Casting equipment for aluminum anti-collision beam

Abstract

The invention relates to casting equipment for an aluminum anti-collision beam. Comprising a fixed base used for fixing a first mold, a movable base arranged on the fixed base, an injector arranged on the fixed base and connected with a casting material channel on the fixed base, a molten metal melting bin used for generating molten metal, a molten metal conveying channel and a metal particle manufacturing device arranged on the molten metal conveying channel. The movable base is used for driving the second mold to move in the direction close to or away from the first mold, the input end of the molten metal conveying channel is connected with the output end of the molten metal melting bin, and the output end of the molten metal conveying channel is connected with the injector. According to the casting equipment for the aluminum anti-collision beam, the semi-solid raw materials used in the casting process are obtained in a liquid and solid continuous mixing mode, the mode can meet the production requirement of continuous casting, and meanwhile the problem of solid metal melting caused by too long mixing time is solved.

Description

Technical Field

[0001] The present application relates to the technical field of casting equipment, and in particular to a casting equipment for an aluminum anti-collision beam. Background Art

[0002] Aluminum alloy anti-collision beams are increasingly used in new energy vehicles. Their advantages mainly lie in lightweight (under the same structural strength, aluminum alloy anti-collision beams can reduce weight by 40%-50%, directly reducing fuel consumption or increasing the range of electric vehicles), energy absorption performance, corrosion resistance, and recyclability.

[0003] A major problem currently existing in the casting process of aluminum alloy anti-collision beams is the lack of fluidity or poor exhaust of the molten aluminum during the casting process, which can easily lead to pores. Especially when the molten metal is driven to flow at a higher speed, the resulting impact and spattering problems can lead to additional surface defects and local quality defects.

[0004] Currently, one technical route is semi-solid casting, which can basically avoid quality defects caused by molten metal flow problems. However, further research is needed in the production of semi-solid raw materials (a mixture of metal particles and molten metal). Summary of the Invention

[0005] The present application provides a casting device for an aluminum anti-collision beam, which obtains semi-solid raw materials used in the casting process by continuously mixing liquid and solid. This method can meet the production needs of continuous casting while avoiding the problem of solid metal melting caused by excessive mixing time.

[0006] The above-mentioned purpose of this application is achieved through the following technical solutions: The present application provides a casting device for an aluminum anti-collision beam, comprising: A fixed base, used for fixing the first mold; The movable base is provided on the fixed base, and is used to drive the second mold to move toward and away from the first mold; an injector, which is disposed on the fixed base and connected to a casting material channel on the fixed base; A molten metal melting chamber, used to produce molten metal; A molten metal transport channel, wherein the input end of the molten metal transport channel is connected to the output end of the molten metal melting tank, and the output end of the molten metal transport channel is connected to the syringe; The metal particle maker is arranged on the molten metal transport channel.

[0007] In a possible implementation of the present application, the molten metal melting tank includes: melting chamber; The gooseneck pipe is located inside the melting chamber, the input end of the gooseneck pipe is connected to the melting chamber, and the output end of the gooseneck pipe is connected to the molten metal transport channel; A first driver, wherein the piston end of the first driver extends into the gooseneck pipe.

[0008] In a possible implementation of the present application, the molten metal transport channel includes: The closed channel has its two ends connected to the output end of the molten metal melting tank and the injector respectively; a push plate, located inside the closed channel and abutting against a working surface of the closed channel; a second driver connected to the push plate and configured to drive the push plate to reciprocate in the closed channel; The moving direction of the push plate is parallel to the flow direction of the medium in the closed channel.

[0009] In a possible implementation of the present application, the metal particle generator includes: The main body is arranged on the molten metal transport channel; Feeding channels are evenly distributed on the main body, both ends of the feeding channels are open, and the feeding channels are connected to the space in the molten metal transport channel; a heating resistor, disposed in the main body; The cutting module is located at the connection between the main body and the molten metal transport channel; The feeding module is arranged on the main body or the molten metal transport channel.

[0010] In a possible implementation of the present application, the cutting module includes: The cutting body is slidably connected to the main body or the molten metal transport channel; The cutting channels are evenly distributed on the cutting body, and the number of the cutting channels is the same as that of the feeding channels and they correspond one to one; A cutting blade is provided on the inner wall of the cutting channel; The third driver is connected to the cutting body and is used to drive the cutting body to move back and forth in a straight line.

[0011] In a possible implementation of the present application, each group of heating resistors is electrically connected to an independent controller.

[0012] In a possible implementation of the present application, a temperature sensor is further provided in the main body, and a detection end of the temperature sensor extends into the feeding channel.

[0013] In a possible implementation of the present application, the feeding module includes: A guide rod is provided on the main body or the molten metal transport channel; The feed base is slidably connected to the guide rod, and the feed holes are evenly distributed on the feed base; The sliding base is slidably connected to the feeding base. The moving direction of the sliding base is perpendicular to the moving direction of the feeding base. The sliding base is evenly distributed with fixing holes, and the number of the fixing holes is the same as that of the feeding holes and they correspond one to one.

[0014] In a possible implementation of the present application, the sliding base is located inside the feeding base.

[0015] The beneficial effects of this application are: The casting equipment for the aluminum anti-collision beam provided in the present application first manufactures molten metal and metal particles that meet the temperature requirements, and then obtains a uniformly mixed semi-solid raw material (a mixture of metal particles and molten metal) through continuous and uniform mixing. The semi-solid raw material is obtained directly, which avoids the problem of solid metal melting caused by excessive mixing time, and has advantages in production time and production quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a structural schematic diagram of a casting device for an aluminum anti-collision beam provided in this application.

[0017] Figure 2 It is a structural schematic diagram of another aluminum anti-collision beam casting equipment provided in this application.

[0018] Figure 3 It is a structural schematic diagram of a molten metal melting tank provided in this application.

[0019] Figure 4 This is a structural schematic diagram of a molten metal transport channel provided in this application.

[0020] Figure 5 It is a structural schematic diagram of a metal particle maker provided in this application.

[0021] Figure 6 This is a schematic diagram of the distribution position of a heating resistor provided in this application.

[0022] Figure 7 This is a schematic diagram of the grouping of heating resistors provided by this application.

[0023] Figure 8 This is a structural diagram of a cutting module provided in this application.

[0024] Figure 9 It is a structural schematic diagram of a feeding module provided in this application.

[0025] In the figure, 1. fixed base, 2. movable base, 3. syringe, 5. molten metal melting chamber, 6. molten metal transport channel, 7. metal particle maker, 51. melting chamber, 52. gooseneck pipe, 53. first drive, 61. closed channel, 62. push plate, 63. second drive, 71. main body, 72. feeding channel, 73. heating resistor, 74. cutting module, 75. feeding module, 76. temperature sensor, 741. cutting body, 742. cutting channel, 743. cutting blade, 744. third drive, 751. guide rod, 752. feeding base, 753. sliding base. DETAILED DESCRIPTION In order to more clearly understand the technical solution in this application, the relevant content of semi-solid casting is first introduced.

[0026] Semi-solid casting is an advanced process that achieves high-performance near-net-shape forming by controlling the metal's microstructure in the solid-liquid two-phase region. Its core principle is to apply intense stirring or physical fields during the metal solidification process to break down the traditional dendritic structure, forming a semi-solid slurry with spherical or quasi-spherical solid particles suspended in a liquid phase. This slurry combines the strength of a solid with the fluidity of a liquid.

[0027] Through mechanical stirring, electromagnetic stirring or strain induction, the liquid metal is cooled to the solid-liquid two-phase region to form a non-dendritic structure slurry. This slurry has thixotropy: high viscosity when still for easy handling, low viscosity when subjected to shear force for easy filling.

[0028] The current preparation methods include mechanical stirring and electromagnetic stirring. Both stirring methods use continuous rotation and relatively precise temperature control to obtain semi-solid raw materials. However, there are problems such as difficulty in determining the ratio and unstable process time, which are not conducive to continuous industrial production.

[0029] The technical solution in this application is further described in detail below with reference to the accompanying drawings.

[0030] The present application discloses a casting device for an aluminum anti-collision beam. In some examples, the casting device for an aluminum anti-collision beam disclosed in the present application includes a fixed base 1, a movable base 2, an injector 3, a molten metal melting chamber 5, a molten metal transport channel 6, and a metal particle maker 7. Figure 1 and Figure 2 The function of the fixed base 1 is to fix the first mold, and the function of the movable base 2 is to fix the second mold and drive the second mold to move toward and away from the first mold.

[0031] The second mold and the first mold ( Figure 1The dotted line part in the figure) is formed after the mold is closed. The injector 3 is fixedly mounted on the fixed base 1 and connected to the casting material channel on the fixed base 1. Its function is to deliver the semi-solid raw material into the casting cavity through the casting material channel.

[0032] exist Figure 1 and Figure 2 In the process, some equipment needs to be deployed on a stand (not shown), and the stand is specifically designed according to the site conditions.

[0033] In some possible implementations, the fixed base 1 and the movable base 2 are positioned by guide shafts (generally four), and the movement of the movable base 2 is achieved by being pushed by a hydraulic cylinder.

[0034] The function of the metal liquid melting tank 5 is to produce metal liquid or temporarily store metal liquid. Producing metal liquid means melting the metal block by heating, and temporarily storing metal liquid means keeping the metal liquid transferred to the metal liquid melting tank 5 in a liquid state by keeping it warm.

[0035] The input end of the molten metal transport channel 6 is connected to the output end of the molten metal melting tank 5, and the output end of the molten metal transport channel 6 is connected to the syringe 3. The metal particle maker 7 is installed on the molten metal transport channel 6. The function of the metal particle maker 7 is to produce solid metal particles that meet the requirements and heat the solid metal particles at the same time.

[0036] The heated solid metal particles fall into the molten metal transport channel 6, mix with the molten metal, and then flow into the syringe 3. The syringe 3 cooperates with the casting material channel to inject the metal particles into the casting cavity.

[0037] For some examples, see Figure 3 The arrow in the figure indicates the flow direction of the molten metal. The molten metal melting tank 5 includes a melting chamber 51, a gooseneck pipe 52 and a first driver 53. The gooseneck pipe 52 is located inside the melting chamber 51. The input end of the gooseneck pipe 52 is connected to the melting chamber 51, and the output end of the gooseneck pipe 52 is connected to the molten metal transport channel 6.

[0038] The piston end of the first actuator 53 extends into the gooseneck pipe 52 and moves within the gooseneck pipe 52, pushing the molten metal inside the gooseneck pipe 52 out of the output end of the gooseneck pipe 52. The melting chamber 51 uses a heater to heat and melt the metal block or keep the molten metal warm, functioning like a crucible.

[0039] Heaters are generally disposed on the sides and bottom of the melting chamber 51 .

[0040] The gooseneck pipe 52 communicates with the interior of the melting chamber 51 through a side channel. The molten metal in the melting chamber 51 flows into the gooseneck pipe 52 through this channel. The piston end of the first actuator 53 is located above the channel on the side of the gooseneck pipe 52. During operation, the piston end of the first actuator 53 moves toward the bottom of the melting chamber 51, pushing out the molten metal in the gooseneck pipe 52, which then flows into the molten metal transport channel 6.

[0041] The quantity at the gooseneck pipe 52 is generally determined by controlling time. This is because the flow area at the output end of the gooseneck pipe 52 is a fixed value, and the moving speed of the first driver 53 is controllable. Through these two parameters, the amount of molten metal flowing out of the gooseneck pipe 52 per unit time can be made a constant value.

[0042] In some possible implementations, there may be multiple molten metal melting chambers 5 for the following reasons: Shorten the supply time of molten metal, reduce the temperature fluctuation of molten metal and shorten the production cycle interval; Shorten the height adjustment time of the molten metal in the molten metal transport channel 6 and reduce the production cycle interval; The temperature of the molten metal at various locations in the molten metal transport channel 6 is made uniform.

[0043] For some examples, see Figure 4 The molten metal transport channel 6 includes a closed channel 61 and a push plate 62. The two ends of the closed channel 61 are respectively connected to the output end of the molten metal melting warehouse 5 and the injector 3, so that the physical contact between the molten metal and the external air can be isolated.

[0044] Of course, the oxidation reaction of the molten metal can be further reduced by injecting inert gas into the molten metal transport channel 6 .

[0045] The push plate 62 is located inside the closed channel 61 and abuts against the working surface of the closed channel 61. The second driver 63 is connected to the push plate 62 and functions to drive the push plate 62 to reciprocate within the closed channel 61. The push plate 62 is used to push the mixture of molten metal and metal particles in the closed channel 61 into the syringe 3. This is because the mixture of molten metal and metal particles reduces its fluidity and prevents it from flowing smoothly into the syringe 3.

[0046] In some possible implementations, an electric gate is further required, which is mounted on the closed channel 61 and has a gate portion located inside the closed channel 61. The function of the electric gate is to adjust the height of the molten metal inside the closed channel 61 by limiting the height, while preventing the pure molten metal from flowing into the injector 3.

[0047] For some examples, see Figure 5 The metal particle maker 7 includes a main body 71, a feeding channel 72, a heating resistor 73, a cutting module 74 and a feeding module 75. The main body 71 is fixedly mounted on the molten metal transport channel 6, and the feeding channels 72 are evenly distributed on the main body 71.

[0048] Both ends of the feeding channel 72 are open ends. At the same time, the feeding channel 72 is also connected to the space in the molten metal transportation channel 6. The function of the feeding channel 72 is to temporarily store the metal bars.

[0049] See also Figure 6 The heating resistor 73 is located within the main body 71. Its function is to heat the metal bar as it passes through it, ensuring that its temperature meets casting requirements. Specifically, the heating resistor 73 first heats the main body 71, causing the metal bar's temperature to quickly rise to the same level as the main body 71 as it passes through it.

[0050] The metal bar and the feeding channel 72 are clearance-fitted in order to increase the contact opening rate as much as possible, thereby increasing the heating rate of the metal bar.

[0051] In some possible implementations, the heating resistors 73 are grouped in a ring shape, such as Figure 7 As shown, this approach can effectively reduce the difficulty of controlling the heating resistors 73 because the heating resistors 73 in the same ring group are controlled by the same controller.

[0052] The cutting module 74 is located at the junction of the main body 71 and the molten metal transport channel 6, and its function is to cut the metal bar into metal particles. The feeding module 75 is located on the main body 71 or the molten metal transport channel 6, and its function is to push the metal bar to move in the feeding channel 72.

[0053] Specifically, during production, the feeding module 75 pushes the metal bar to move at a set speed in the feeding channel 72. During this process, the heating resistor 73 synchronously heats the metal bar located in the heating resistor 73.

[0054] Then the cutting module 74 cuts the metal bar into metal particles that meet the requirements. These metal particles fall into the molten metal below to obtain a semi-solid raw material (a mixture of metal particles and molten metal).

[0055] For some examples, see Figure 8 The cutting module 74 includes a cutting body 741, a cutting channel 742, a cutting blade 743 and a third driver 744. The cutting body 741 is slidingly connected to the main body 71 or the molten metal transport channel 6. The third driver 744 is connected to the cutting body 741 and is used to drive the cutting body 741 to move back and forth in a straight line.

[0056] The number of the cutting channels 742 and the feeding channels 72 are the same and correspond one to one. Each metal bar passes through the corresponding cutting channel 742 and is cut into metal particles.

[0057] The cutting body 741 is evenly distributed with cutting channels 742, and each cutting channel 742 is mounted on its inner wall with a cutting blade 743. When the cutting body 741 moves, all the cutting blades 743 move synchronously. This method has the advantage of being able to produce a large number of metal particles at once, significantly reducing the waiting time of the molten metal within the molten metal transport channel 6.

[0058] In some possible implementations, each group of heating resistors 73 is electrically connected to an independent controller to adjust the power or temperature of each heating resistor 73 individually. This is because the temperature distribution on the cut-off body 741 varies due to different locations, requiring the heating resistors 73 at different locations to provide different heating powers.

[0059] The temperature consistency of the metal particles can be improved by adding a controller.

[0060] For some possible implementations, see Figure 7 A temperature sensor 76 is also provided in the main body 71. The detection end of the temperature sensor 76 extends into the feeding channel 72. Its function is to detect the temperature of the metal particles. The temperature value of the metal particles can provide a reference basis for the power adjustment of the heating resistor 73.

[0061] For some examples, see Figure 9 The feeding module 75 includes a guide rod 751, a feeding base 752 and a sliding base 753. The guide rod 751 is fixed on the main body 71 or the molten metal transport channel 6. The feeding base 752 is slidingly connected to the guide rod 751, and the sliding base 753 is slidingly connected to the feeding base 752.

[0062] The moving direction of the sliding base 753 is perpendicular to the moving direction of the feeding base 752 , that is, when the feeding base 752 moves in the vertical direction, the sliding base 753 moves in the horizontal direction.

[0063] Feed holes are evenly distributed on the feed base 752, and fixing holes are evenly distributed on the sliding base 753. The number of fixing holes is the same as that of the feed holes and they correspond one to one. The metal bar will pass through a feed hole and a fixing hole at the same time. When the relative positions of these two holes (a feed hole and a fixing hole) change, the metal bar can be clamped.

[0064] Both the feed base 752 and the sliding base 753 need to be equipped with a driver, and in this application, a pneumatic telescopic device (such as a cylinder) is generally used for control.

[0065] In some possible implementations, the sliding base 753 is located inside the feed base 752. The feed base 752 divides the feed hole on the feed base 752 into two layers, with the fixed hole between the two layers of feed holes. This fixation of the metal bar can, to a certain extent, prevent local deformation of the metal bar, thereby preventing the metal bar from moving easily within the feeding channel 72.

[0066] It should also be noted that the diameter of the metal bar is generally 1-2mm, and the proportion of metal particles in the semi-solid raw material (a mixture of metal particles and molten metal) is generally controlled at 20%-60%. The metal particles and molten metal used to make the metal bar are produced using a multi-layer stacking method. This means that a layer of molten metal is first laid down, and then the metal particles are placed on top of the molten metal. Under the influence of gravity, the metal particles partially or completely sink into the molten metal. This process is repeated until a sufficient amount of semi-solid raw material (a mixture of metal particles and molten metal) is obtained for a single casting.

[0067] The connecting pipe between the injector 3 and the metal liquid transport channel 6 needs to add additional insulation (insulation cotton) and heating measures (electromagnetic heating) because a small amount of material will be retained here.

[0068] The embodiments of this specific implementation method are all preferred embodiments of the present application and are not intended to limit the scope of protection of the present application. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the scope of protection of the present application.

Claims

1. A casting device for an aluminum anti-collision beam, characterized in that: include: A fixed base (1) for fixing the first mold; A movable base (2) is provided on the fixed base (1), and the movable base (2) is used to drive the second mold to move toward and away from the first mold; An injector (3) is provided on the fixed base (1) and is connected to a casting material channel on the fixed base (1); A metal liquid melting chamber (5) for producing metal liquid; A molten metal transport channel (6), wherein the input end of the molten metal transport channel (6) is connected to the output end of the molten metal melting chamber (5), and the output end of the molten metal transport channel (6) is connected to the injector (3); The metal particle maker (7) is arranged on the metal liquid transport channel (6).

2. The casting equipment for aluminum anti-collision beam according to claim 1, characterized in that: The metal molten tank (5) comprises: melting chamber (51); A gooseneck pipe (52) is located inside the melting chamber (51), an input end of the gooseneck pipe (52) is connected to the melting chamber (51), and an output end of the gooseneck pipe (52) is connected to the molten metal transport channel (6); A first driver (53) has a piston end extending into the gooseneck pipe (52).

3. The casting equipment for aluminum anti-collision beam according to claim 1, characterized in that: The molten metal transport channel (6) includes: A closed channel (61) with both ends connected to the output end of the molten metal tank (5) and the injector (3) respectively; A push plate (62) is located inside the closed channel (61) and abuts against a working surface of the closed channel (61); a second driver (63) connected to the push plate (62) and configured to drive the push plate (62) to reciprocate within the closed channel (61); The moving direction of the push plate (62) is parallel to the flow direction of the medium in the closed channel (61).

4. The casting equipment for aluminum anti-collision beam according to claim 1 or 3, characterized in that: The metal particle maker (7) comprises: The main body (71) is provided on the molten metal transport channel (6); Feeding channels (72) are evenly distributed on the main body (71), both ends of the feeding channels (72) are open ends, and the feeding channels (72) are connected to the space in the metal liquid transport channel (6); A heating resistor (73) is provided in the main body (71); A cutting module (74) is provided at the connection between the main body (71) and the molten metal transport channel (6); The feeding module (75) is arranged on the main body (71) or the molten metal transport channel (6).

5. The casting equipment for aluminum anti-collision beam according to claim 4, characterized in that: The cutting module (74) comprises: A cutting body (741) is slidably connected to the main body (71) or the molten metal transport channel (6); Cutting channels (742) are evenly distributed on the cutting body (741), and the number of the cutting channels (742) and the feeding channels (72) are the same and correspond one to one; A cutting blade (743) is provided on the inner wall of the cutting channel (742); The third driver (744) is connected to the cutting body (741), and the third driver (744) is used to drive the cutting body (741) to perform linear reciprocating movement.

6. The casting equipment for aluminum anti-collision beam according to claim 4, characterized in that: Each set of heating resistors (73) is electrically connected to an independent controller.

7. The casting equipment for aluminum anti-collision beam according to claim 6, characterized in that: A temperature sensor (76) is also provided in the main body (71), and a detection end of the temperature sensor (76) extends into the feeding channel (72).

8. The casting equipment for aluminum anti-collision beam according to claim 4, characterized in that: The feeding module (75) comprises: A guide rod (751) is provided on the main body (71) or the molten metal transport channel (6); A feed base (752) is slidably connected to the guide rod (751), and feed holes are evenly distributed on the feed base (752); The sliding base (753) is slidably connected to the feeding base (752). The moving direction of the sliding base (753) is perpendicular to the moving direction of the feeding base (752). The sliding base (753) is evenly distributed with fixing holes. The number of the fixing holes is the same as that of the feeding holes and they correspond one to one.

9. The casting equipment for aluminum anti-collision beam according to claim 8, characterized in that: The sliding base (753) is located inside the feed base (752).

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