Casting system and method of gear motor integrated shell

Abstract

The invention discloses a casting system and method for a gear motor integrated shell. The casting system comprises a mold support, a pouring mold, a water bucket and a sand core assembly. The pouring mold is detachably installed on the mold support, the sand core assembly is detachably installed in the pouring mold, and the pouring mold and the sand core assembly jointly define a casting cavity for containing casting liquid. The water bucket is arranged at the top of the pouring mold and used for containing casting liquid, and an opening of the water bucket and a liquid inlet of the casting cavity communicate with each other and are perpendicular to each other; the sand core assembly comprises a water channel sand core and an inner cavity sand core, the inner cavity sand core is arranged in the water channel sand core, and a plurality of feeding grooves which are concave inwards are formed in the side wall of the inner cavity sand core. According to the casting system and method for the gear motor integrated shell, the structural characteristics of the gear motor integrated shell can be adapted, the problem of casting feeding is solved, the defects of internal shrinkage cavities and shrinkage porosity are eliminated, and the defects in the prior art are overcome.

Description

Technical Field

[0001] This invention relates to the field of gravity casting technology, and in particular to a casting system and method for an integrated housing of a geared motor. Background Technology

[0002] Gear motors, as core transmission devices integrating power transmission, speed regulation, and torque amplification, are widely used in intelligent manufacturing, automated production lines, construction machinery, and new energy equipment. To meet the core demands of modern industry for "compactness, lightweight, and high rigidity" in equipment, the industry commonly adopts an "integrated gear motor housing" design. This involves structural integration, where the reducer front housing and motor housing are molded as a single unit, replacing the traditional structure where the motor housing and reducer front housing are machined separately and then bolted together. This integrated design not only significantly reduces the overall size of the equipment and assembly errors but also improves the structural rigidity and vibration resistance of the housing, effectively reducing energy loss and noise during transmission, making it the mainstream structural development direction for gear motors.

[0003] However, the existing integrated housing structure of geared motors is complex. The front housing of the gearbox in an integrated housing is basically a weight-reduction structure. There are few machined surfaces that can accommodate risers, and the machined surfaces are very narrow. It is difficult to place risers in gravity casting or use them as gates in low-pressure casting. Therefore, the problems of shrinkage cavities and porosity inside this type of motor have always been a pain point for this type of motor. Summary of the Invention

[0004] The purpose of this invention is to propose a casting system and method for an integrated housing of a geared motor, which can adapt to the structural characteristics of the integrated housing of the geared motor, solve the problem of casting shrinkage compensation, eliminate internal shrinkage cavities and porosity defects, and overcome the shortcomings of the prior art.

[0005] To achieve this objective, the present invention adopts the following technical solution: A casting system for an integrated housing of a geared motor includes a mold support, a casting mold, a water hopper, and a sand core assembly. The casting mold is detachably mounted on the mold support, and the sand core assembly is detachably mounted inside the casting mold. The casting mold and the sand core assembly together form a casting cavity for containing molten casting. The water hopper is located on top of the casting mold and is used to hold the molten casting. The opening of the water hopper is connected to and perpendicular to the inlet of the casting cavity. The sand core assembly includes a waterway sand core and an inner cavity sand core. The inner cavity sand core is disposed inside the waterway sand core, and the sidewall of the inner cavity sand core is provided with a plurality of inwardly recessed feeding grooves.

[0006] Preferably, the inner cavity sand core includes an upper sand core and a lower sand core, the upper sand core is installed on the top of the lower sand core, and the upper part of the plurality of the feeding grooves is formed on the side wall of the upper sand core, the lower part of the plurality of the feeding grooves is formed on the side wall of the lower sand core, and the upper and lower parts of a feeding groove are connected at the connection position of the upper sand core and the lower sand core. The top two ends of the upper sand core extend outward and are integrally formed with positioning arms. The top of the mold support is provided with a positioning groove, and the end of the positioning arm can be matched and installed inside the positioning groove. The bottom of the lower sand core is provided with a positioning seat, which can be matched and installed on the top of the bottom mold of the casting mold.

[0007] Preferably, the sidewall of the upper sand core includes a riser sidewall and a cavity sidewall arranged sequentially from top to bottom, and the upper part of the plurality of feeding grooves is formed on the cavity sidewall; The top of the riser sidewall is inclined inward, and the angle between the riser sidewall and the vertical direction is 12 to 15°. The bottom of the cavity sidewall slopes outward, and the angle between the cavity sidewall and the vertical direction is 1 to 1.5°.

[0008] Preferably, the top of the sidewall of the lower sand core is inclined outward, and the angle between the sidewall of the lower sand core and the vertical direction is 1 to 1.5°.

[0009] Preferably, the casting mold includes a bottom mold, a left side mold, a right side mold, a front mold, and a rear mold; The bottom mold is installed at the bottom of the mold support, and the upper surface of the bottom mold is the front housing surface of the reducer in the casting cavity; The left mold and the right mold are slidably mounted on two sides of the mold support, and the front mold and the rear mold are slidably mounted on the other two sides of the mold support, respectively. The bottom mold, the left mold, the right mold, the front mold, and the rear mold are joined together to form the cavity wall of the casting cavity and surround the liquid inlet of the casting cavity; The water bucket is installed on top of the front mold.

[0010] Preferably, the casting mold further includes multiple retaining strips; One end of the fixing strip is detachably inserted into the front mold and / or the rear mold, and the other end of the fixing strip is pressed against the top of the positioning arm.

[0011] Preferably, the shrinkage groove is provided with three grooves.

[0012] A method for casting an integral housing of a geared motor, using the aforementioned casting system for an integral housing of a geared motor, includes the following steps: A. Open the left mold, the right mold, the front mold, and the rear mold; B. Place the steel sleeve at the top of the bottom mold in the steel sleeve placement position; C. Place the waterway sand core, the lower sand core, and the upper sand core in sequence; D. Close the left mold and the right mold, then close the front mold and the rear mold, and finally install the fixing strip; E. Invert the casting system of the integrated housing of the geared motor and place the opening of the water tank horizontally; inject the casting liquid into the water tank; F. Flip the casting system of the integrated housing of the geared motor and place the liquid inlet of the casting cavity horizontally. At this time, the casting liquid in the water tank is injected into the casting cavity under the action of gravity. G. After the casting liquid solidifies, the casting is obtained by demolding and sand removal in sequence; H. Remove the riser from the casting to obtain the casting.

[0013] The technical solution provided by this invention may include the following beneficial effects: 1. The casting system of this solution is adapted to gravity casting. The riser of the casting is placed on the end face of the motor housing in the integrated housing of the geared motor. The inner cavity of the integrated housing of the geared motor is formed by sand core assembly. Without changing the product structure of the integrated housing of the geared motor, an easy-to-cut riser can be placed, which solves the technical problem that the front housing of the reducer in the product structure needs to be connected to the shape of the gearbox and it is difficult to place the inlet.

[0014] 2. This solution adds a shrinkage-compensating groove to the side wall of the inner cavity sand core at the position corresponding to the product structure design. This groove serves as a shrinkage-compensating rib for the thicker parts of the product, playing a key role in compensating for localized areas. By utilizing the plasticity of the sand core shape, the technical challenge of not being able to set corresponding shrinkage-compensating channels for localized hot nodes in the product cavity due to demolding requirements is overcome. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the casting system for an integrated housing of a geared motor according to the present invention.

[0016] Figure 2 This is a partial structural schematic diagram of a casting system for an integrated housing of a geared motor according to the present invention.

[0017] Figure 3 This is a partial exploded view of the casting system for an integrated housing of a geared motor according to the present invention.

[0018] Figure 4 This is a schematic diagram of the inner cavity sand core from one perspective in the casting system of the integrated housing of a geared motor according to the present invention.

[0019] Figure 5 This is a structural schematic diagram of the inner cavity sand core from another perspective in the casting system of the integrated housing of a geared motor according to the present invention.

[0020] Figure 6 This is a flowchart illustrating steps D to H in the casting method of an integrated housing for a geared motor according to the present invention.

[0021] The components include: mold support 1, positioning groove 11, casting mold 2, bottom mold 21, left mold 22, right mold 23, front mold 24, rear mold 25, fixing strip 26, water tank 3, sand core assembly 4, water channel sand core 41, inner cavity sand core 42, upper sand core 421, riser sidewall 4211, cavity sidewall 4212, lower sand core 422, feeding groove 423, positioning arm 424, positioning seat 425, and casting cavity 5. Steel sleeve 100, casting 200, riser 300, casting 400. Detailed Implementation

[0022] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0023] This technical solution provides a casting system for an integrated housing of a geared motor, including a mold support 1, a casting mold 2, a water tank 3, and a sand core assembly 4; the casting mold 2 is detachably installed on the mold support 1, and the sand core assembly 4 is detachably installed inside the casting mold 2, and the casting mold 2 and the sand core assembly 3 together form a casting cavity 5 for containing casting liquid; the water tank 3 is located on the top of the casting mold 2, the water tank 3 is used to hold casting liquid, and the opening of the water tank 3 is connected to and perpendicular to the liquid inlet of the casting cavity 5; The sand core assembly 4 includes a waterway sand core 41 and an inner cavity sand core 42. The inner cavity sand core 42 is disposed inside the waterway sand core 41, and the sidewall of the inner cavity sand core 42 is provided with a plurality of inwardly recessed shrinkage grooves 423.

[0024] To address the problem of feeding issues in the casting of integrated geared motor housings and eliminate internal shrinkage cavities and porosity defects, this technical solution proposes a casting system for integrated geared motor housings, such as... Figure 1-5 As shown, it includes a mold support 1, a casting mold 2, a water tank 3, and a sand core assembly 4.

[0025] The casting system of this solution is adapted to gravity casting. The riser 300 of the casting 200 is placed on the end face of the motor housing in the integrated housing of the geared motor. The inner cavity of the integrated housing of the geared motor is formed by sand core component 4. Without changing the product structure of the integrated housing of the geared motor, an easily cut-off riser can be placed, which solves the technical problem that the front housing of the geared motor in the product structure needs to be connected to the shape of the gearbox and it is difficult to place the inlet.

[0026] Furthermore, this solution adds a shrinkage groove 423 to the side wall of the inner cavity sand core 42 at the position corresponding to the product structure design, which serves as a shrinkage rib for the thick part of the product and plays a key shrinkage role in the local area; through the plasticity of the sand core shape, it overcomes the technical problem that the inner cavity of the product cannot set corresponding shrinkage channels for local hot nodes due to the demolding requirements.

[0027] To further explain, the inner cavity sand core 42 includes an upper sand core 421 and a lower sand core 422. The upper sand core 421 is installed on the top of the lower sand core 422, and the upper part of the plurality of shrinkage grooves 423 is formed on the side wall of the upper sand core 421, and the lower part of the plurality of shrinkage grooves 423 is formed on the side wall of the lower sand core 422. The upper and lower parts of a shrinkage groove 423 are connected at the connection position of the upper sand core 421 and the lower sand core 422. The top two ends of the upper sand core 421 extend outward and are integrally formed with positioning arms 424. The top of the mold support 1 is provided with a positioning groove 11, and the end of the positioning arm 424 can be matched and installed inside the positioning groove 11. The bottom of the lower sand core 422 is provided with a positioning seat 425, which can be matched and installed on the top of the bottom mold 21 of the casting mold 2.

[0028] In a preferred embodiment of this technical solution, the inner cavity sand core 42 includes an upper sand core 421 and a lower sand core 422. The upper sand core 421 has a positioning arm 424 extending outward from both ends of its top and integrally formed to facilitate the top positioning of the inner cavity sand core 42. At the same time, a positioning seat 425 is provided at the bottom of the lower sand core 422 to facilitate the bottom positioning of the inner cavity sand core 42. This allows the casting system to be displaced during the gravity casting process, thereby ensuring casting quality.

[0029] To further explain, the sidewall of the upper sand core 421 includes a riser sidewall 4211 and a cavity sidewall 4212 arranged sequentially from top to bottom, and the upper part of the plurality of feeding grooves 423 is formed on the cavity sidewall 4212. The top of the riser sidewall 4211 is inclined inward, and the angle between the riser sidewall 4211 and the vertical direction is 12 to 15°. The bottom of the cavity sidewall 4212 is inclined outward, and the angle between the cavity sidewall 4212 and the vertical direction is 1 to 1.5°.

[0030] As a preferred embodiment of the above, this solution also utilizes the plasticity of the sand core to set different slopes in the two sidewalls of the upper sand core 421 to ensure the feeding capacity of the riser.

[0031] To further explain, the top of the sidewall of the lower sand core 422 is inclined outward, and the angle between the sidewall of the lower sand core 422 and the vertical direction is 1 to 1.5°.

[0032] As a preferred embodiment of the above, this solution also utilizes the plasticity of the sand core to set a certain slope in the side wall of the lower sand core 422, and its draft direction is opposite to the draft direction of the cavity side wall 4212, so as to reduce the problem of excessive machining allowance in the product cavity caused by the draft slope.

[0033] To further explain, the casting mold 2 includes a bottom mold 21, a left mold 22, a right mold 23, a front mold 24, and a rear mold 25; The bottom mold 21 is installed at the bottom of the mold support 1, and the upper surface of the bottom mold 21 is the front housing surface of the reducer of the casting cavity 5; The left mold 22 and the right mold 23 are slidably mounted on two sides of the mold support 1, and the front mold 24 and the rear mold 25 are slidably mounted on the other two sides of the mold support 1. The bottom mold 21, the left mold 22, the right mold 23, the front mold 24, and the rear mold 25 are joined together to form the cavity wall of the casting cavity 5 and surround the liquid inlet of the casting cavity 5; The water tank 3 is installed on top of the front mold 24.

[0034] Furthermore, the casting mold 2 also includes a plurality of fixing strips 26; One end of the fixing strip 26 is detachably inserted into the front mold 24 and / or the rear mold 25, and the other end of the fixing strip 26 is pressed against the top of the positioning arm 424.

[0035] This helps to prevent displacement of the casting system during the gravity casting process, thus ensuring casting quality.

[0036] To further explain, the shrinkage groove 423 is provided with three grooves.

[0037] A method for casting an integral housing of a geared motor, using the aforementioned casting system for an integral housing of a geared motor, includes the following steps: A. Open the left mold 22, the right mold 23, the front mold 24 and the rear mold 25; B. Place the steel sleeve 100 at the steel sleeve placement position on the top of the bottom mold 21; C. Place the waterway sand core 41, the lower sand core 422 and the upper sand core 421 in sequence; D. Close the left mold 22 and the right mold 23, then close the front mold 24 and the rear mold 25, and finally install the fixing strip 26; E. Flip the casting system of the integrated housing of the geared motor and place the opening of the water tank 3 horizontally; inject the casting liquid into the water tank 3; F. Flip the casting system of the integrated housing of the geared motor and place the liquid inlet of the casting cavity 5 horizontally. At this time, the casting liquid in the water tank 3 is injected into the casting cavity 5 under the action of gravity. G. After the casting liquid solidifies, it goes through demolding and sand removal to obtain casting part 200. H. Remove the riser 300 from the casting 200 to obtain the casting 400.

[0038] This technical solution also proposes a casting method for an integrated housing of a geared motor using the above-mentioned casting system, and the flowchart of steps D to H is shown below. Figure 6 As shown, it should be noted that casting 400 refers to the product blank that the casting system needs to cast.

[0039] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0040] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0041] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0042] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0043] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0044] It should be noted that the terms "first," "second," etc., used in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in sequences other than those illustrated or described herein.

[0045] The technical principles of the present invention have been described above with reference to specific embodiments. These descriptions are merely for explaining the principles of the invention and should not be construed as limiting the scope of protection of the invention in any way. Based on this explanation, those skilled in the art can readily conceive of other specific embodiments of the invention without inventive effort, and these embodiments will all fall within the scope of protection of the present invention.

Claims

1. A casting system for an integrated housing of a reduction gear motor, characterized by: The application relates to a casting system for a reducer motor integrated shell, which comprises a mold support, a pouring mold, a water bucket and a sand core assembly; the pouring mold is detachably mounted on the mold support, the sand core assembly is detachably mounted in the pouring mold, and the pouring mold and the sand core assembly jointly form a casting cavity for containing casting liquid; the water bucket is arranged on the top of the pouring mold, the water bucket is used for containing casting liquid, and the opening of the water bucket and the liquid inlet of the casting cavity are in communication and perpendicular to each other. The sand core assembly comprises a water channel sand core and an inner cavity sand core, the inner cavity sand core is arranged in the water channel sand core, and the side wall of the inner cavity sand core is provided with a plurality of inwardly recessed feeding recesses.

2. The casting system of an integrated housing of a reduction gear motor according to claim 1, wherein: The inner cavity sand core comprises an upper sand core and a lower sand core, the upper sand core is mounted on the top of the lower sand core, the upper parts of the plurality of feeding recesses are formed on the side wall of the upper sand core, the lower parts of the plurality of feeding recesses are formed on the side wall of the lower sand core, and the upper part and the lower part of a feeding recess are through the connecting position of the upper sand core and the lower sand core. The top of the upper sand core extends outwardly at both ends and is integrally formed with a positioning arm, the top of the mold support is provided with a positioning groove, and the end of the positioning arm is matchingly mounted in the positioning groove. The bottom of the lower sand core is provided with a positioning seat, and the positioning seat is matchingly mounted on the top of the bottom mold of the pouring mold.

3. The casting system of an integrated housing of a reduction gear motor according to claim 2, characterized in that: The side wall of the upper sand core comprises a riser side wall and a cavity side wall arranged in sequence from top to bottom, and the upper parts of the plurality of feeding recesses are formed on the cavity side wall. The top of the riser side wall is inwardly inclined, and the angle between the riser side wall and the vertical direction is 12-15 degrees. The bottom of the cavity side wall is outwardly inclined, and the angle between the cavity side wall and the vertical direction is 1-1.5 degrees.

4. The casting system of an integrated housing for a reduction gear motor according to claim 2, wherein: The top of the side wall of the lower sand core is outwardly inclined, and the angle between the side wall of the lower sand core and the vertical direction is 1-1.5 degrees.

5. The casting system of an integrated housing for a reduction gear motor according to claim 2, wherein: The pouring mold comprises a bottom mold, a left side mold, a right side mold, a front side mold and a rear side mold. The bottom mold is mounted on the bottom of the mold support, and the upper surface of the bottom mold is the front shell surface of the reducer of the casting cavity. The left side mold and the right side mold are oppositely arranged and slidably mounted on the two side surfaces of the mold support, and the front side mold and the rear side mold are oppositely arranged and slidably mounted on the other two side surfaces of the mold support. The bottom mold, the left side mold, the right side mold, the front side mold and the rear side mold jointly splice to form the cavity wall of the casting cavity and enclose the liquid inlet of the casting cavity. The water bucket is mounted on the top of the front side mold.

6. The casting system of an integrated housing of a reduction gear motor according to claim 5, wherein: The pouring mold further comprises a plurality of fixing strips. One end of the fixing strip is detachably inserted into the front side mold and / or the rear side mold, and the other end of the fixing strip is pressed on the top of the positioning arm.

7. The casting system of an integrated housing of a reduction gear motor according to claim 1, wherein: The feeding recess is provided with three parts.

8. A casting method of an integrated housing of a reduction motor, characterized by, The application further discloses a casting method of the casting system for the reducer motor integrated shell. A, open the left side mold, the right side mold, the front side mold and the rear side mold; B, place a steel sleeve on the steel sleeve placing position on the top of the bottom mold; C, place the water channel sand core, the lower sand core and the upper sand core in sequence. D, close the left side mold and the right side mold, then close the front side mold and the rear side mold, and finally install the fixing strip; E, turn over the casting system of the reduction motor integrated shell, and place the opening of the water bucket horizontally; pour the casting liquid into the water bucket; F, turn over the casting system of the reduction motor integrated shell, and place the liquid inlet of the casting cavity horizontally; at this time, the casting liquid in the water bucket is poured into the casting cavity under the action of gravity; G, after the casting liquid solidifies, the casting part is obtained through demolding and knockout in sequence; H, remove the riser of the casting part to obtain the casting.

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