A high-quality integrated equipment for casting and welding of copper castings

Abstract

This invention relates to the field of copper casting technology, specifically to a high-quality integrated casting and welding equipment for copper castings. It includes a frame, a microcontroller, and a casting cylinder, and further comprises: a vibration frame slidably mounted on the frame, with an excitation system installed between the vibration frame and the frame. The excitation system drives the vibration frame to generate vertical vibrations of different strokes and frequencies during the filling, solidification, and cooling stages of casting; a reciprocating frame slidably mounted on the vibration frame, with a synchronization system on the frame. When the vibration frame vibrates vertically, the synchronization system drives the reciprocating frame to vibrate horizontally synchronously; a lower support frame and a pressure frame, with the lower support frame fixedly connected to the reciprocating frame. The beneficial effects of this invention are: it addresses the problem that traditional casting equipment vibration systems use a single mode with fixed frequency and stroke, which cannot adapt to the characteristics of the various stages of copper molten metal filling, solidification, and cooling. A breakthrough improvement is achieved through the deep linkage between the excitation system and the synchronization system.

Description

Technical Field

[0001] This invention relates to the field of copper casting technology, specifically to an integrated equipment for casting and welding high-quality copper castings. Background Technology

[0002] In the field of copper casting technology, the production of high-quality copper castings has always faced multiple technical challenges. Existing casting equipment and processes have significant shortcomings in several key aspects, making it difficult to meet the production requirements of high-precision, high-density, and high-performance copper castings. The main problems are reflected in the following aspects:

[0003] First, the vibration system of traditional casting equipment mostly adopts a single vibration mode with fixed frequency and stroke, which cannot be dynamically adjusted according to the characteristics of different stages of copper liquid filling, solidification and cooling.

[0004] Secondly, the existing casting equipment gating system mostly adopts an open or simple protective structure. The high-temperature copper liquid comes into direct contact with air during the pouring process, which easily causes oxidation reaction and generates oxide inclusions, resulting in defects such as porosity and inclusions inside the casting, reducing the density and surface quality of the casting.

[0005] Furthermore, although some existing equipment has introduced a casting rotation mechanism, the rotation speed and cycle are fixed and there is a lack of coordination with the vibration system. Moreover, existing casting equipment mostly relies on the experience of operators to set process parameters and lacks a real-time monitoring mechanism for key parameters such as vibration frequency, amplitude, copper liquid temperature, and casting rotation speed.

[0006] Based on this, the present invention provides a high-quality copper casting casting and welding integrated equipment to solve the problems mentioned in the background art. Summary of the Invention

[0007] This invention addresses the problem that traditional casting equipment vibration systems use a single mode with fixed frequency and stroke, which cannot adapt to the characteristics of each stage of copper liquid filling, solidification and cooling. It achieves a breakthrough improvement through deep linkage between the excitation system and the synchronization system.

[0008] The technical solution of this invention to solve the above-mentioned technical problems is as follows: A high-quality copper casting integrated casting and welding equipment, comprising a frame, a microcontroller, and a casting cylinder, and further comprising:

[0009] The vibratory frame is slidably mounted on the machine frame. An excitation system is installed between the vibratory frame and the machine frame. The excitation system drives the vibratory frame to generate vertical vibrations of different strokes and frequencies during the filling, solidification and cooling stages of casting.

[0010] The reciprocating frame is slidably mounted on the vibrating frame. The frame is equipped with a synchronization system. When the vibrating frame vibrates vertically, the synchronization system drives the reciprocating frame to vibrate horizontally synchronously.

[0011] The lower support frame and the pressure frame are fixedly connected. Two support shafts supporting the casting cylinder are rotatably installed on the reciprocating frame. A set of electric pressure rods is installed between the reciprocating frame and the pressure frame. A pressure shaft is rotatably installed on the reciprocating frame at the position corresponding to the two support shafts. The reciprocating frame is equipped with a transmission system. When the transmission system is working, it drives the pressure shaft to alternately rotate at the first speed, idle, rotate at the second speed, and idle.

[0012] The casting pipe is rotatably mounted on the frame, on which a servo motor is mounted. The servo motor is connected to the casting pipe via a first toothed belt. The casting pipe has an air intake ring channel and a casting flow channel that are isolated from each other from the outside to the inside. Multiple sets of inert gas nozzles and casting holes are alternately arranged on the casting pipe. The inert gas nozzles are connected to the air intake ring channel, and the casting holes are connected to the casting flow channel.

[0013] The beneficial effects of this invention are:

[0014] 1. Addressing the problem that traditional casting equipment vibration systems, with their fixed frequency and stroke, cannot adapt to the characteristics of different stages of copper molten filling, solidification, and cooling, this invention achieves a breakthrough improvement through deep linkage between the excitation system and the synchronization system. The excitation system is equipped with drive wheels with three different tooth profiles, which, in conjunction with the precise switching of the linear transmission module, can provide 5mm stroke, 50Hz high-frequency vibration during the filling stage to promote rapid copper molten spreading. During the solidification stage, it switches to 3mm stroke, 30Hz medium-frequency vibration to refine the grains. During the cooling stage, it reduces to 1mm stroke, 10Hz low-frequency vibration to release internal stress. The synchronization system, through gear and toothed belt transmission, transforms vertical vibration into synchronous horizontal vibration, forming a three-dimensional composite vibration effect. This solves the problem of uneven copper molten flow caused by unidirectional vibration. Compared with traditional equipment, this dynamic adjustment mechanism improves the density of castings, refines grain size, and reduces internal stress, overcoming the defects of uneven pouring, coarse grains, and cracking that easily occur in castings under fixed vibration modes.

[0015] 2. To address the problem of inclusion defects caused by oxidation of molten copper at high temperatures due to the lack of effective protection in existing gating systems, this invention innovatively designs an integrated gating structure combining rotary gating and inert gas protection. The gating pipe is driven to rotate by a servo motor, and its alternately arranged gating holes and inert gas nozzles form a dynamic synergy. As the gating holes rotate, they spirally inject molten copper into the casting cylinder, improving the uniformity of filling. Simultaneously, the inert gas nozzles spray argon gas to form an annular gas curtain, isolating air from contact with the molten copper. The design of the air inlet ring channel and the gating flow channel is mutually isolated, ensuring that the protective gas does not interfere with the molten copper. This structure solves the oxidation problem of traditional open gating, significantly reducing the content of oxide inclusions in castings and improving surface finish. It is especially suitable for the production of high-quality oxygen-free copper castings, filling the technical gap in the existing technology where it is difficult to simultaneously achieve oxidation prevention and filling uniformity during the gating stage.

[0016] 3. To address the problems of fixed rotation speed and cycle in existing equipment, lack of coordination with the vibration system, and lack of real-time monitoring of key parameters, this invention constructs an intelligent linkage mechanism for the transmission system, excitation system, and monitoring system. The transmission system drives the pressure shaft to alternately achieve cyclical motion of low-speed rotation at 100 r / min, idling, high-speed rotation at 300 r / min, and idling through 180° misaligned meshing of the large and small sector gears. This creates a resonance effect with the vibration frequency of the excitation system, enhancing the activation energy of copper liquid flow. Simultaneously, the triaxial accelerometer, temperature probe, and speed sensor on the pressure frame collect vibration parameters, temperature field, and rotation speed data in real time. After analysis by the microcontroller, the vibration frequency, rotation cycle, and pouring speed are dynamically adjusted. This mechanism solves the drawbacks of traditional reliance on manual experience, improves the efficiency of copper liquid filling, refines grains, reduces porosity defects, and narrows the fluctuation range of casting mechanical properties, achieving precise and controllable casting process.

[0017] Based on the above technical solution, the present invention can be further improved as follows.

[0018] As a preferred technical solution of the present invention, a triaxial accelerometer, a temperature probe and a speed sensor are respectively installed on the pressure frame. The data terminals of the triaxial accelerometer, the temperature probe and the speed sensor are all connected to the microcontroller. The measurement and control terminals of the temperature probe and the speed sensor are both facing the casting cylinder.

[0019] As a preferred embodiment of the present invention, the excitation system includes a square shaft rotatably connected to a frame, a drive motor mounted on the frame, the output shaft of the drive motor being fixedly connected to the square shaft, a linear transmission module mounted on the frame, a conversion frame mounted on the linear transmission module, the conversion frame being slidably connected to the frame, a wheel sleeve rotatably mounted on the conversion frame, the wheel sleeve being driven by the square shaft, three drive wheels mounted on the wheel sleeve, each of the three drive wheels having a fixedly arranged toothed working section, a toothed frame slidably mounted on the bottom surface of the vibration frame, a set of elastic limiting members being installed between the toothed frame and the vibration frame, a first toothed plate being mounted on the toothed frame to mesh with the toothed working section, the transmission strokes of the three toothed working sections to the first toothed plate being different, the vibration frame being slidably connected to the frame, two first return springs mounted on the top surface of the vibration frame, the other ends of the two first return springs being fixedly connected to the frame, and two second return springs mounted on the side of the reciprocating frame, the other ends of the two second return springs being fixedly connected to the vibration frame.

[0020] As a preferred technical solution of the present invention, the inside of the wheel sleeve is fixedly provided with a through groove that is open at both ends and slidably connected to a square shaft. The cross-section of the through groove and the square shaft are both regular polygons. A ranging probe is installed on the frame facing the conversion frame. The data terminal of the ranging probe is connected to the microcontroller. The central angles corresponding to the toothed working sections on the three driving wheels along the arrangement direction of the three driving wheels are 180°, 140° and 100°, respectively. The toothed working sections are evenly distributed with teeth. The teeth of the toothed working sections are evenly distributed circumferentially and have equal tooth pitch. The initial teeth of the toothed working sections of the three driving wheels are in the same phase in the circumferential direction.

[0021] As a preferred embodiment of the present invention, the synchronization system includes a first gear shaft rotatably connected to the frame, a tensioning frame slidably connected to the frame, and a second gear shaft rotatably connected to the vibration frame. A second gear plate is mounted on the vibration frame, and a driven gear meshing with the first gear plate is mounted on the first gear shaft. A tension spring is mounted on the side of the tensioning frame, and the other end of the tension spring is fixedly connected to the frame. A tension wheel is rotatably mounted on the tensioning frame, and a second gear belt is drivenly mounted on the tension wheel. Both the first gear shaft and the second gear shaft are drivenly connected to the second gear belt. A driving gear is mounted on the second gear shaft, and a third gear plate meshing with the driving gear is mounted on the reciprocating frame.

[0022] As a preferred embodiment of the present invention, the transmission system includes a drive motor mounted on the pressure frame and a coupling and a differential shaft rotatably connected to the pressure frame. The output shaft of the drive motor is connected to the coupling via a third toothed belt. A large sector gear and a small sector gear are respectively mounted on the coupling. Two symmetrically arranged transmission interruption zones are provided on the coupling, corresponding to the positions between the large sector gear and the small sector gear. A low-speed gear and a high-speed gear are mounted on the differential shaft. The low-speed gear is connected to the large sector gear, and the high-speed gear is connected to the small sector gear. A fourth toothed belt is driven on the differential shaft, and the fourth toothed belt is connected to the pressure shaft.

[0023] As a preferred embodiment of the present invention, the center angles corresponding to the effective meshing areas on the large and small sector gears are both 140°, the effective meshing areas on the large and small sector gears are offset by 180° on the coupling, the center angles corresponding to the two transmission interruption areas are both 40°, the radius of the large sector gear is 1.5 times the radius of the small sector gear, the radius of the large sector gear is twice the radius of the high-speed gear, the radius of the small sector gear is 1.15 times the radius of the low-speed gear, the large and small sector gears have the same module, the rotation speed of the first speed is 100 r / min, the corresponding continuous rotation time is 0.4 seconds, the idle time after the first speed rotation is 0.12 seconds, the rotation speed of the second speed is 300 r / min, the corresponding continuous rotation time is 0.4 seconds, and the idle time after the second speed rotation is 0.12 seconds.

[0024] As a preferred technical solution of the present invention, two rollers are installed on both the support shaft and the pressure shaft, an electric heating table is installed on the reciprocating frame at the position corresponding to the two support shafts, a plurality of support springs are hinged between the bottom surface of the reciprocating frame and the frame, and a hopper communicating with the casting channel is fixedly installed on the frame.

[0025] As a preferred technical solution of the present invention, it further includes an inert gas storage tank installed on a frame, wherein a gas chamber is provided on the frame, the air inlet ring is rotatably connected to the gas chamber, and the gas outlet end of the inert gas storage tank is connected to the gas chamber.

[0026] As a preferred technical solution of the present invention, it further includes a transfer rack installed on the frame, the transfer rack having multiple transfer wheels, a multi-axis robotic arm installed on the frame, and a welding torch installed at the execution end of the multi-axis robotic arm. Attached Figure Description

[0027] Figure 1 A schematic diagram of the overall structure of a high-quality copper casting and welding integrated equipment;

[0028] Figure 2 for Figure 1 A structural diagram from another perspective;

[0029] Figure 3 A schematic diagram of the filling hopper and the electric heating platform;

[0030] Figure 4 for Figure 3 A magnified schematic diagram of the local structure at point A;

[0031] Figure 5 This is a schematic diagram of the structure of the inert gas nozzle and the pouring hole;

[0032] Figure 6 This is a cross-sectional structural diagram of the servo motor and the heating table;

[0033] Figure 7 This is a schematic diagram of the second gear shaft and the reciprocating frame.

[0034] Figure 8 for Figure 7 A magnified schematic diagram of the local structure at point B;

[0035] Figure 9 A schematic diagram of the drive motor and the ranging probe;

[0036] Figure 10 This is a structural schematic diagram of the drive wheel and the toothed working section;

[0037] Figure 11 This is a schematic diagram of the driven gear.

[0038] The attached diagram lists the components represented by each number as follows:

[0039] 1. Frame; 2. Microcontroller; 3. Casting cylinder; 4. Vibration frame; 5. Reciprocating frame; 6. Lower support frame; 7. Pressure frame; 8. Support shaft; 9. Electric pressure rod; 10. Pressure shaft; 11. Gating pipe; 12. Servo motor; 13. Inert gas nozzle; 14. Gating hole; 15. Square shaft; 16. Drive motor; 17. Linear transmission module; 18. Conversion frame; 19. Wheel sleeve; 20. Drive wheel; 21. Toothed working section; 22. Tooth frame; 23. Elastic limit component; 24. First toothed plate; 25. First return spring; 26. Second return spring; 27. Distance measuring probe; 28. 1. First gear shaft; 29. ​​Tensioning frame; 30. Second gear shaft; 31. Second gear plate; 32. Driven gear; 33. Tensioning spring; 34. Tensioning wheel; 35. Drive gear; 36. Third gear plate; 37. Drive motor; 38. Coupling; 39. Differential shaft; 40. Large sector gear; 41. Small sector gear; 42. Low-speed gear; 43. High-speed gear; 44. Transfer rack; 45. Heating table; 46. Support spring; 47. Inert gas storage tank; 48. Multi-axis robotic arm; 49. Three-axis accelerometer; 50. Temperature probe; 51. Speed ​​sensor; 52. Feed hopper. Detailed Implementation

[0040] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0041] The present invention provides the following preferred embodiments: such as Figure 1-11 As shown, a high-quality copper casting and welding integrated equipment includes a frame 1, a microcontroller 2, and a casting cylinder 3, and also includes:

[0042] Vibration frame 4 is slidably mounted on frame 1. An excitation system is installed between vibration frame 4 and frame 1. The excitation system drives vibration frame 4 to generate vertical vibrations of different strokes and frequencies during the filling, solidification and cooling stages of casting.

[0043] The excitation system includes a square shaft 15 rotatably connected to the frame 1, a drive motor 16 mounted on the frame 1, the output shaft end of the drive motor 16 being fixedly connected to the square shaft 15, a linear transmission module 17 mounted on the frame 1, a conversion frame 18 being driven on the linear transmission module 17, and the conversion frame 18 being slidably connected to the frame 1.

[0044] A wheel sleeve 19 is rotatably mounted on the conversion frame 18, and the wheel sleeve 19 is driven by a square shaft 15.

[0045] The inside of the sleeve 19 is fixedly provided with a through groove that is open at both ends and slidably connected to the square shaft 15. The cross-sections of the through groove and the square shaft 15 are both regular polygons.

[0046] A ranging probe 27 is mounted on the rack 1, facing the conversion frame 18. The data terminal of the ranging probe 27 is connected to the microcontroller 2.

[0047] Three drive wheels 20 are mounted on the wheel sleeve 19. Each of the three drive wheels 20 is fixedly provided with a toothed working section 21. A toothed frame 22 is slidably mounted on the bottom surface of the vibration frame 4. A set of elastic limiting members 23 are installed between the toothed frame 22 and the vibration frame 4. A first toothed plate 24 that meshes with the toothed working section 21 is mounted on the toothed frame 22. The transmission strokes of the three toothed working sections 21 to the first toothed plate 24 are different. The vibration frame 4 is slidably connected to the frame 1. Two first return springs 25 are mounted on the top surface of the vibration frame 4. The other ends of the two first return springs 25 are fixedly connected to the frame 1.

[0048] Along the arrangement direction of the three drive wheels 20, the central angles corresponding to the toothed working sections 21 on the three drive wheels 20 are 180°, 140° and 100° respectively. The toothed working sections 21 are evenly distributed with teeth. The teeth of the toothed working sections 21 are evenly distributed in the circumferential direction and the tooth pitch is equal. The initial teeth of the toothed working sections 21 of the three drive wheels 20 are in the same phase in the circumferential direction.

[0049] By driving the square shaft 15 to rotate through the drive motor 16, and controlling the position switching of the conversion frame 18 through the linear transmission module 17, the drive wheels 20 of the three different toothed working sections 21 on the wheel sleeve 19 can mesh with the first toothed plate 24 of the tooth frame 22. The center angles of the toothed working sections 21 of the three drive wheels 20 are 180°, 140° and 100° respectively, and the tooth pitch is equal and the phase is consistent. With the help of the elastic limiter 23 and the first return spring 25, vertical vibrations with different strokes and frequencies can be accurately generated during the filling, solidification and cooling stages of casting.

[0050] During the filling stage, the drive wheel 20 corresponding to the first toothed plate 24 is a drive wheel 20 with a central angle of 180°. The vertical and horizontal vibration strokes are both 5mm, and the vibration frequency is 50Hz. During the filling stage, it is necessary to ensure that the copper liquid fills the mold cavity quickly and evenly. The 180° drive wheel 20 meshes with the first toothed plate 24 through the maximum tooth working section 21. Combined with the 50Hz high-frequency vibration, the fluidity of the copper liquid can be significantly improved, promoting its rapid spread in the complex cavity. The 5mm large stroke vibration can effectively break the surface tension of the copper liquid and avoid uneven pouring defects caused by poor flow. At the same time, the synergistic effect of horizontal and vertical vibration forms a three-dimensional stirring effect, reducing the entrapment of air bubbles and improving the density of the casting.

[0051] During the solidification stage, the drive wheel 20 that meshes with the first toothed plate 24 is a drive wheel 20 with a center angle of 140°, with a vertical and horizontal vibration stroke of 3mm and a vibration frequency of 30Hz.

[0052] The solidification stage is the key period for grain refinement of castings. The medium stroke and 30Hz medium frequency vibration of the 140° drive wheel 20 can generate periodic mechanical disturbance in the early stage of copper liquid solidification, break up the primary dendrites, promote the formation of equiaxed crystals, and refine the grain size. At the same time, the vibration energy is transferred to the solidification interface through the casting cylinder 3, reducing solute segregation, improving the uniformity of casting composition, and significantly improving its mechanical properties such as tensile strength.

[0053] During the cooling stage, the drive wheel 20 meshing with the first toothed plate 24 is a drive wheel 20 with a center angle of 100°. The vertical and horizontal vibration strokes are both 1mm, and the vibration frequency is 10Hz. During the cooling stage, it is necessary to control the internal stress of the casting to avoid cracking. The 1mm small stroke and 10Hz low frequency vibration of the 100° drive wheel 20 can promote the uniform diffusion of heat inside the casting through micro-amplitude disturbance and reduce the temperature gradient. At the same time, the micro-plastic deformation generated by the vibration can release residual stress and keep the deformation of the casting within the set value. Compared with traditional natural cooling, the vibration in this stage can shorten the cooling time of the casting and avoid surface crack defects caused by rapid cooling.

[0054] The reciprocating frame 5 is slidably mounted on the vibrating frame 4;

[0055] The vibration frame 4 has a set of guide grooves fixedly opened inside, and the reciprocating frame 5 is fixedly installed with guide rails that are slidably connected to the guide grooves at the corresponding positions of each guide groove.

[0056] Two second return springs 26 are installed on the side of the reciprocating frame 5, and the other ends of the two second return springs 26 are fixedly connected to the vibration frame 4.

[0057] The frame 1 is equipped with a synchronization system. When the vibrating frame 4 vibrates vertically, the synchronization system drives the reciprocating frame 5 to vibrate horizontally in sync.

[0058] The synchronization system includes a first gear shaft 28 rotatably connected to the frame 1, a tensioning frame 29 slidably connected to the frame 1, and a second gear shaft 30 rotatably connected to the vibrating frame 4. A second gear plate 31 is mounted on the vibrating frame 4. A driven gear 32 that meshes with the first gear plate 24 is mounted on the first gear shaft 28. A tension spring 33 is mounted on the side of the tensioning frame 29. The other end of the tension spring 33 is fixedly connected to the frame 1. A tension wheel 34 is rotatably mounted on the tensioning frame 29. A second toothed belt is driven on the tension wheel 34. Both the first gear shaft 28 and the second gear shaft 30 are driven by the second toothed belt. A driving gear 35 is mounted on the second gear shaft 30. A third gear plate 36 that meshes with the driving gear 35 is mounted on the reciprocating frame 5.

[0059] When the vibrating frame 4 vibrates vertically under the drive of the excitation system, the driven gear 32 of the first gear shaft 28 is driven by the second toothed plate 31 to rotate. The power is then transmitted to the second gear shaft 30 through the tensioning wheel 34 and the second toothed belt. Finally, the reciprocating frame 5 is driven by the engagement of the driving gear 35 and the third toothed plate 36 to achieve horizontal vibration. The tensioning frame 29 and the tensioning spring 33 ensure the tension of the toothed belt during the transmission process and avoid slippage or tooth skipping. This synchronization mechanism solves the problem of uneven flow of molten metal and density differences in various parts of the casting caused by vibration in one direction. Through the synergistic effect of vertical and horizontal vibration, the molten copper can be uniformly filled in the casting cylinder 3, reducing local eddies and accumulation phenomena, improving the dimensional accuracy and uniformity of the casting, and is especially suitable for the forming requirements of complex-shaped copper castings.

[0060] The lower support frame 6 and the pressure frame 7 are fixedly connected to the reciprocating frame 5. Two support shafts 8 that support the casting cylinder 3 are rotatably installed on the reciprocating frame 5. A set of electric pressure rods 9 are installed between the reciprocating frame 5 and the pressure frame 7. A pressure shaft 10 is rotatably installed on the reciprocating frame 5 at the position corresponding to the two support shafts 8.

[0061] Two rollers are installed on both the support shaft 8 and the pressure shaft 10. An electric heating table 45 is installed on the reciprocating frame 5 at the position corresponding to the two support shafts 8. Multiple support springs 46 are hinged between the bottom surface of the reciprocating frame 5 and the frame 1. A hopper 52 connected to the pouring channel is fixedly installed on the frame 1.

[0062] The lower support 6 is fixedly connected to the reciprocating frame 5, and together with the rollers on the support shaft 8 and the pressure shaft 10, it provides stable support for the casting cylinder 3. The electric pressure rod 9 can adjust the pressure of the pressure frame 7 according to the size of the casting to ensure that the casting cylinder 3 does not shift during vibration. The support spring 46 at the bottom of the reciprocating frame 5 can buffer the vibration impact, and the electric heating table 45 at the top can heat and keep the bottom of the casting cylinder 3 warm to prevent the copper liquid from cracking due to excessive temperature gradient during the solidification stage. This structure solves the problems of casting deformation and cold shut caused by unstable mold positioning and insufficient temperature control in traditional casting. Through the synergy of mechanical clamping and temperature control, the stability of the casting process is improved, and the surface defect rate of the casting is reduced, providing a high-quality blank for subsequent welding processes.

[0063] During the filling stage, the operating temperature of the electric heating stage 45 is 1200℃, which ensures that the copper liquid maintains good fluidity.

[0064] During the solidification stage, the operating temperature of the electric heating platform 45 is 900℃;

[0065] During the cooling phase, the operating temperature of the electric heating platform 45 is 500℃;

[0066] By combining the real-time closed-loop feedback of the microcontroller 2 and the temperature probe 50, the operating temperature of the electric heating stage 45 can be precisely controlled.

[0067] A triaxial accelerometer 49, a temperature probe 50, and a speed sensor 51 are respectively installed on the pressure frame 7. The data terminals of the triaxial accelerometer 49, the temperature probe 50, and the speed sensor 51 are all connected to the microcontroller 2. The measurement and control terminals of the temperature probe 50 and the speed sensor 51 are facing the casting cylinder 3.

[0068] The triaxial accelerometer 49 on the pressure frame 7 monitors the amplitude and frequency of the vibration frame 4 in real time. The temperature probe 50 and the speed sensor 51 collect the temperature field distribution and rotation speed of the casting cylinder 3, respectively. After the data is analyzed by the microcontroller 2, the parameters of the excitation system and the transmission system can be dynamically adjusted.

[0069] When the temperature probe 50 detects that the solidification rate of the copper liquid is too fast, the microcontroller 2 can instruct the excitation system to reduce the vibration frequency to avoid thermal stress cracks in the casting. The abnormal rotation speed fed back by the speed sensor 51 can trigger the emergency shutdown of the transmission system to prevent equipment overload. This closed-loop control mechanism solves the problem that traditional casting relies on manual experience and process parameters cannot be optimized in real time. Through intelligent monitoring and control, the stability of the production process is significantly improved, and the range of fluctuations in the mechanical properties of copper castings is reduced.

[0070] The triaxial accelerometer 49, temperature probe 50, and speed sensor 51 can all be customized or selected according to actual needs.

[0071] The reciprocating frame 5 is equipped with a transmission system. When the transmission system is working, it drives the pressure shaft 10 to alternately rotate at the first speed, idle, rotate at the second speed, and idle.

[0072] The transmission system includes a drive motor 37 mounted on the pressure frame 7 and a coupling 38 and a differential shaft 39 rotatably connected to the pressure frame 7. The output shaft end of the drive motor 37 is connected to the coupling 38 via a third toothed belt. A large sector gear 40 and a small sector gear 41 are respectively mounted on the coupling 38. Two symmetrically arranged transmission interruption zones are provided on the coupling 38 at positions corresponding to the positions between the large sector gear 40 and the small sector gear 41. A low-speed gear 42 and a high-speed gear 43 are mounted on the differential shaft 39. The low-speed gear 42 is connected to the large sector gear 40, and the high-speed gear 43 is connected to the small sector gear 41. A fourth toothed belt is installed on the differential shaft 39 and is connected to a pressure shaft 10.

[0073] The effective meshing areas of the large sector gear 40 and the small sector gear 41 are both 140°. The effective meshing areas of the large sector gear 40 and the small sector gear 41 are offset by 180° on the coupling 38. The center angles of the two transmission interruption areas are both 40°.

[0074] The radius of the large sector gear 40 is 1.5 times the radius of the small sector gear 41, the radius of the large sector gear 40 is 2 times the radius of the high-speed gear 43, the radius of the small sector gear 41 is 1.15 times the radius of the low-speed gear 42, and the large sector gear 40 and the small sector gear 41 have the same module.

[0075] The first rotation speed is 100 r / min, the corresponding continuous rotation time is 0.4 seconds, and the idle time after the first rotation speed is 0.12 seconds. The second rotation speed is 300 r / min, the corresponding continuous rotation time is 0.4 seconds, and the idle time after the second rotation speed is 0.12 seconds.

[0076] The pressure shaft 10 achieves periodic motion of low-speed rotation, idling, high-speed rotation, and idling through the 180° misaligned meshing of the large sector gear 40 and the small sector gear 41.

[0077] The aforementioned periodic motion can improve the fluidity of molten copper and the cavity filling capacity during the filling stage. Through the first rotation speed for 0.4 seconds, the molten copper forms a stable circulation in the casting cylinder 3, avoiding eddy air entrapment caused by high-speed rotation. It is especially suitable for filling thin-walled areas of complex cavity castings, reducing the risk of cold shut-off. The subsequent high-speed rotation generates centrifugal force, which quickly pushes the molten copper to the end of the cavity. Combined with the 50Hz high-frequency vibration of the excitation system, the molten copper can complete more than 95% cavity filling within 3 seconds, which is more efficient than traditional gravity casting.

[0078] The aforementioned periodic motion can refine grains and reduce internal defects during the solidification stage;

[0079] In the early stage of copper liquid solidification, the first rotation speed forms laminar flow stirring, breaks up the nascent dendrite arms, promotes the growth of equiaxed crystals, and refines the grain size. After the dendrite network is formed, the shear force generated by high-speed rotation can tear the viscous layer at the solid-liquid interface, reduce solute segregation, improve the uniformity of the casting composition, and increase the tensile strength.

[0080] The 0.12-second idling interval between the first and second rotation speeds can avoid mechanical impact during speed switching and reduce the contact pressure between the pressure shaft 10 and the casting cylinder 3.

[0081] During the idling stage, the copper liquid is allowed to stand for a short period of time, which helps the air bubbles to rise to the surface and reduces the porosity defect rate of the casting.

[0082] The rotation cycle of the pressure shaft 10 resonates with the vibration frequency of the excitation system, which enhances the flow activation energy of the copper liquid under the combined action of vibration and rotation, further reducing the viscosity and achieving filling without dead angles.

[0083] The casting pipe 11 is rotatably mounted on the frame 1. A servo motor 12 is mounted on the frame 1. The servo motor 12 is connected to the casting pipe 11 via a first toothed belt. The casting pipe 11 has an air intake ring channel and a casting flow channel that are isolated from each other from the outside to the inside. Multiple sets of inert gas nozzles 13 and casting holes 14 are alternately arranged on the casting pipe 11. The inert gas nozzles 13 are connected to the air intake ring channel, and the casting holes 14 are connected to the casting flow channel.

[0084] It also includes an inert gas storage tank 47 installed on the frame 1. The frame 1 has a gas chamber, the air inlet ring is rotatably connected to the gas chamber, and the gas outlet of the inert gas storage tank 47 is connected to the gas chamber.

[0085] Argon is stored in inert gas storage tank 47;

[0086] Servo motor 12 drives the pouring pipe 11 to rotate. Its internal air intake ring channel is connected to the inert gas storage tank 47, and the pouring channel is connected to the copper liquid supply system. Alternating inert gas nozzles 13 and pouring holes 14 can form an annular protective air curtain during the pouring process. The inert gas enters the air intake ring channel through the gas chamber and is sprayed out from the nozzle to isolate the air and prevent the high-temperature copper liquid from oxidizing. At the same time, the rotating pouring hole 14 makes the copper liquid enter the casting cylinder 3 in a spiral shape, improving the uniformity of filling. This structure solves the problems of easy oxidation and air entrapment of copper liquid in the traditional pouring process. Through the synergistic effect of gas and liquid, the content of oxide inclusions in the casting is reduced and the surface finish is improved. It is especially suitable for the production of high-quality oxygen-free copper castings.

[0087] Specifically, during the filling stage, the rotation speed of the pouring pipe 11 is set to 15-20 r / min. The pouring pipe 11 rotates at a low speed of 15-20 r / min, which, together with the alternately distributed pouring holes 14, allows the copper liquid to be injected into the casting cylinder 3 in a spiral shape, forming a dynamic annular flow field. This avoids the local impact and eddy air entrapment caused by traditional fixed pouring, and improves the uniformity of casting filling.

[0088] During the rotation, the inert gas nozzle 13 simultaneously sprays argon gas, forming a continuous gas curtain around the casting hole 14, which isolates the air from contact with the high-temperature copper liquid and reduces the content of oxide inclusions.

[0089] The rotational speed during the filling stage and the 50Hz vibration frequency of the excitation system form a composite energy field of rotational vibration, which enhances the activation energy of the copper liquid flow.

[0090] During the solidification stage, the rotation speed of the casting tube 11 is set to 5-8 r / min. The shear force generated by the rotation of the casting tube 11 at 5-8 r / min acts on the solidification interface of the copper liquid, breaking the primary dendrites and promoting the formation of equiaxed crystals. The rotation drives the copper liquid to slowly convect, avoiding the enrichment of solute elements at the grain boundaries.

[0091] During the cooling stage, the pouring pipe 11 completely stops rotating. The cooling stage stops rotating to avoid secondary defects in the solidification structure caused by mechanical disturbance, and the internal density of the casting is increased. After the rotation stops, the inert gas nozzle 13 continuously sprays gas for 30 seconds to form a dense oxide protective film on the surface of the casting, providing clean base material for subsequent welding processes.

[0092] It also includes a material transfer rack 44 installed on the frame 1, which has multiple material transfer wheels. A multi-axis robotic arm 48 is installed on the frame 1, and a welding gun is installed at the execution end of the multi-axis robotic arm 48.

[0093] After casting is completed, the transfer wheel on the transfer rack 44 can transport the casting to the welding station. The multi-axis robotic arm 48 on the frame 1 drives the welding gun to perform automated welding on the casting, realizing the integrated operation of casting and welding. The multi-axis linkage of the robotic arm ensures that the welding path is precise and controllable. Combined with the improvement of dimensional accuracy in the casting stage, the misalignment and porosity of the weld joint can be significantly reduced. This design solves the problems of low production efficiency and large secondary positioning error of workpiece caused by the separation of casting and welding processes in traditional processes. Through process integration, the production cycle is shortened.

[0094] Welding is used to achieve an integral connection between two cast blanks;

[0095] The working principle of this invention is as follows: This high-quality copper casting and welding integrated equipment achieves efficient and precise operation through the deep linkage of the excitation system, synchronization system, transmission system, pouring system and monitoring and control system. During operation, the excitation system is driven by the drive motor 16 to rotate the square shaft 15. Combined with the linear transmission module 17 to switch the position of the conversion frame 18, the drive wheels 20 of different toothed working sections 21 on the wheel sleeve 19 mesh with the first toothed plate 24 of the tooth frame 22. With the help of the elastic limiter 23 and the first return spring 25, vertical vibrations with different strokes and frequencies are generated in the filling, solidification and cooling stages respectively.

[0096] The synchronization system uses the meshing of the second toothed plate 31 and the driven gear 32 of the first toothed shaft 28 when the vibration frame 4 vibrates vertically. The transmission is then transmitted to the second toothed shaft 30 via the tension wheel 34 and the second toothed belt. Finally, the reciprocating frame 5 is driven to vibrate horizontally by the meshing of the driving gear 35 and the third toothed plate 36, forming a three-dimensional composite vibration to improve the fluidity and filling uniformity of the copper liquid.

[0097] In the transmission system, the transmission motor 37 drives the coupling 38 to rotate. The large sector gear 40 and the small sector gear 41 on the coupling are offset by 180° and mesh with the low speed and high speed gears 43 of the differential shaft 39 respectively. This drives the pressure shaft 10 to perform periodic movements of rotating at the first speed, idling, rotating at the second speed, and idling. It also forms a resonance effect with the vibration frequency of the excitation system, further reducing the viscosity of the copper liquid and reducing bubbles.

[0098] In the casting system, the servo motor 12 drives the casting pipe 11 to rotate, and the alternately arranged casting holes 14 inject the copper liquid into the casting cylinder 3 in a spiral manner as it rotates. At the same time, the inert gas storage tank 47 sprays argon gas from the nozzle through the gas chamber and the air inlet ring to form a protective gas curtain to prevent the high-temperature copper liquid from oxidizing. Combined with vibration and rotation, it achieves filling without dead angles.

[0099] The triaxial accelerometer 49, temperature probe 50, and speed sensor 51 on the pressure frame 7 collect vibration, temperature, and speed data in real time and transmit them to the microcontroller 2. The microcontroller 2 dynamically adjusts the vibration parameters of the excitation system, the rotation period of the transmission system, and the speed of the casting pipe 11 to ensure that the process at each stage is precise and controllable.

[0100] After casting is completed, the transfer rack 44 transports the casting to the welding station through the transfer wheel, and the multi-axis robotic arm 48 drives the welding gun to complete the automated welding, realizing the integration of casting and welding.

[0101] Among them, the coordination between the excitation system and the synchronization system is particularly crucial. Unidirectional vibration can easily lead to local eddies or accumulation of copper liquid, while the three-dimensional linkage of vertical and horizontal vibration forms a dynamic stirring effect, which can significantly reduce bubble entrainment and improve the density of castings, demonstrating the strong correlation between the systems.

[0102] This equipment solves the problems of uneven structure caused by the single vibration mode during casting, easy oxidation of copper liquid and gas entrapment, and large precision error caused by the separation of casting and welding processes by multi-system linkage vibration, rotation, gas protection coordinated control and intelligent monitoring and adjustment. It realizes the efficient integrated production of high-quality copper castings.

[0103] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-quality copper casting and welding integrated equipment, comprising a frame (1), a microcontroller (2), and a casting cylinder (3), characterized in that, Also includes: Vibration frame (4) is slidably mounted on frame (1). A vibration system is installed between vibration frame (4) and frame (1). The vibration system drives vibration frame (4) to generate vertical vibrations of different strokes and frequencies during the filling, solidification and cooling stages of casting. The reciprocating frame (5) is slidably mounted on the vibrating frame (4). The frame (1) is equipped with a synchronization system. When the vibrating frame (4) vibrates vertically, the synchronization system drives the reciprocating frame (5) to vibrate horizontally synchronously. The lower support (6) and the pressure frame (7) are fixedly connected to the reciprocating frame (5). Two support shafts (8) supporting the casting cylinder (3) are rotatably installed on the reciprocating frame (5). A set of electric pressure rods (9) is installed between the reciprocating frame (5) and the pressure frame (7). A pressure shaft (10) is rotatably installed on the reciprocating frame (5) at the position corresponding to the two support shafts (8). The reciprocating frame (5) is equipped with a transmission system. When the transmission system is working, it drives the pressure shaft (10) to alternately rotate at the first speed, idle, rotate at the second speed, and idle. A casting pipe (11) is rotatably mounted on a frame (1). A servo motor (12) is mounted on the frame (1). The servo motor (12) is connected to the casting pipe (11) via a first toothed belt. An air intake ring and a casting flow channel, which are isolated from each other, are respectively opened on the casting pipe (11) from the outside to the inside. Multiple sets of inert gas nozzles (13) and casting holes (14) are alternately arranged on the casting pipe (11). The inert gas nozzles (13) are connected to the air intake ring, and the casting holes (14) are connected to the casting flow channel. The vibration system includes a square shaft (15) rotatably connected to a frame (1). A drive motor (16) is mounted on the frame (1), and the output shaft of the drive motor (16) is fixedly connected to the square shaft (15). A linear transmission module (17) is mounted on the frame (1), and a conversion frame (18) is driven and mounted on the linear transmission module (17). The conversion frame (18) is slidably connected to the frame (1), and a wheel is rotatably mounted on the conversion frame (18). The sleeve (19) is driven by a square shaft (15). Three drive wheels (20) are installed on the sleeve (19). A toothed working section (21) is fixedly provided on each of the three drive wheels (20). A toothed frame (22) is slidably installed on the bottom surface of the vibration frame (4). A set of elastic limiting members (23) is installed between the toothed frame (22) and the vibration frame (4). A first toothed plate (24) that meshes with the toothed working section (21) is installed on the toothed frame (22). The transmission strokes of the three toothed working sections (21) to the first toothed plate (24) are different. The vibration frame (4) is slidably connected to the frame (1). Two first return springs (25) are installed on the top surface of the vibration frame (4). The other ends of the two first return springs (25) are fixedly connected to the frame (1). Two second return springs (26) are installed on the side of the reciprocating frame (5). The other ends of the two second return springs (26) are fixedly connected to the vibration frame (4).

2. The high-quality copper casting and welding integrated equipment according to claim 1, characterized in that, A triaxial accelerometer (49), a temperature probe (50), and a speed sensor (51) are respectively installed on the pressure frame (7). The data terminals of the triaxial accelerometer (49), the temperature probe (50), and the speed sensor (51) are all connected to the microcontroller (2). The measurement and control terminals of the temperature probe (50) and the speed sensor (51) are directly facing the casting cylinder (3). The synchronization system includes a first gear shaft (28) rotatably connected to the frame (1), a tensioning frame (29) slidably connected to the frame (1), and a second gear shaft (30) rotatably connected to the vibration frame (4). A second gear plate is installed on the vibration frame (4). (31) A driven gear (32) meshing with the first gear plate (24) is installed on the first gear shaft (28). A tension spring (33) is installed on the side of the tension frame (29). The other end of the tension spring (33) is fixedly connected to the frame (1). A tension wheel (34) is rotatably installed on the tension frame (29). A second toothed belt is driven on the tension wheel (34). The first gear shaft (28) and the second gear shaft (30) are both driven by the second toothed belt. A driving gear (35) is installed on the second gear shaft (30). A third gear plate (36) meshing with the driving gear (35) is installed on the reciprocating frame (5).

3. The high-quality copper casting and welding integrated equipment according to claim 1, characterized in that, The inside of the wheel sleeve (19) is fixedly provided with a through groove that is open at both ends and slidably connected to the square shaft (15). The cross-section of the through groove and the square shaft (15) are both regular polygons. A ranging probe (27) is installed on the frame (1) facing the conversion frame (18). The data terminal of the ranging probe (27) is connected to the microcontroller (2). The central angles corresponding to the toothed working sections (21) on the three driving wheels (20) along the arrangement direction of the three driving wheels (20) are 180°, 140° and 100° respectively. The toothed working sections (21) are evenly distributed with teeth. The teeth of the toothed working sections (21) are evenly distributed in the circumferential direction and the tooth pitch is equal. The initial teeth of the toothed working sections (21) of the three driving wheels (20) are in the same phase in the circumferential direction.

4. The high-quality copper casting and welding integrated equipment according to claim 1, characterized in that, The transmission system includes a drive motor (37) mounted on the pressure frame (7) and a coupling (38) and a differential shaft (39) rotatably connected to the pressure frame (7). The output shaft end of the drive motor (37) is connected to the coupling (38) via a third toothed belt. A large sector gear (40) and a small sector gear (41) are respectively mounted on the coupling (38). Two symmetrically arranged transmission interruption zones are provided on the coupling (38) at positions corresponding to the large sector gear (40) and the small sector gear (41). A low-speed gear (42) and a high-speed gear (43) are mounted on the differential shaft (39). The low-speed gear (42) is connected to the large sector gear (40), and the high-speed gear (43) is connected to the small sector gear (41). A fourth toothed belt is installed on the differential shaft (39), and the fourth toothed belt is connected to a pressure shaft (10).

5. The high-quality copper casting and welding integrated equipment according to claim 4, characterized in that, The effective meshing areas of the large sector gear (40) and the small sector gear (41) are both 140° at their respective center angles. The effective meshing areas of the large sector gear (40) and the small sector gear (41) are offset by 180° on the coupling (38). The center angles of the two transmission interruption areas are both 40°. The radius of the large sector gear (40) is 1.5 times the radius of the small sector gear (41). The radius of the large sector gear (40) is twice the radius of the high-speed gear (43). The radius of (41) is 1.15 times the radius of the low-speed gear (42). The large sector gear (40) and the small sector gear (41) have the same module. The rotation speed of the first speed is 100 r / min, and the corresponding continuous rotation time is 0.4 seconds. The idle time after the first speed rotation is 0.12 seconds. The rotation speed of the second speed is 300 r / min, and the corresponding continuous rotation time is 0.4 seconds. The idle time after the second speed rotation is 0.12 seconds.

6. The high-quality copper casting and welding integrated equipment according to claim 1, characterized in that, Two rollers are installed on both the support shaft (8) and the pressure shaft (10). An electric heating table (45) is installed on the reciprocating frame (5) at the position corresponding to the two support shafts (8). Multiple support springs (46) are hinged between the bottom surface of the reciprocating frame (5) and the frame (1). A hopper (52) communicating with the pouring channel is fixedly installed on the frame (1).

7. The high-quality copper casting and welding integrated equipment according to claim 1, characterized in that, It also includes an inert gas storage tank (47) installed on a frame (1), the frame (1) having an air chamber, the air inlet ring being rotatably connected to the air chamber, and the air outlet of the inert gas storage tank (47) being connected to the air chamber.

8. The high-quality copper casting and welding integrated equipment according to claim 1, characterized in that, It also includes a transfer rack (44) installed on the frame (1), the transfer rack (44) is provided with multiple transfer wheels, and a multi-axis robotic arm (48) is installed on the frame (1), the execution end of the multi-axis robotic arm (48) is equipped with a welding gun.

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