Planet carrier casting system and casting method

Abstract

A planetary carrier casting system and method relate to the field of planetary carrier casting technology. These systems address the technical issues of inclusion accumulation and shrinkage defects easily occurring on the webs of existing planetary carrier casting systems. These systems can effectively and significantly improve the quality and yield of primary planetary carrier castings. In the planetary carrier casting system, multiple shaped chills are evenly arranged on the web surface, and multiple air outlet devices are evenly distributed on the web surface. These air outlet devices include an air outlet pipe, with the air outlet aperture in the bottom section of the air outlet pipe being smaller than the air outlet aperture in the top section of the air outlet pipe. A water storage column is disposed outside the top section 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:

[0007] 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;

[0008] 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.

[0009] 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;

[0010] The plurality of air outlet devices are evenly distributed along the circumferential direction of the web surface.

[0011] Specifically, the planet carrier casting system further includes: a plurality of ingates connected to the web surface; the plurality of ingates are connected to a runner, and two adjacent runners are connected to a sprue.

[0012] Furthermore, a filter screen is provided at the junction area where each of the inner runners communicates with the runner;

[0013] A filter screen is also provided in the area where the horizontal runner and the straight runner communicate with each other.

[0014] A planet carrier casting method comprises the following steps:

[0015] Formed chills are evenly arranged on the web surface of the first-stage planet carrier, and an air outlet device is placed;

[0016] The molten iron first flows from the sprue into the runner, where it is filtered through a filter to remove impurities. The filtered molten iron then flows through the ingrown channel into the casting. Once inside, the molten iron gradually fills the mold cavity along its long axis.

[0017] When the mold cavity is completely filled with molten iron, the pouring speed slows down and the molten iron slowly enters the gas outlet device from the web surface. During this process, the inclusions in the molten iron will enter the gas outlet device together with the rising molten iron level, effectively reducing the inclusions on the web surface.

[0018] The cross-sectional area of ​​the air outlet pipe at the bottom of the air outlet device is small, and it will complete solidification before the casting; at the same time, the forming chill at the web surface plays a role in promoting the synchronous solidification of the web surface and the air outlet pipe, so as to avoid shrinkage defects on the web surface; and the cross-sectional area of ​​the air outlet pipe is small, which can be easily polished away after the casting is formed, so as to effectively save polishing time and improve production efficiency.

[0019] Compared with the prior art, the planetary carrier casting system and casting method of the present invention have the following advantages:

[0020] In the planetary carrier casting system and casting method provided by the present invention, under the quenching effect of the formed cold iron, the metal solidification process at the processing position of the web surface is accelerated, and the crystallization is finer, thereby making the area denser, significantly improving the quality of the casting, and effectively reducing the internal loose defects; 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 the bottom of the gas outlet device retains a reasonable gas outlet size, it can ensure that the gas is discharged smoothly, the gas outlet volume space is increased at the top, and the water storage capacity of the gas outlet device is increased, so that 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 slag has more sufficient time to fully float up, so that the inclusions can be more fully gathered therein, thereby effectively improving the inclusion defects on the web surface, and fundamentally avoiding the generation of shrinkage defects, greatly improving the quality and yield of the first-level planetary carrier casting. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 A schematic structural diagram of a planet carrier casting system provided by an embodiment of the present invention;

[0022] Figure 2 This is a schematic structural diagram of the gas outlet device in the planetary carrier casting system provided by an embodiment of the present invention.

[0023] Reference numerals:

[0024] 1-web surface; 2-forming chill; 3-air outlet device; 31-air outlet pipe; 32-water storage column; 41-introduction channel; 42-horizontal runner; 43-sprue; 5-filter screen. DETAILED DESCRIPTION

[0025] For ease of understanding, the planet carrier casting system and casting method provided by the embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0026] The embodiment of the present invention provides a planet carrier casting system, such as Figure 1 and Figure 2 As shown, it comprises: a web surface 1, a plurality of formed chills 2 are evenly arranged on the web surface 1, and a plurality of air outlet devices 3 are evenly arranged on the web surface 1;

[0027] The air outlet device 3 includes: an air outlet pipe 31, and the air outlet hole diameter of the bottom section area of ​​the air outlet pipe 31 is smaller than the air outlet hole diameter of the top section area of ​​the air outlet pipe 31; a water storage column 32 is provided outside the top section area of ​​the air outlet pipe 31.

[0028] An embodiment of the present invention further provides a planet carrier casting method, comprising the following steps:

[0029] Step S1, evenly arranging the formed chills 2 on the web surface 1 of the first-stage planet carrier, and placing the air outlet device 3;

[0030] Step S2: The molten iron first flows from the sprue 43 into the runner 42. In the runner 42, the molten iron is filtered through the filter 5 to remove impurities. The filtered molten iron then flows into the casting along the ingrown 41. After entering the casting, the molten iron gradually fills the mold cavity along the longitudinal direction.

[0031] Step S3: When the mold cavity is completely filled with molten iron, the pouring speed is slowed down, and the molten iron slowly enters the gas outlet device 3 from the web surface 1. During this process, inclusions in the molten iron will enter the gas outlet device 3 together with the rising liquid level of the molten iron, thereby effectively reducing the inclusions on the web surface 1.

[0032] In 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 complete solidification before the casting; at the same time, the formed cold iron 2 at the web surface 1 plays a role, prompting the web surface 1 and the air outlet pipe 31 to solidify synchronously, so as to avoid shrinkage defects on the web surface 1; and the cross-sectional area 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 grinding time and improve production efficiency.

[0033] Compared with the prior art, the planetary carrier casting system and casting method described in the embodiments of the present invention have the following advantages:

[0034] In the planetary carrier casting system and casting method provided by the embodiments of the present invention, under the quenching effect of the formed cold iron, the metal solidification process at the processing position of the web surface is accelerated, and the crystallization is finer, thereby making the area denser, significantly improving the quality of the casting, and effectively reducing the internal loose defects; 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 the bottom of the gas outlet device retains a reasonable gas outlet size, it can ensure that the gas is discharged smoothly, the gas outlet volume space is increased at the top, and the water storage capacity of the gas outlet device is increased, so that 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 slag has more sufficient time to fully float up, so that the inclusions can be more fully gathered therein, thereby effectively improving the inclusion defects on the web surface, and fundamentally avoiding the generation of shrinkage defects, greatly improving the quality and yield of the first-level planetary carrier castings.

[0035] It should be noted that, compared with the ingrow in the pouring system, the bottom of the gas 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 risers is 10-16, the total root area of ​​the gas riser is 8000mm²-12800mm², the total cross-sectional area of ​​the ceramic tube is 12560mm², and the gas riser / ingrow ratio is 0.65-1%. On the one hand, it slows down the rising speed of the molten iron to ensure that the molten iron will not float out of the mold cavity in a short time. At the same time, it also ensures that the molten iron delay speed is not too slow, resulting in excessive loss of molten iron fluidity and affecting mold filling. It also ensures that the "dirt" in the molten iron can effectively float to the gas riser, which plays a role in improving defects.

[0036] In addition, in the air outlet device, the size of the water storage column 32 is 80mm*80mm*350mm. Relative to 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 big impact on the yield of the casting. At the same time, it will not interfere with the placement of the air outlet riser and the sand box; the size of the air outlet pipe 31 is 40mm*20mm*150mm, of which 40mm*20mm is to ensure that the bottom will not be concave, and the height of 150mm is designed based on the on-site chiller height. The chiller height is 100mm, which is 50mm higher than the chiller here.

[0037] In actual application, such as Figure 1 As shown, the cross-sectional area of ​​the air outlet holes in the bottom section of the above-mentioned air outlet pipe 31 is smaller than the cross-sectional area of ​​the (traditional) heating riser, and there is no traditional heating riser in the casting system device, so the grinding workload is greatly reduced and the grinding efficiency is significantly improved; while ensuring product quality, the production cost is effectively reduced and the production efficiency is improved.

[0038] Among them, Figure 1 As shown, the plurality of formed chills 2 may preferably be evenly distributed along the circumferential direction of the web surface 1, and a plurality of circles of formed chills 2 may be provided along the radial direction;

[0039] The plurality of air outlet devices 3 may preferably be evenly distributed along the circumferential direction of the web surface 1;

[0040] The air outlet devices 3 are evenly distributed on the web surface 1 so that as much impurities in the molten iron as possible can float up to the air outlet devices 3. Since the molten iron enters the upper web from the web support position, all the air outlet devices 3 are placed on both sides of the web column, and at the same time cannot block the position of the upper web through-hole. The number of air outlet devices 3 is twice the number of web columns.

[0041] Specifically, if Figure 1As shown, the planetary carrier casting system provided by the embodiment of the present invention may further include: a plurality of ingrowns 41 connected to the web surface 1; the plurality of ingrowns 41 may be connected to a runner 42, and two adjacent runners 42 may be connected to a sprue 43.

[0042] Further, if Figure 1 As shown, a filter screen 5 may be provided at the junction area where each ingrown channel 41 communicates with the runner 42;

[0043] A filter 5 may also be provided in the area where the runner 42 communicates with the sprue 43 .

[0044] In summary, the planetary carrier casting system and casting method provided by the embodiments of the present invention have the following advantages:

[0045] 1. Compared with the original process, the design of the gas outlet device effectively avoids the occurrence of root shrinkage defects, which greatly reduces the scrap rate of castings caused by shrinkage problems and greatly improves the casting yield rate;

[0046] Second, the gas outlet device can efficiently discharge inclusions from the web surface, greatly improving the quality of the casting. It is also reusable, effectively reducing the cost of consumables compared to disposable heating risers.

[0047] 3. The root cross-sectional area of ​​the exhaust device is significantly smaller than that of the traditional heating riser. This design optimization makes the grinding work easier and more time-consuming, significantly improves the grinding efficiency, and reduces the time and labor costs of subsequent processing.

[0048] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in the present invention should be included in the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

1. A planetary carrier casting system, characterized in that: include: A web surface, wherein a plurality of formed chills are evenly arranged on the web surface, 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 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.

2. The planet carrier casting system according to claim 1, characterized in that: 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.

3. The planet carrier casting system according to claim 2, characterized in that: Also includes: a plurality of ingates in communication with the web surface; The plurality of inner runners are connected to a horizontal runner, and two adjacent horizontal runners are connected to a vertical runner.

4. The planet carrier casting system according to claim 3, characterized in that: A filter screen is provided at the junction area where each of the inner runners communicates with the cross runner; A filter screen is also provided in the area where the horizontal runner and the straight runner communicate with each other.

5. A planet carrier casting method, characterized in that: The planet carrier gating system according to claim 4 is used, and includes the following steps: Formed chills are evenly arranged on the web surface of the first-stage planet carrier, and an air outlet device is placed; The molten iron first flows from the sprue into the runner, where it is filtered through a filter to remove impurities. The filtered molten iron then flows through the ingrown channel into the casting. Once inside, the molten iron gradually fills the mold cavity along its long axis. When the mold cavity is completely filled with molten iron, the pouring speed slows down and the molten iron slowly enters the gas outlet device from the web surface. During this process, the inclusions in the molten iron will enter the gas outlet device together with the rising molten iron level, effectively reducing the inclusions on 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 complete solidification before the casting; at the same time, the forming chill at the web surface plays a role in promoting the synchronous solidification of the web surface and the air outlet pipe, so as to avoid shrinkage defects on the web surface; and the cross-sectional area of ​​the air outlet pipe is small, which can be easily polished away after the casting is formed, so as to effectively save polishing time and improve production efficiency.

Images