveyor (35). An extension frame (38) is fixed to the upper end of the support base (37). Symmetrical second telescopic cylinders (39) are fixed to the lower end of the extension frame (38). An inclined plate (42) is fixed to the output end of one of the second telescopic cylinders (39). A flat plate (41) is fixed to the output end of the other second telescopic cylinder (39). The inclined plate (42) and the flat plate (41) adjust the placement angle of the castings.

7. A casting sorting system according to claim 2, characterized in that: The stepped loader (36) returns the leveled defective castings to the vibrating bowl (1) for cyclic detection.

8. A casting sorting system according to claim 2, wherein: The first conveyor (2), the second conveyor (18), the third conveyor (35), and the stepped loader (36) are all electrically connected to the main controller.

9. A casting sorting system according to claim 2, wherein: A number of anti-slip strips (3) with equal spacing are fixed to the conveyor belt of the first conveyor (2). The anti-slip strips (3) are arrow-shaped and arranged in the same direction as the conveying direction of the first conveyor (2).

10. A casting sorting system according to claim 3, characterized in that: The upper end surface of the stop bar (15) is inclined, and the inclination angle at the end close to the casting is an obtuse angle. The upper end of the stop bar (15) is provided with a circular arc surface.

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