An adaptive adjustment mold device for casting wind turbine gearboxes

Abstract

This invention relates to the field of casting mold technology, specifically disclosing an adaptive adjustment mold device for casting wind turbine gearboxes. The device includes an upper mold and a lower mold. The lower mold comprises a stackable top mold, multiple composite molds, and a bottom mold. The bottom mold has an ejection hole at its bottom, and a lifting mechanism is provided at the bottom of the lower mold. The height of the lower mold can be adjusted simply by adding or removing composite molds without replacing the bottom mold. The lifting mechanism at the bottom of the lower mold provides a stable and reliable auxiliary demolding force for the casting, effectively overcoming the adhesion force between the casting and the mold cavity and the clamping force of the molding sand, reducing tensile stress on the casting during demolding, and lowering the risk of defects such as cracks and deformation in the casting. When the hydraulic push rod drives the assembly plate to move, the support frame can expand or contract accordingly and automatically adjust its support position to the center area of ​​the assembly plate, providing central support force and enhancing its stability under stress.

Description

Technical Field

[0001] This invention relates to the field of casting mold technology, specifically to an adaptive adjustment mold device for casting wind turbine gearboxes. Background Technology

[0002] As a core transmission component in wind turbine generators, the performance and reliability of the wind turbine directly affect the overall power generation efficiency and service life of the turbine. Wind turbine gearboxes are typically complex in structure, large in size, and bear high loads, placing extremely high demands on their manufacturing precision and material properties. Casting, as one of the main processes for producing large, complex-shaped metal parts, plays a crucial role in the production of wind turbine gearbox blanks.

[0003] In traditional wind turbine gearbox casting mold design, the mold is customized for specific gearbox models, forming an integral or semi-integral structure. This design approach has significant drawbacks: First, when different gearbox models need to be produced, the entire mold must be replaced or a large-scale modification must be made, resulting in high mold manufacturing costs and long production preparation cycles, making it difficult to adapt to the market demands of the wind power industry for its diverse product models and rapid product updates; second, demolding is a technical challenge for large wind turbine gearbox castings, and traditional molds may require complex demolding aids, and when large castings cool and shrink unevenly, the demolding process can easily damage the casting or cause mold wear; third, the molds have poor versatility and interchangeability, which is not conducive to standardized production and inventory management, and also increases the complexity of production management.

[0004] Therefore, there is an urgent need for an adaptive adjustment mold device that can adapt to the casting requirements of different gearbox models, facilitate quick replacement and adjustment, and effectively solve the problem of demolding large castings. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an adaptive adjustment mold device for wind turbine gearbox casting, which solves the problems of fixed gearbox sand boxes that are inconvenient to replace and adjust, as well as inconvenient demolding.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an adaptive adjustment mold device for casting wind turbine gearboxes, comprising an upper mold and a lower mold, wherein the upper mold can be fastened onto the lower mold, and the lower mold comprises a stackable top mold, multiple composite molds, and a bottom mold. The outer walls of the top mold and the bottom mold are provided with multiple lugs in the circumferential direction, and the lugs on the outer walls of the top mold and the bottom mold are fixed together by a fixing component, thereby clamping and fixing the multiple composite molds between the top mold and the bottom mold.

[0007] The bottom mold has an ejection hole, and the bottom of the lower mold is provided with a lifting mechanism, the output end of which is located at the ejection hole.

[0008] Preferably, the fixing component includes a screw that passes through the lugs on the outer walls of the top mold and the bottom mold, and a plurality of nuts are screwed onto the screw, with each pair of nuts clamping the upper and lower ends of each lug.

[0009] Preferably, the bottom end of the top mold is provided with an upper stepped opening in the circumferential direction, and the top end of the bottom mold is provided with a lower stepped opening in the circumferential direction, and the upper stepped opening and the lower stepped opening are adapted to each other.

[0010] Preferably, each of the composite molds is provided with composite stepped openings at its top and bottom circumferentially, and the composite stepped openings are respectively adapted to the upper stepped opening and the lower stepped opening.

[0011] Preferably, the lifting mechanism includes: an assembly plate, a push assembly, a lifting rod assembly, and a top cap; the push assembly is disposed below the assembly plate and pushes and pulls the assembly plate up and down; the lifting rod assembly is disposed on the assembly plate; the top cap is disposed on the lifting rod assembly and is located in the ejection hole.

[0012] Preferably, the lifting rod assembly includes: a base cylinder, a lifting rod, an air nozzle, an air chamber, and an air supply pipe; the base cylinder is fixedly connected to the assembly plate; the lifting rod is inserted into the base cylinder, with its top end extending through the base cylinder, and the top cap is disposed at the top end of the lifting rod; the air nozzle is disposed circumferentially at the top of the lifting rod, with its air outlet facing the ejection hole; the air chamber is formed inside the lifting rod and communicates with the air nozzle;

[0013] The air supply pipe is connected to the base cylinder, and a solenoid valve is installed on the air supply pipe.

[0014] Preferably, the lifting rod assembly further includes: a sealing plate, a piston disc, a lifting rod, a cam, and a drive motor; the sealing plate is disposed inside the base cylinder, dividing the inner cavity of the base cylinder into an inflation chamber and a lower chamber, and the lifting rod is located in the inflation chamber; the piston disc is fixed to the bottom of the lifting rod and is provided with a sealing ring in the circumferential direction; the lifting rod is disposed at the bottom of the piston disc, and the bottom end of the lifting rod penetrates the sealing plate and is inserted into the lower chamber; a roller is rotatably connected to the bottom of the lifting rod; the cam is rotatably connected to the lower chamber, and its outer wall surface abuts against the roller; the drive motor is fixed on the base cylinder, and its output end is connected to the cam.

[0015] Preferably, the air chamber includes: a central chamber, an air inlet, a gap chamber, and several branch air chambers; the central chamber is located at the center of the inside of the push rod and includes a first compression chamber, a second compression chamber, and a third compression chamber whose diameter decreases in a stepped manner from bottom to top; the air inlet is located on the outer wall of the push rod and communicates with the central chamber; the gap chamber is located above the central chamber; the tops of the several branch air chambers communicate with each jet nozzle, and the bottoms communicate with the gap chambers.

[0016] Preferably, the propulsion assembly includes: a bottom tank, a hydraulic push rod, two side support plates, and a support frame; the bottom tank is mounted on a fixed object; the hydraulic push rod is fixed inside the bottom tank, and its output end is fixed to the assembly plate; the two side support plates are slidably connected to both sides of the assembly plate; and the support frame is hinged between the assembly plate and the two side support plates.

[0017] Preferably, the assembly plate is provided with limit plates on both sides; the outer wall of the assembly plate is provided with a sliding groove, and the inner wall of the side support plate is provided with a slider that can slide in the sliding groove.

[0018] The beneficial effects of the present invention are as follows: By using the adaptive adjustment mold device for casting wind turbine gearboxes provided by the present invention, the following technical effects are achieved:

[0019] 1. The lower mold consists of stackable modules such as the top mold, composite mold, and bottom mold. This allows for easy adjustment of the number of composite molds based on the model and size requirements of the gearbox to be cast, thereby precisely adjusting the overall height and usable cavity of the lower mold. This enables the same mold system to adapt to the casting needs of various wind turbine gearboxes, avoiding the need for separate mold design and manufacturing for each model. This significantly reduces mold manufacturing costs and inventory pressure, shortens production preparation time, and improves the flexibility and intelligence of the production line.

[0020] 2. When it is necessary to change molds to produce different models of gearboxes, the height of the lower mold can be adjusted simply by adding or removing composite molds without replacing the bottom mold. Compared to the traditional method of replacing the entire mold, the partial adjustment method is simpler and faster, reducing downtime for mold changes and significantly improving production efficiency. At the same time, replacing the upper mold only requires reassembling and repositioning according to the adjusted top mold position, further simplifying the operation.

[0021] 3. The lifting mechanism at the bottom of the lower mold can provide a stable and reliable auxiliary demolding force for the casting. It can effectively overcome the adhesion force between the casting and the mold cavity and the clamping force of the molding sand, reduce the tensile stress on the casting during demolding, reduce the risk of defects such as cracks and deformation in the casting, and at the same time help protect the precision of the mold cavity, improve the casting yield and mold service life.

[0022] 4. When the hydraulic push rod drives the assembly plate to move, the support frame can expand or retract accordingly and automatically adjust the support position to the center area of ​​the assembly plate, providing central support force for the assembly plate, enhancing its stability under stress, preventing tilting or shaking, and optimizing the force transmission through the lever principle, making the support more stable and reliable, able to adapt to larger working loads, and ensuring the safety and stability of the entire mold device during operation. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the three-dimensional structure of the mold of the present invention;

[0024] Figure 2 For the present invention Figure 1 Main view;

[0025] Figure 3 This is a schematic diagram of the structure of the first embodiment of the lower mold of the present invention;

[0026] Figure 4 This is a schematic diagram of the second embodiment of the lower mold of the present invention;

[0027] Figure 5 For the present invention Figure 4 Enlarged structural diagram at point A in the middle;

[0028] Figure 6 This is a schematic diagram of the assembly structure of the top mold, composite mold, and bottom mold of the present invention;

[0029] Figure 7 This is a schematic diagram of the lifting mechanism structure of the present invention;

[0030] Figure 8 This is a front view of the lifting mechanism of the present invention;

[0031] Figure 9 This is a top view of the lifting mechanism of the present invention;

[0032] Figure 10 This is a schematic diagram of the lifting mechanism of the present invention under normal operating conditions;

[0033] Figure 11 This is a schematic diagram of the structure of the hydraulic push rod after it has been pushed forward according to the present invention;

[0034] Figure 12 This is a schematic diagram of the internal air cavity structure of the push rod of the present invention.

[0035] Explanation of reference numerals in the diagram: 1. Upper mold; 2. Lower mold; 201. Top mold; 202. Composite mold; 203. Bottom mold; 204. Ejector hole; 205. Lug; 206. Screw; 207. Nut; 208. Upper stepped opening; 209. Lower stepped opening; 210. Composite stepped opening; 3. Top cap; 4. Ejector rod; 5. Base cylinder; 6. Air supply pipe; 7. Drive motor; 8. Assembly plate; 9. Side support plate; 10. Support frame; 11. 11. Slide rail; 12. Slider; 13. Limiting plate; 14. Bottom groove box; 15. Hydraulic push rod; 16. Air nozzle; 17. Air chamber; 171. Support air chamber; 172. Gap chamber; 173. First compression chamber; 174. Second compression chamber; 175. Third compression chamber; 176. Air inlet; 18. Piston disc; 19. Lifting rod; 20. Roller; 21. Cam; 22. Inflation chamber; 23. Sealing plate; 24. Lower chamber; 25. Solenoid valve. Detailed Implementation

[0036] To better explain and facilitate understanding of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Various changes can be made to the implementation schemes as long as the effects of the present invention can be achieved.

[0038] Those skilled in the art can connect the components in this case sequentially. The specific connection and operation sequence should refer to the working principle described below. The detailed connection methods are well-known technologies in the field. The working principle and process are mainly described below.

[0039] like Figure 1 As shown in the figure, this application proposes an adaptive adjusting mold device for casting wind turbine gearboxes. The device includes an upper mold 1 and a lower mold 2, wherein the upper mold 1 can be fastened onto the lower mold 2, together forming a complete cavity to accommodate molding sand and form the gearbox casting; furthermore, as... Figure 2 As shown, the bottom of the lower mold 2 is equipped with a lifting mechanism. The lifting mechanism provides an auxiliary demolding function. Especially after the casting has cooled and solidified, the lifting mechanism can apply a lifting force to the casting from below to overcome the adhesion force between the casting and the mold cavity and the clamping force of the molding sand, thereby significantly reducing the demolding difficulty and improving the automation level of the demolding process and the casting yield.

[0040] In this embodiment, as Figure 1 and Figure 2 As shown, the lower mold 2 is composed of multiple modular components that can be independently separated and stacked, including a top mold 201, multiple composite molds 202 and a bottom mold 203; the top mold 201 is located at the top of the stacked structure, the bottom mold 203 is located at the bottom, and the multiple composite molds 202 are placed between the top mold 201 and the bottom mold 203 as needed; in order to ensure that these modules can be firmly combined into a whole, the outer walls of the top mold 201 and the bottom mold 203 are provided with multiple lugs 205 in the circumferential direction, and the lugs 205 on the outer walls of the top mold 201 and the bottom mold 203 are fixed together by a fixing component, clamping and fixing the multiple composite molds 202 between the top mold 201 and the bottom mold 203.

[0041] It should be noted that the lower mold 2 adopts a modular and stackable design, which can adapt to the casting needs of various wind turbine gearboxes of different models and sizes, and realizes the adaptive adjustment of the mold device. The lower mold 2 has at least two composition forms to cast various models of gearboxes. For example, when casting conventional gearboxes, the top mold 201 and the bottom mold 203 can be used. When changing molds, the bottom mold 203 of the lower mold 2 does not need to be replaced. The number of composite molds 202 can be added as needed to adjust the usage height of the lower mold 2.

[0042] For example, such as Figure 3 As shown, in the first embodiment of the lower mold 2, the top mold 201 and the bottom mold 203 are fixed together by a fixing component. In this case, it is only necessary to firmly fix the top mold 201 and the bottom mold 203 together by the fixing component to form a relatively fixed lower mold assembly of standard height, which can then be put into production.

[0043] For example, such as Figure 4 As shown, in the second embodiment of the lower mold 2, this embodiment is designed for scenarios requiring the casting of larger gearboxes. First, the original top mold 201 can be removed. Then, according to the required increase in height, a corresponding number of composite molds 202 are stacked and added on the bottom mold 203. After precisely achieving the target height by adjusting the number of composite molds 202, the top mold 201 is reinstalled. It is worth noting that the replacement or adjustment of the upper mold 1 must also match the position of the reassembled top mold 201 to ensure precise alignment of the cavities of the upper and lower molds. The core advantage of this setup is that when changing molds to adapt to different product models, the bottom mold 203 of the lower mold 2 can remain stationary, and its positional relationship relative to the upper mold 1 or other reference surfaces remains unchanged. This ensures that after mold replacement, the reference values ​​of the entire mold system (such as the relative coordinates of the cavities, key dimensions, etc.) remain stable, avoiding positioning errors that may be introduced due to the replacement of the bottom mold. This greatly reduces the complexity and workload of the replacement process, making the mold replacement process more convenient, efficient, and reliable.

[0044] In some embodiments, such as Figure 6 As shown, the fixing component includes a screw 206, which passes through the lugs 205 on the outer walls of the top mold 201 and the bottom mold 203. Multiple nuts 207 are screwed onto the screw 206, with each pair of nuts 207 clamping the upper and lower ends of each lug 205. Different lengths of screws 206 are used depending on the number of composite molds 202 stacked. When in use, the screw 206 passes through the lugs 205 on the outer walls of the top mold 201 and the bottom mold 203 and is fastened by the nuts 207, making the operation convenient and quick.

[0045] like Figure 5As shown, in this embodiment, to enhance the stability of the multi-layered lower mold 2 after assembly and prevent misalignment or deformation under casting pressure or high temperature, the bottom end of the top mold 201 is provided with an upper stepped opening 208, and the top end of the bottom mold 203 is provided with a lower stepped opening 209. The upper stepped opening 208 and the lower stepped opening 209 are adapted to each other. When the top mold 201 is placed on the bottom mold 203 (or when the composite molds 202 are stacked), the upper stepped opening 208 can be precisely embedded in the lower stepped opening 209. The staggered stepped opening design effectively prevents obvious gaps between the top mold 201 and the bottom mold 203 (or adjacent composite molds), thus avoiding the problem of molding sand leakage (sand leakage) that may occur during the casting process and ensuring the sealing of the cavity. Secondly, this stepped nested design allows the two modules to abut against each other at the contact surface, forming multi-point or surface contact, which significantly enhances the connection strength between them and the rigidity of the overall structure, so that the multi-layered lower mold 2 can remain stable when subjected to various loads during the casting process.

[0046] Furthermore, to ensure that each composite mold 202 maintains good connection stability and overall strength with the top mold 201 and bottom mold 203 (and adjacent composite molds) after assembly, this embodiment also incorporates a corresponding design for the structure of the composite mold 202. Specifically, composite stepped openings 210 are provided in the circumferential directions of both the top and bottom ends of each composite mold 202. The structure and dimensions of the composite stepped openings 210 can respectively connect with the upper stepped opening 208 on the top mold 201 and the lower stepped opening 209 on the bottom mold 203 (or connect with...). The composite mold 202 is adapted to the upper step opening 208 and the lower step opening 209 after the composite mold 202 is assembled. This ensures that after the composite mold 202 is installed, it can be precisely connected and firmly pressed with the top mold 201, the bottom mold 203 and the adjacent composite mold 202 through the step opening. This greatly improves the connection stability of the composite mold 202 after installation and ensures that even after multiple composite molds 202 are installed, the entire lower mold 2 can still maintain high overall strength and structural reliability.

[0047] In this embodiment, as Figure 2 As shown, the bottom mold 203 has an ejection hole 204 at its bottom. The output end of the lifting mechanism is located at the ejection hole 204, which assists in demolding the gearbox.

[0048] For example, such as Figure 7As shown, the lifting mechanism includes an assembly plate 8, a push assembly, a lifting rod assembly, and a top cap 3. The push assembly is located below the assembly plate 8, the lifting rod assembly is located on the assembly plate 8, and the top cap 3 is located on the lifting rod assembly and within the ejection hole 204. During implementation, the push assembly pushes and pulls the assembly plate 8 up and down, causing the lifting rod assembly to move within the ejection hole 204 to repeatedly lift the formed gearbox, assisting in demolding.

[0049] In this embodiment, as Figure 7-10 As shown, the lifting rod assembly includes a base cylinder 5, a lifting rod 4, an air nozzle 16, an air chamber 17, and an air supply pipe 6. Specifically, the base cylinder 5 is fixedly connected to the mounting plate 8, the lifting rod 4 is inserted into the base cylinder 5, and its top end extends out of the base cylinder 5. A top cap 3 is set at the top end of the lifting rod 4. The air nozzle 16 is set around the top of the lifting rod 4, with the air outlet facing the ejection hole 204. The air chamber 17 is formed inside the lifting rod 4 and is connected to the air nozzle 16. The air supply pipe 6 is connected to the base cylinder 5, and a solenoid valve 25 is installed on the air supply pipe 6.

[0050] During implementation, the push assembly plate 8 is pushed up by the push component, which drives the push rod 4 and the top cap 3 to move within the ejection hole 204 to lift the formed gearbox. At this time, the air supply pipe 6 injects high-pressure gas into the base cylinder 5. The high-pressure gas is ejected through the air chamber 17 and the air nozzle 16. The ejected gas acts on the ejection hole 204 and enters the lower mold 2. As the top cap 3 lifts the formed gearbox, a gap is formed between the formed gearbox and the sand body. The high-pressure gas is injected into the gap to assist the formed gearbox in demolding.

[0051] Furthermore, the lifting rod assembly also includes a sealing plate 23, a piston disc 18, a lifting rod 19, a roller 20, a cam 21, and a drive motor 7. The sealing plate 23 is disposed inside the base cylinder 5, dividing the inner cavity of the base cylinder 5 into an inflation chamber 22 and a lower chamber 24. The lifting rod 4 is located inside the inflation chamber 22. The piston disc 18 is fixed to the bottom of the lifting rod 4 and has a circumferential sealing ring to prevent high-pressure gas leakage into the lower chamber 24. The lifting rod 19 is disposed at the bottom of the piston disc 18, and its bottom end penetrates the sealing plate 23 and inserts into the lower chamber 24. The roller 20 is rotatably connected to the bottom of the lifting rod 19. The cam 21 is rotatably connected to the lower chamber 24, and its outer wall surface abuts against the roller 20. The drive motor 7 is fixed to the base cylinder 5, and its output end is connected to the cam 21.

[0052] In some embodiments, the drive motor 7 drives the cam 21 to rotate continuously. When the cam 21 rotates, it drives the lifting rod 19 to rise and fall continuously through cooperation with the roller 20, so that the lifting rod 4 and the top cap 3 move up and down continuously within a small range. This causes the molded gearbox to move continuously during demolding, creating a vibration effect. This allows the sand on the surface of the gearbox to fall off to the maximum extent, and continuously adjusts the size of the gap between the gearbox and the sand body. This allows the high-pressure airflow to be continuously adjusted within the gap, improving the demolding effect of the gearbox.

[0053] In this embodiment, as Figure 12 As shown, the air chamber 17 includes a central chamber, an air inlet 176, a gap chamber 172, and several branch air chambers 171. The central chamber is located at the center of the push rod 4 and includes a first compression chamber 173, a second compression chamber 174, and a third compression chamber 175 whose diameters decrease in a stepped manner from bottom to top. The air inlet 176 is located on the outer wall of the push rod 4 and communicates with the central chamber. The gap chamber 172 is located above the central chamber. The top ends of the several branch air chambers 171 communicate with each jet nozzle 16, and the bottom ends communicate with the gap chambers 172.

[0054] During implementation, high-pressure gas entering the inflation chamber 22 through the air supply pipe 6 enters the central chamber through the air inlet 176. After being compressed by the first compression chamber 173, the second compression chamber 174 and the third compression chamber 175 with progressively smaller diameters, the high-pressure gas is ejected by multiple jet nozzles 16 distributed in the gap chamber 172, thereby increasing the intensity of the airflow.

[0055] In addition, such as Figure 11 As shown, the propulsion assembly in this embodiment includes a bottom tank 14, a hydraulic push rod 15, two side support plates 9, and a support frame 10; wherein, the bottom tank 14 is mounted on a fixed object, the hydraulic push rod 15 is fixed inside the bottom tank 14, and its output end is fixed to the assembly plate 8; the two side support plates 9 are slidably connected to both sides of the assembly plate 8; the support frame 10 is hinged between the assembly plate 8 and the two side support plates 9.

[0056] Furthermore, limit plates 13 are provided on both sides of the assembly plate 8; the outer wall of the assembly plate 8 is provided with a sliding groove 11, and the inner wall of the side support plate 9 is provided with a slider 12 that can slide in the sliding groove 11.

[0057] When the hydraulic push rod 15 is pushed forward, the support frame 10 is driven to unfold by the rising assembly plate 8, which causes the two side support plates 9 to retract inward on the assembly plate 8, so that the support position of the support frame 10 retracts and supports the center of the assembly plate 8, thereby improving the support stability of the support frame 10 on the assembly plate 8.

[0058] The specific working principle is as follows:

[0059] The lower mold 2 adopts a stacked modular structure of top mold 201, composite mold 202, and bottom mold 203. The height can be adjusted by increasing or decreasing the number of composite molds 202 to adapt to the casting requirements of different gearbox models. The specific process is as follows:

[0060] The upper stepped opening 208 at the bottom of the top mold 201, the composite stepped openings 210 at both ends of the composite mold 202, and the lower stepped opening 209 at the top of the bottom mold 203 are mutually compatible and form a nested structure when stacked to ensure that the modules are sealed and there is no misalignment.

[0061] The lugs 205 on the outer walls of the top mold 201 and the bottom mold 203 are passed through by screws 206 and secured by nuts 207, thus clamping and fixing the composite mold 202 in the middle. When the mold height needs to be adjusted, it is only necessary to loosen the nuts 207, increase or decrease the number of composite molds 202, and then tighten them again. There is no need to replace the bottom mold 203, which greatly shortens the mold change time. The same set of molds can be matched with the cavity requirements of wind turbine gearboxes of different height specifications by adjusting the number of composite molds 202, thereby improving the versatility of the mold and reducing the customization cost.

[0062] The demolding working principle of the lifting mechanism: The lifting mechanism is located at the bottom of the lower mold 2 and acts on the casting through the ejection hole 204 to achieve efficient demolding. Its core includes the coordinated operation of the propulsion component and the lifting rod component.

[0063] Support and lifting drive of the propulsion component: When the hydraulic push rod 15 extends or retracts, it drives the assembly plate 8 to move up and down, causing the entire lifting rod assembly to move synchronously; at the same time, the side support plate 9 slides in the slide groove 11 of the assembly plate through the slider 12, and the support frame 10 (hinged between the assembly plate 8 and the side support plate 9) automatically unfolds or retracts with the rise and fall of the assembly plate 8, adjusting the support position to the center area of ​​the assembly plate 8, and enhancing the stability of the force through the lever principle to prevent tilting during the lifting process.

[0064] The combined demolding power of the lifting rod assembly: the drive motor 7 drives the cam 21 in the lower cavity 24 to rotate, and the cam pushes the lifting rod 19 up and down through the roller 20, which in turn drives the lifting rod 4 and the top cap 3 to vibrate at a high frequency and a small amplitude (achieved by the reciprocating motion of the piston disc 18 in the air filling cavity 22); this vibration can loosen the connection between the casting and the molding sand and reduce the adhesion force;

[0065] Pneumatic assisted demolding: The air supply pipe 6 pressurizes the base cylinder 5 with air through the solenoid valve 25. The gas is compressed in the air chamber 17 in the ejector rod and then ejected from the air nozzle 16 (the air chamber 17 contains a first compression chamber 173, a second compression chamber 174 and a third compression chamber 175 with a stepped diameter to enhance the airflow pressure). The ejected gas enters the gap between the casting and the cavity along the ejector hole 204 to form an air film, reduce frictional resistance, and achieve efficient demolding in conjunction with the mechanical thrust of the top cap 3.

[0066] In the description of this invention, each embodiment focuses on the differences from other embodiments, and the same or similar parts between the embodiments can be referred to each other; as for the apparatus disclosed in the embodiments, since it corresponds to the method disclosed in the embodiments, the description is relatively simple, and the relevant parts can be referred to the method section description;

[0067] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An adaptive adjustment mold device for casting wind turbine gearboxes, comprising an upper mold (1) and a lower mold (2), wherein the upper mold (1) can be fastened onto the lower mold (2), characterized in that: The lower mold (2) includes a stackable top mold (201), multiple composite molds (202) and a bottom mold (203). The outer walls of the top mold (201) and the bottom mold (203) are provided with multiple lugs (205). The lugs (205) on the outer walls of the top mold (201) and the bottom mold (203) are fixed together by a fixing component, and the multiple composite molds (202) are clamped and fixed between the top mold (201) and the bottom mold (203). The bottom mold (203) has an ejection hole (204) at its bottom, and the bottom of the lower mold (2) is provided with a lifting mechanism, the output end of which is located at the ejection hole (204); The lifting mechanism includes: Assembly plate (8); A push assembly is located below the assembly plate (8) to push and pull the assembly plate (8) up and down; The lifting rod assembly is mounted on the assembly plate (8); The top cap (3) is disposed on the lifting rod assembly and located inside the ejection hole (204); The lifting rod assembly includes: The base tube (5) is fixedly connected to the assembly plate (8); The top rod (4) is inserted into the base tube (5) and its top end extends through the base tube (5). The top cap (3) is set at the top end of the top rod (4). A sealing plate (23) is set inside the base cylinder (5) to divide the inner cavity of the base cylinder (5) into an inflation chamber (22) and a lower chamber (24), and the top rod (4) is located inside the inflation chamber (22); The piston disc (18) is fixed to the bottom of the push rod (4) and is provided with a sealing ring in the circumferential direction; A lifting rod (19) is provided at the bottom of the piston disc (18), and the bottom end of the lifting rod (19) passes through the sealing plate (23) and is inserted into the lower cavity (24); Roller (20) is rotatably connected to the bottom of the lifting rod (19); The cam (21) is rotatably connected in the lower cavity (24), and its outer wall surface abuts against the roller (20); The drive motor (7) is fixed on the base cylinder (5), and its output end is connected to the cam (21).

2. The adaptive adjustment mold device for casting wind turbine gearboxes according to claim 1, characterized in that: The fixing component includes a screw (206) that passes through the lugs (205) on the outer wall of the top mold (201) and the bottom mold (203). A plurality of nuts (207) are screwed onto the screw (206), and each pair of nuts (207) is clamped at the upper and lower ends of each lug (205).

3. The adaptive adjustment mold device for casting wind turbine gearboxes according to claim 1, characterized in that: The top mold (201) has an upper stepped opening (208) circumferentially arranged at the bottom end, and the bottom mold (203) has a lower stepped opening (209) circumferentially arranged at the top end. The upper stepped opening (208) and the lower stepped opening (209) are adapted to each other.

4. The adaptive adjustment mold device for casting wind turbine gearboxes according to claim 3, characterized in that: Each of the composite molds (202) is provided with composite stepped openings (210) at its top and bottom circumferentially, and the composite stepped openings (210) are adapted to the upper stepped opening (208) and the lower stepped opening (209) respectively.

5. The adaptive adjustment mold device for casting wind turbine gearboxes according to claim 1, characterized in that: The lifting rod assembly also includes: The jet nozzle (16) is disposed on the top circumferential direction of the top rod (4), with the air outlet facing the ejector hole (204); An air chamber (17) is formed inside the top rod (4) and is connected to the air nozzle (16); An air supply pipe (6) is connected to the base cylinder (5), and a solenoid valve (25) is provided on the air supply pipe (6).

6. The adaptive adjustment mold device for casting wind turbine gearboxes according to claim 5, characterized in that: The air cavity (17) includes: The central cavity is located at the center of the top rod (4) and includes a first compression cavity (173), a second compression cavity (174) and a third compression cavity (175) whose diameters decrease in a step-like manner from bottom to top. An air inlet (176) is formed on the outer wall of the top rod (4) and communicates with the central cavity; The interstitial cavity (172) is located above the central cavity; Several air chambers (171) are connected at the top to each air nozzle (16) and at the bottom to the gap chamber (172).

7. The adaptive adjustment mold device for casting wind turbine gearboxes according to claim 1, characterized in that: The propulsion component includes: The bottom groove box (14) is set on a fixed object; The hydraulic push rod (15) is fixed inside the bottom groove box (14), and its output end is fixed to the assembly plate (8); Two side support plates (9) are slidably connected to both sides of the assembly plate (8); The support frame (10) is hinged between the mounting plate (8) and the two side support plates (9).

8. The adaptive adjustment mold device for casting wind turbine gearboxes according to claim 7, characterized in that: Limiting plates (13) are provided on both sides of the assembly plate (8); the outer wall of the assembly plate (8) is provided with a sliding groove (11), and the inner wall of the side support plate (9) is provided with a slider (12) that can slide in the sliding groove (11).

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