Planet carrier pouring system and pouring method

Abstract

The invention discloses a planet carrier pouring system and a pouring method, relates to the technical field of planet carrier pouring, is used for solving the technical problems that an upper web plate of an existing planet carrier pouring system is easy to gather inclusions and is easy to generate a shrinkage cavity defect, and can effectively and obviously improve the quality and the yield of a primary planet carrier casting. In the planet carrier pouring system, a plurality of forming chilling blocks are evenly distributed on the web face, and a plurality of air outlet devices are evenly distributed on the web face. The air outlet device comprises an air outlet pipe, and the diameter of an air outlet hole in the bottom section area of the air outlet pipe is smaller than that of an air outlet hole in the top section area of the air outlet pipe. A water storage column is arranged on the outer side of the top section area of the air outlet pipe.

Description

Technical Field

[0001] The present invention relates to the technical field of planetary carrier casting, and in particular to a planetary carrier casting system and a casting method. Background Art

[0002] As a key component in wind turbines, the primary planetary carrier casting must withstand heavy loads, placing stringent demands on its density and internal quality. Scientific and rational casting process design not only directly determines casting quality but also has a profound impact on its service life.

[0003] When designing a casting process, multiple factors must be considered comprehensively. The long axis, as the client interface, is the core of the entire casting. Therefore, it should be positioned downward during casting. However, during the molten iron flow, it flows from the long axis end and eventually converges on the upper web surface. This causes inclusions carried by the molten iron to also accumulate on the upper web surface, making this area susceptible to defects that are exposed during subsequent processing and affect product quality.

[0004] Specifically, the original casting process incorporates a heat riser on the upper web. During solidification, the molten iron rises from the web to the heat riser, and inclusions also rise further, reducing inclusions in the upper web to a certain extent. However, the inventors of this application discovered that the heat riser is significantly affected by ambient temperature. When the ambient temperature fluctuates significantly, the root of the riser is prone to shrinkage, and the shrinkage depth often far exceeds the machining allowance, resulting in the scrapping of the casting. Furthermore, the large cross-sectional area of the riser root makes subsequent polishing difficult and time-consuming. Summary of the Invention

[0005] The purpose of the present invention is to provide a planetary carrier casting system and casting method, which are used to solve the technical problems that the upper web of the existing planetary carrier casting system is prone to accumulation of inclusions and shrinkage defects, and can effectively and significantly improve the quality and yield of the first-level planetary carrier castings.

[0006] In order to achieve the above object, the present invention adopts the following technical solutions: A planet carrier casting system comprises: a web surface, wherein a plurality of formed chills are evenly arranged on the web surface, and a plurality of gas outlet devices are evenly arranged on the web surface; The air outlet device includes: an air outlet pipe, and the air outlet hole diameter of the bottom section area of the air outlet pipe is smaller than the air outlet hole diameter of the top section area of the air outlet pipe; a water storage column is provided on the outer side of the top section area of the air outlet pipe.

[0007] Wherein, the plurality of formed chills are evenly distributed along the circumferential direction of the web surface, and are arranged in multiple circles along the radial direction; The plurality of air outlet devices are evenly distributed along the circumferential direction of the web surface.

[0008] Specifically, the planet carrier gating system further includes: a plurality of ingates communicating with the web surface; a plurality of the ingates communicate with a runner, and two adjacent runners jointly communicate with a sprue.

[0009] Furthermore, a filter screen is provided at the junction area where each ingate communicates with the runner; A filter screen is also provided in the area where the runner communicates with the sprue.

[0010] A method for casting a planet carrier includes the following steps: Uniformly arrange chill blocks on the web surface of the first-stage planet carrier and place a gas venting device; The molten iron first flows into the runner from the sprue. In the runner, the molten iron is filtered through the filter screen to remove impurities therein; subsequently, the filtered molten iron enters the casting along the ingate; after entering the casting, the molten iron gradually fills the cavity along the long axis direction; When the cavity is completely filled with molten iron, the pouring speed slows down, and the molten iron slowly enters the gas venting device from the web surface; during this process, the inclusions in the molten iron will enter the gas venting device together with the rising molten iron level, effectively reducing the inclusions at the web surface; The cross-sectional area of the air outlet pipe at the bottom of the gas venting device is small and will solidify prior to the casting; meanwhile, the chill blocks at the web surface play a role, promoting the synchronous solidification of the web surface and the air outlet pipe to avoid shrinkage cavity defects at the web surface; moreover, the cross-sectional area at the position of the air outlet pipe is small and is easy to grind and remove after the casting is formed, effectively saving grinding man-hours and improving production efficiency.

[0011] Compared with the prior art, the planet carrier gating system and casting method of the present invention have the following advantages: In the planet carrier gating system and casting method provided by the present invention, under the chilling effect of the chill blocks, the solidification process of the metal at the machining position of the web surface is accelerated, the crystallization is finer, so that this area is denser, and the quality of the casting is significantly improved, effectively reducing the defect of internal porosity; meanwhile, the molten iron at the web will flow upward into the gas venting device, and the inclusions carried in the molten iron also enter. Since a reasonable gas venting size is reserved at the bottom of the gas venting device, it can ensure the smooth discharge of gas, the upper part increases the gas venting volume space, and the water storage capacity of the gas venting device is increased. Therefore, the rising speed of the molten iron can be effectively controlled, that is, the rising speed of the molten iron is effectively slowed down, allowing the floating slag to have more sufficient time to fully float up, so that the inclusions can be more fully converged therein, thereby effectively improving the inclusion defect of the web surface, and fundamentally avoiding the generation of shrinkage cavity defects, greatly improving the quality and yield of the first-stage planet carrier casting. Description of the Drawings

[0012] Figure 1 Schematic structural diagram of the planet carrier pouring system provided by an embodiment of the present invention; Figure 2 Schematic structural diagram of the air outlet device in the planet carrier pouring system provided by an embodiment of the present invention.

[0013] Reference numerals: 1 - abdominal plate surface; 2 - forming chill; 3 - air outlet device; 31 - air outlet pipe; 32 - water storage column; 41 - ingate; 42 - runner; 43 - downsprue; 5 - filter screen. Detailed implementation manners

[0014] For the convenience of understanding, the planet carrier pouring system and pouring method provided by an embodiment of the present invention will be described in detail below with reference to the accompanying drawings of the specification.

[0015] An embodiment of the present invention provides a planet carrier pouring system, as Figure 1 and Figure 2 shown, including: an abdominal plate surface 1, on which a plurality of forming chills 2 are uniformly arranged, and a plurality of air outlet devices 3 are evenly arranged on the abdominal plate surface 1; The air outlet device 3 includes: an air outlet pipe 31, and the aperture of the air outlet holes in the bottom section area of the air outlet pipe 31 is smaller than the aperture of the air outlet holes in the top section area of the air outlet pipe 31; a water storage column 32 is arranged outside the top section area of the air outlet pipe 31.

[0016] An embodiment of the present invention further provides a planet carrier pouring method, including the following steps: Step S1, uniformly arrange forming chills 2 on the abdominal plate surface 1 of the primary planet carrier, and place the air outlet device 3; Step S2, the molten iron first flows into the runner 42 from the downsprue 43. In the runner 42, the molten iron passes through the filter screen 5 for filtration to remove the impurities existing therein; subsequently, the filtered molten iron enters the casting along the ingate 41; after entering the casting, the molten iron gradually fills the cavity along the long axis direction; Step S3, when the cavity is completely filled with molten iron, the pouring speed slows down, and the molten iron slowly enters the air outlet device 3 from the abdominal plate surface 1; during this process, the inclusions in the molten iron will enter the air outlet device 3 together with the rising of the molten iron liquid level, so as to effectively reduce the inclusions at the abdominal plate surface 1; Step S4, the cross-sectional area of the air outlet pipe 31 at the bottom of the air outlet device 3 is small, and it will solidify prior to the casting; meanwhile, the forming chill 2 at the abdominal plate surface 1 plays a role to promote the synchronous solidification of the abdominal plate surface 1 and the air outlet pipe 31, so as to avoid shrinkage cavity defects at the abdominal plate surface 1; moreover, the cross-sectional area at the position of the air outlet pipe 31 is small, and it is easy to grind and remove after the casting is formed, so as to effectively save the grinding working hours and improve the production efficiency.

[0017] Compared with the prior art, the planet carrier pouring system and pouring method according to the embodiments of the present invention have the following advantages: In the planet carrier pouring system and pouring method provided by the embodiments of the present invention, under the chilling effect of the chill iron for forming, the solidification process of the metal at the machining position of the web surface is accelerated, and the crystallization is finer, so that this area becomes denser, the quality of the casting is significantly improved, and the defect of internal porosity is effectively reduced; at the same time, the molten iron at the web will flow upward into the gas outlet device, and the inclusions entrained in the molten iron will also enter. Since a reasonable gas outlet size is reserved at the bottom of the gas outlet device, it can ensure the smooth discharge of gas. The upper part increases the gas outlet volume space and increases the water storage capacity of the gas outlet device. Therefore, the rising speed of the molten iron can be effectively controlled, that is, the rising speed of the molten iron is effectively slowed down, so that the floating slag has more sufficient time to float up sufficiently, so that the inclusions can converge more sufficiently therein, thereby effectively improving the inclusion defect of the web surface and fundamentally avoiding the generation of shrinkage cavity defects, greatly improving the quality and yield of the first-stage planet carrier castings.

[0018] It should be supplemented and explained here that compared with the ingate in the pouring system, the bottom of the gas outlet riser is designed to be 40*20mm, the diameter of the ceramic tube is φ40mm, the number of ceramic tubes is 10, the number of gas outlet risers is 10-16, the total area of the roots of the gas outlet risers is 8000mm²-12800mm², the total cross-sectional area of the ceramic tubes is 12560mm², and the gas outlet riser / ingate is 0.65-1%. On the one hand, it slows down the rising speed of the molten iron, ensures that the molten iron will not float out of the cavity in a short time, and at the same time ensures that the delay speed of the molten iron will not be too slow to cause too much loss of molten iron fluidity and affect filling, and also ensures that the "dirt" in the molten iron can effectively float up into the gas outlet riser and play a role in improving the defect. In addition, in the gas outlet device, the size of the water storage column 32 is 80mm*80mm*350mm. Compared with the pouring system, the water storage capacity here is about 1.8-3% of the weight of the pouring system, which will not have a great impact on the material yield rate of the casting, and at the same time, for the placement of the gas outlet riser, it will not interfere with the sand box; the size of the gas outlet pipe 31 is 40mm*20mm*150mm, where 40mm*20mm is to ensure that there is no concave shrinkage at the bottom, and the height of 150mm is designed based on the height of the chill iron on site. The height of the chill iron is 100mm, and here it is 50mm higher than the chill iron.

[0019] During actual application, as Figure 1 shown, the cross-sectional area of the gas outlet holes in the bottom section area of the above-mentioned gas outlet pipe 31 is smaller than the cross-sectional area of the (traditional) exothermic riser, and there is no setting of the traditional exothermic riser in this pouring system device, so the grinding workload is greatly reduced and the grinding efficiency is significantly improved; while ensuring the product quality, the production cost is effectively reduced and the production efficiency is improved.

[0020] Among them, asFigure 1 As shown, multiple forming chill blocks 2 can preferably be evenly distributed along the circumferential direction of the web plate surface 1, and multiple circles of forming chill blocks 2 can be arranged along the radial direction; Multiple gas outlet devices 3 can preferably be evenly distributed along the circumferential direction of the web plate surface 1; The gas outlet devices 3 are evenly distributed on the web plate surface 1 so as to make all the impurities in the molten iron float up into the gas outlet devices 3 as much as possible. And since the molten iron enters the upper web from the web pillar position, all the gas outlet devices 3 are selected to be placed on both sides of the web column, and at the same time, it cannot obstruct the position of the skin-penetrating holes of the upper web. The number of gas outlet devices 3 is twice the number of web columns.

[0021] Specifically, as Figure 1 shown, the planet carrier gating system provided by the embodiment of the present invention may further include: multiple ingates 41 communicated with the web plate surface 1; multiple ingates 41 can be communicated with a runner 42, and two adjacent runners 42 can be jointly communicated with a downsprue 43.

[0022] Furthermore, as Figure 1 shown, a filter screen 5 can be arranged in the junction area where each ingate 41 is communicated with the runner 42; A filter screen 5 can also be arranged in the area where the above-mentioned runner 42 is communicated with the downsprue 43.

[0023] In summary, the planet carrier gating system and gating method provided by the embodiment of the present invention mainly have the following advantages: First, compared with the original process, the gas outlet device effectively avoids the generation of root shrinkage defects in the design, which greatly reduces the rejection rate of castings caused by shrinkage problems and greatly improves the finished product rate of castings; Second, the gas outlet device can efficiently discharge the inclusions on the web plate surface, greatly improve the quality of castings, and can be reused. Compared with the disposable exothermic riser, it effectively reduces the consumable cost; Third, the cross-sectional area of the root of the gas outlet device is significantly smaller than that of the traditional exothermic riser. This design optimization reduces the difficulty of grinding work, shortens the time-consuming, significantly improves the grinding efficiency, and reduces the time and labor costs of post-processing.

[0024] The above is only the specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention can easily think of changes or substitutions, which should all be covered within the protection scope of the present invention. Therefore, the protection scope of the present invention should be subject to the protection scope of the claims.

Claims

1. A planet carrier casting system, characterized in that, Including: The web surface, on which a plurality of formed chill blocks are evenly arranged, and a plurality of air outlet devices are evenly arranged on the web surface; The air outlet device includes: an air outlet pipe, and the pore diameter of the air outlet holes in the bottom section area of the air outlet pipe is smaller than the pore diameter of the air outlet holes in the top section area of the air outlet pipe; a water storage column is arranged outside the top section area of the air outlet pipe.

2. The planet carrier casting system according to claim 1, wherein The plurality of formed chill blocks are evenly distributed along the circumferential direction of the web surface and are arranged in multiple circles along the radial direction; The plurality of air outlet devices are evenly distributed along the circumferential direction of the web surface.

3. The planet carrier casting system according to claim 1 or 2, characterized in that It further includes: A plurality of inner runners communicating with the web surface; The plurality of inner runners are communicated with a cross runner, and two adjacent cross runners are jointly communicated with a sprue.

4. The planet carrier pouring system according to claim 3, wherein A filter screen is arranged at the junction area where each inner runner communicates with the cross runner; A filter screen is also arranged in the area where the cross runner communicates with the sprue.

5. A method for casting a planet carrier, characterized in that, Including the following steps: Evenly arrange formed chill blocks on the web surface of the first-stage planet carrier and place the air outlet devices; The molten iron first flows into the cross runner from the sprue. In the cross runner, the molten iron passes through the filter screen for filtration to remove the impurities existing therein; subsequently, the filtered molten iron enters the casting along the inner runner; After entering the casting, the molten iron gradually fills the cavity along the long axis direction; When the cavity is completely filled with molten iron, the pouring speed slows down, and the molten iron slowly enters the air outlet device from the web surface; during this process, the inclusions in the molten iron will enter the air outlet device together with the rising of the molten iron liquid level, so as to effectively reduce the inclusions at the web surface; The cross-sectional area of the air outlet pipe at the bottom of the air outlet device is small, and it will solidify prior to the casting; at the same time, the formed chill blocks at the web surface play a role, promoting the synchronous solidification of the web surface and the air outlet pipe, so as to avoid shrinkage cavity defects on the web surface; moreover, the cross-sectional area at the position of the air outlet pipe is small, and it is easy to grind and remove after the casting is formed, so as to effectively save the grinding working hours and improve the production efficiency.

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