Multifunctional foundry furnace and material changing method

Abstract

The invention provides a multifunctional casting furnace and a material changing method, and relates to the technical field of die casting equipment and processes. Comprising a melting cavity and a casting cavity installed on one side of the melting cavity, and a connecting channel is arranged between the melting cavity and the casting cavity; the casting cavity is suitable for placing a casting mold; the melting cavity is provided with a feeding port and an air inlet pressurizing port, and a heating and melting device is arranged in the melting cavity to melt metal materials into molten liquid. The multifunctional casting furnace is configured to apply first pressure and third pressure to the melting cavity so as to press molten liquid in the melting cavity into the casting cavity through the connecting channel, and the molten liquid in the casting cavity can be pressed into the casting mold through the pressure difference. According to the scheme, the casting process quality and efficiency are improved.

Description

Technical Field

[0001] This invention relates to the field of die-casting equipment and process technology, and more specifically, to a multi-functional casting furnace and a material changing method. Background Technology

[0002] Traditional multi-functional casting furnaces typically employ an integrated design of the melting and casting chambers, concentrating the functions of feeding, melting, and casting within a single cavity. In actual production, compressed air is directly introduced into the sealed furnace, using pressure to force the high-temperature molten metal into the mold via a riser pipe. However, this integrated design has several inherent drawbacks: First, because the feeding and casting processes share the same space, the temperature of the molten metal fluctuates drastically during feeding, directly affecting the final casting quality. Second, the molten metal surface within the cavity cannot maintain a stable suspended state, resulting in a significant height difference (typically 235-250 mm) between the inside and outside of the riser pipe. This not only increases the metal filling distance, prolonging the casting cycle and reducing production efficiency, but also causes continuous erosion of the riser pipe wall during the rising process, significantly shortening the riser pipe's lifespan. In addition, the traditional structure has obvious shortcomings in terms of equipment maintenance: when it is necessary to replace the molten metal or clean the furnace body, due to the deep and narrow structure of the molten groove and the extremely high temperature of the molten metal, the operators can only use tools to manually scoop it out multiple times and deal with the residual molten metal by repeatedly cleaning and diluting it. This operation is not only labor-intensive and dangerous, but also difficult to guarantee the cleaning effect, which seriously affects the production efficiency and equipment maintenance quality. Summary of the Invention This application provides a multifunctional casting furnace and its material changing method, which has the advantages of improving casting efficiency, enhancing casting quality, and extending the service life of the riser pipe.

[0003] The present invention adopts the following solution: A multifunctional casting furnace includes: a melting chamber and a casting chamber installed on one side of the melting chamber, wherein a connecting channel is provided between the melting chamber and the casting chamber; wherein, The melting chamber is provided with a feeding port and a first air inlet pressurizing port to apply a first pressure or a third pressure to the top of the melting chamber, and a heating and melting device is provided inside the melting chamber; The casting cavity is adapted to connect to a casting mold, and it is provided with a second air inlet and pressurization port for applying a second pressure to the molten material in the casting cavity; The multi-functional casting furnace is configured as follows: Before casting, a first pressure is applied to the melting chamber to force the molten liquid in the melting chamber into the casting chamber through the connecting channel, and to raise the molten liquid in the casting chamber to a preset height. During casting, a second pressure can be applied to the casting cavity to keep the molten liquid in the casting cavity at a preset suspension height during the casting process; and a third pressure, which is greater than the second pressure, can be applied to the melting cavity to force the molten liquid in the casting cavity into the casting mold by utilizing the pressure difference.

[0004] Furthermore, the casting mold is adapted to be connected to the casting cavity via a riser pipe, the bottom of which is located below the height at which the molten liquid is suspended in the casting cavity, and when a first pressure is applied in the melting cavity, the liquid level inside the riser pipe is the same as the liquid level inside the casting cavity.

[0005] Furthermore, the heating and melting device is a first heating induction device disposed below the melting chamber, and the first heating induction device has a melting groove communicating with the melting chamber for melting metal materials by electromagnetic induction.

[0006] Furthermore, the casting cavity is detachably mounted on one side of the melting cavity.

[0007] Furthermore, the sidewall of the casting cavity is provided with a horizontal continuous casting channel. When horizontal continuous casting is performed, a first pressure can be applied to the melting cavity to keep the casting cavity at a preset suspended liquid level height during the process, thereby forming a high potential energy that meets the requirements of the horizontal continuous casting process, so as to improve the density of the casting.

[0008] Furthermore, a tilting cylinder is provided on the melting chamber, and the tilting cylinder is configured to drive the melting chamber to tilt so that the molten liquid in the melting groove flows out into the tilted melting chamber for easy removal; a material storage area is formed on the melting chamber, which is used to allow the solution to accumulate in the material storage area after the melting chamber is tilted at a certain angle.

[0009] Furthermore, a second heating induction device is provided below the casting cavity to keep the liquid in the casting cavity warm, so that the casting cavity remains at a constant temperature.

[0010] Furthermore, a low-pressure side inclined casting channel is provided on one side of the casting cavity. The low-pressure side inclined casting channel is inclined in the casting cavity so as to use pressure to inject molten liquid into the casting mold that is connected to the outside of the low-pressure side inclined casting channel.

[0011] Furthermore, the melting chamber and the casting chamber are respectively provided with sealing caps so that the melting chamber and the casting chamber are connected only through the connecting channel.

[0012] It also includes a robotic arm device, which is disposed on the side or top of the casting cavity to drive the movement of the casting mold.

[0013] Furthermore, the robotic arm is rotatably connected to one side of the casting cavity via a base.

[0014] Furthermore, the base is rotatably connected to one side of the casting cavity via a suspension mechanism.

[0015] Furthermore, the base is provided with several cooperating drive mechanisms to drive the robotic arm to perform the process of mold closing, moving, rotating and demolding on the casting mold.

[0016] Furthermore, the casting mold is arranged horizontally, and its pouring port is located in the middle of the casting mold to achieve horizontal low-pressure casting.

[0017] Furthermore, the robotic arm is adapted to drive the casting mold to rotate in order to achieve rotary low-pressure casting.

[0018] Furthermore, the casting mold is connected to the pouring gate at a preset inclination, and the pouring gate is located in the middle of the casting mold to achieve inclined low-pressure casting.

[0019] Furthermore, the casting mold is arranged vertically, and its pouring port is located below the casting mold to achieve vertical low-pressure casting.

[0020] Furthermore, the casting mold is arranged vertically, and the pouring gate is located on the top of the mold to implement vertical gravity casting.

[0021] Furthermore, the casting mold is arranged vertically, and the robotic arm is adapted to drive the casting mold to rotate in order to achieve rotational gravity casting.

[0022] The present invention also provides a material changing method for the aforementioned multifunctional casting furnace, comprising the following steps: S1. When changing materials, the casting cavity is separated from the melting cavity, and then the remaining molten liquid in the melting cavity is cast into the ingot mold using the low-pressure casting production mode. The ingot mold does not contain a sand core and is used to solidify the copper into an ingot before removing it. S2. When the molten liquid level in the melting chamber is lower than the preset height, the melting chamber is tilted using the tilting cylinder, causing the molten liquid in the melting groove and the molten liquid in the melting chamber to accumulate in the corner of the melting chamber. The molten liquid in the corner is then manually removed and cleaned. S3. Pour the molten new liquid onto the ladle, and use the ladle to inject the new liquid into the melting chamber through the feeding port, so that the new liquid enters the melting channel to achieve rapid material replacement.

[0023] Beneficial effects: This application provides a multi-functional casting furnace and its material changing method. Through the design of a split melting chamber and a casting chamber, combined with pressure control, the furnace achieves molten liquid suspension and mold filling optimization. At the same time, it adopts a first heating induction device and a tilting cylinder structure, which effectively solves the problems of large temperature fluctuations, unstable liquid levels, and difficult maintenance of traditional equipment. It has the advantages of improving casting efficiency, enhancing casting quality, and extending the service life of the riser pipe. Attached Figure Description

[0024] Figure 1 This is a cross-sectional schematic diagram of a multifunctional casting furnace with various riser pipe shapes according to an embodiment of the present invention; Figure 2 This is a cross-sectional schematic diagram of a multifunctional casting furnace according to an embodiment of the present invention; Figure 3 This is a front view of a multifunctional casting furnace according to an embodiment of the present invention; Figure 4 This is a top view schematic diagram of the melting chamber of a multifunctional casting furnace according to an embodiment of the present invention; Figure 5 This is a schematic diagram of step S1 of a material changing method for a multifunctional casting furnace according to an embodiment of the present invention; Figure 6 This is a schematic diagram of step S2 of a material changing method for a multifunctional casting furnace according to an embodiment of the present invention; Figure 7 This is a schematic diagram of step S3 of a material changing method for a multifunctional casting furnace according to an embodiment of the present invention; Figure 8 This is a schematic diagram of a multifunctional casting furnace with a horizontal continuous casting channel according to an embodiment of the present invention; Figure 9 This is a schematic diagram of a multifunctional casting furnace with a second heating induction device according to an embodiment of the present invention; Figure 10 This is a schematic diagram of a multifunctional casting furnace with a low-pressure side-tilted casting channel and a robotic arm device according to an embodiment of the present invention; Figure 11 This is a top view schematic diagram of a multifunctional casting furnace with a robotic arm device according to an embodiment of the present invention; Figure 12 This is a schematic diagram of a robotic arm device with a suspension mechanism for a multifunctional casting furnace according to an embodiment of the present invention; Figure 13 This is a schematic diagram of the horizontal arrangement of the casting molds in a multifunctional casting furnace according to an embodiment of the present invention; Figure 14 This is a schematic diagram of a multifunctional casting furnace with a low-pressure side inclined casting channel and the casting mold rotated to a certain inclined angle for fixed casting according to an embodiment of the present invention. Figure 15This is a schematic diagram of a multifunctional casting furnace with a low-pressure side inclined casting channel and a rotatable casting mold according to an embodiment of the present invention. Figure 16 This is a schematic diagram of a multifunctional casting furnace according to an embodiment of the present invention, in which the casting molds are arranged vertically and the pouring gate mold is at the bottom. Figure 17 This is a schematic diagram of a multifunctional casting furnace according to an embodiment of the present invention, in which the casting mold is arranged vertically and the casting gate is on the top of the mold. Figure 18 This is a schematic diagram of the casting mold pouring gate of a multifunctional casting furnace according to an embodiment of the present invention, when it is initially located on the top of the mold. Figure label: 1. Melting chamber; 2. Casting chamber; 3. Connecting channel; 4. Lifting pipe; 5. Casting mold; 6. First heating induction device; 7. Feed port; 8. First air inlet and pressurization port; 9. Tilting cylinder; 10. Melting groove; 11. Discharge storage area; 12. Automatic telescopic protective cover; 13. Ingot mold; 14. Ladle; 15. Second air inlet and pressurization port; 16. Sealing cover; 17. Horizontal continuous casting channel; 18. Second heating induction device; 19. Low-pressure side inclined casting channel; 20. Robotic arm device; 201. First robotic arm; 202. Second robotic arm; 203. First fixture; 204. Second fixture; 205. First drive; 206. Second drive; 207. Third drive; 208. Fourth drive; 209. Fifth drive; 210. Sixth drive; 211. Seventh drive; 211. Base; 22. Suspension mechanism; 23. Base; 24. Irregular lifting pipe. Detailed Implementation

[0025] Combination Figures 1 to 4 As shown, this embodiment provides a multi-functional casting furnace, including: a melting chamber 1 and a casting chamber 2 installed on one side of the melting chamber 1, with a connecting channel 3 between the melting chamber 1 and the casting chamber 2; wherein, the casting chamber 2 is provided with a second air inlet pressurization port 15, and is suitable for placing a riser pipe 4 connecting to the casting mold 5; the melting chamber 1 is provided with a feeding port 7 and a first air inlet pressurization port 8, and a heating and melting device is provided in the melting chamber to melt the metal material into molten metal; the multi-functional casting furnace is configured to: before casting, pressurize the first air inlet pressurization port... Port 8 applies a first pressure P1 to the melting chamber 1 to force the molten liquid in the melting chamber 1 into the casting chamber 2 through the connecting channel 3, and suspends the molten liquid in the casting chamber 2 at a preset height; during casting, a second pressure P2 is applied to the casting chamber 2 through the second air inlet pressurization port 15, and a third pressure P3 is applied to the melting chamber 1 through the first air inlet pressurization port 8, and the third pressure P3 is greater than the second pressure P2, so as to use the pressure difference to force the molten liquid in the casting chamber 2 into the casting mold 5 through the riser pipe 4.

[0026] The melting chamber 1 refers to an independent, sealed space for melting metal materials. It can be implemented using a cylindrical structure cast from a high-temperature alloy, and its volume design must meet the needs of continuous production. The casting chamber 2 refers to a molding operation area physically isolated from the melting chamber 1. It can be implemented using a detachable box connected by a flange, with an insulating coating on its internal surface. In this embodiment, a sealing cover 16 is respectively installed above the melting chamber 1 and the casting chamber 2, thus forming independent sealed chambers. The molten liquid is connected only through a connecting channel 3, allowing for liquid level control by applying different pressures above the melting chamber 1 and the casting chamber 2. The connecting channel 3 is the fluid passage connecting the two chambers, and can be implemented, for example, using an inclined ceramic pipe, with a cross-sectional area matching the molten liquid flow rate. The feeding port 7 refers to the material input port at the top of the melting chamber 1, which can be implemented using a funnel structure with a sealing cover equipped with a pressure balancing device. The first inlet pressurization port 8 refers to the gas pressure input interface of the melting chamber 1. For example, it can be implemented using a pipeline system controlled by a multi-stage solenoid valve. A pressure sensor can be installed to monitor the chamber pressure in real time. The second inlet pressurization port 15 is located on the casting chamber 2 and is used to apply gas pressure to the inside of the casting chamber 2. The heating and melting device refers to the equipment for melting metal materials. Specifically, it can be implemented using a bottom-mounted induction heater, which generates heat energy through the electromagnetic eddy current effect.

[0027] After the metal material is fed into the melting chamber 1 through the feeding port 7, the heating and melting device continuously provides heat energy to melt it into a liquid state. Before casting, gas is first injected into the melting chamber 1 to form a first pressure P1, which pushes the molten liquid into the casting chamber 2 through the connecting channel 3, and keeps the liquid level in the casting chamber 2 suspended at a preset height, that is, the first pressure is used to control the liquid level height in the casting chamber 2 to remain fixed. At this time, the liquid level in the casting chamber 2 can rise to be level with the liquid level inside the riser pipe 4, forming a static equilibrium state. During low-pressure casting, the pressure is further increased to the value of the third pressure, and at the same time, a second pressure is applied to the casting chamber 2 through the second air inlet pressurization port 15. Since the third pressure is greater than the second pressure, the pressure difference causes the molten liquid in the casting chamber 2 to break the equilibrium state and continue to rise along the riser pipe 4 into the mold to complete the filling. The filling pressure P = P3 - P2. The two-chamber separation design keeps the casting chamber 2 in a constant temperature environment, and the inclined angle of the connecting channel 3 promotes the natural backflow of the molten liquid. It should be noted that during the casting gap, the second pressure on the casting cavity 2 is removed, and the first pressure is continued to be applied in the melting cavity so that the liquid level in the casting cavity 2 is kept flush with the liquid level in the riser pipe 4.

[0028] This solution eliminates interference from the feeding operation on the casting temperature field through a physically isolated cavity structure. Pressure control ensures a balanced liquid level inside and outside the riser tube 4, shortening the filling path. The independent casting chamber 2 prevents oxide impurities generated during melting from entering the molding area, improving the surface quality pass rate of the castings. The modular structure design facilitates subsequent maintenance operations, reducing equipment downtime for maintenance. This solution effectively shortens the molten metal filling time, eliminates energy loss caused by the height difference between the inside and outside of the riser tube 4 in traditional processes, and extends the service life of the riser tube 4. The constant-temperature casting environment reduces internal defects in the castings and improves the consistency of product mechanical properties.

[0029] In this embodiment, when a first pressure is applied to the melting chamber 1 through the first air inlet pressurization port 8, the liquid level in the riser tube 4 can be kept the same as the liquid level in the casting chamber 2. That is, by controlling the copper liquid inside and outside the riser tube 4 in the casting chamber 2 to be suspended at the same height, the temperature of the inner and outer walls of the riser tube is the same, which is beneficial to improving the life of the riser tube 4. The liquid level in the riser tube 4 refers to the liquid level position of the molten liquid inside the riser tube 4. The liquid level can be controlled by adjusting the gas pressure in the melting chamber 1 to balance the internal and external pressures of the riser tube 4, so that the liquid level in the casting chamber 2 is at the same level as the liquid level inside the riser tube 4.

[0030] When the first pressure is applied to the melting chamber 1, the gas pressure inside the melting chamber 1 is transmitted to the casting chamber 2 through the connecting channel 3. At this time, the molten liquid in the casting chamber 2 enters the riser tube 4 under pressure. Since the pressure inside the riser tube 4 is balanced with that inside the casting chamber 2, the liquid level in the riser tube 4 tends to be the same as that in the casting chamber 2. During this process, the temperature of the molten liquid in contact with the inner and outer walls of the riser tube 4 is the same, avoiding the temperature difference between the inner and outer walls caused by the difference in liquid level.

[0031] Compared to existing technologies, the difference in liquid level between the inside and outside of the riser tube 4 in existing multi-functional casting furnaces can reach 235 mm to 250 mm, resulting in a significant temperature difference between the inner and outer walls of the riser tube 4. Repeated scouring accelerates the wear and tear of the riser tube 4. This solution, however, uses pressure balance control to ensure consistent liquid level between the inside and outside of the riser tube 4, eliminating the temperature gradient caused by the liquid level difference and reducing thermal stress damage to the riser tube 4. Therefore, this embodiment avoids the temperature difference between the inner and outer walls of the riser tube 4 caused by the liquid level difference, reducing the risk of cracks or deformation caused by thermal stress during the casting process, thereby extending the service life of the riser tube 4.

[0032] Combination Figures 1 to 3As shown, in this embodiment, the heating and melting device of the multifunctional casting furnace is a first heating induction device 6 located below the melting chamber 1. The first heating induction device 6 has a melting groove 10 connected to the melting chamber 1 for melting metal materials by electromagnetic induction. Copper can be placed in the melting groove 10 for initial melting and continuous heat generation by electromagnetic induction. The feeding port 7 can be used to put in solid metal blocks and separate the feeding area from the casting area.

[0033] The first heating induction device 6 refers to a heating unit that generates heat energy through the principle of electromagnetic induction. Specifically, it can be implemented using an iron core structure with coil windings. An alternating magnetic field is generated by alternating current, causing eddy currents to heat the metal material. The melting groove 10 refers to a channel for the flow of molten metal connected to the melting chamber 1. Specifically, it can be implemented using a ring or U-shaped structure made of high-temperature resistant ceramic material. Copper is pre-placed within the melting groove 10 as an initial conductive material to initiate the electromagnetic induction process. Solid metal blocks enter the melting chamber 1 through an independent feeding port 7, preventing unmelted solid impurities from entering the casting area.

[0034] Here, the first heating induction device 6 is arranged at the bottom of the melting chamber 1, and the melting groove 10 passes through the induction device and forms a closed loop with the melting chamber 1. When the alternating current passes through the induction coil, the copper in the melting groove 10 first melts due to eddy currents generated by electromagnetic induction. Subsequently, the molten copper acts as a conductive medium and continuously generates Joule heat, causing the solid metal block put into the feeding port 7 to gradually melt in the melting chamber 1. Since the melting groove 10 is directly connected to the melting chamber 1, the molten liquid can circulate naturally under the action of gravity. Through the independent first heating induction device 6 and the separate melting groove 10 design, the metal melting process is concentrated in the bottom area, and the casting chamber 2 always maintains a constant temperature of molten liquid; at the same time, the closed current path formed by copper as the initial molten material avoids the energy loss caused by directly heating the solid metal block, and the high purity of copper does not affect the copper solution material used for subsequent casting.

[0035] It should be noted that in this embodiment, a maximum of two first heating induction devices 6 are provided. This avoids the increased difficulty of rotating the furnace body due to the presence of more than three induction devices. Having a maximum of two first heating induction devices ensures that all material in the melting groove of the first heating induction device can flow out. When material needs to be changed, the tilting cylinder 9 drives the melting chamber 1 to tilt, causing the residual molten liquid in the melting groove 10 to flow out into the material storage area 11 along the tilting direction of the melting chamber 1. The first heating induction device 6 achieves overall heating of the melting chamber 1, which not only simplifies the equipment structure but also reduces the difficulty of complete cleaning during material change and cleaning caused by multiple melting grooves 10. Combination Figure 8As shown, in a preferred embodiment, a second heating induction device 18 is also provided below the casting cavity 2. The second heating induction device 18 can keep the liquid in the casting cavity 2 warm, so that the liquid in the cavity is in a constant temperature state. The constant temperature molten liquid can improve the quality of the casting.

[0036] In a preferred embodiment, the casting chamber 2 is detachably installed on one side of the melting chamber 1. Detachable installation means that the casting chamber 2 and the melting chamber 1 are separated and fixed via a mechanical connection structure, specifically using a flange connection and bolt locking method. This ensures that the casting chamber 2 remains sealed during operation, and can be independently disassembled for maintenance or material replacement. The connecting channel 3 between the casting chamber 2 and the melting chamber 1 remains connected in the assembled state. When it is necessary to replace the casting mold 5 or clean the melting chamber 1, the fixing device of the casting chamber 2 can be released to separate it from the melting chamber 1. At this time, the residual molten liquid in the melting chamber 1 can be discharged through an independently provided tilting mechanism, while the casting chamber 2 can be maintained independently by the riser pipe 4 or the mold can be replaced. The detachable structure allows for independent operation of the two chambers. During material replacement, the molten liquid in the melting chamber 1 can be handled independently without being affected by the casting chamber 2. It also facilitates targeted cleaning of the connecting channel 3 and the riser pipe 4, effectively preventing slag accumulation at the chamber connection.

[0037] In the above embodiment, a tilting cylinder 9 is provided on the melting chamber 1. The tilting cylinder 9 is configured to drive the melting chamber 1 to tilt so that the molten liquid in the melting groove 10 flows out into the tilted melting chamber 1 for easy removal. The tilting cylinder 9 refers to a hydraulic drive device installed on the melting chamber 1, thereby changing the spatial orientation of the melting chamber 1. Tilting the melting chamber 1 means that the chamber is rotated around its axis by a certain angle, for example, 15 to 60 degrees, driven by the cylinder, so that the molten liquid flows from the melting groove 10 to a specific area of ​​the melting chamber 1 under the action of gravity, preventing molten liquid from remaining at the bottom of the melting groove 10. The material storage area 11 refers to a wide groove-shaped structure formed on one side wall of the melting chamber 1, used to collect molten liquid after the melting chamber 1 is tilted, facilitating manual or mechanical removal.

[0038] When the molten metal in the melting chamber 1 needs to be replaced, the tilting cylinder 9 is activated and pushes the melting chamber 1 to rotate around the hinge axis to a preset tilt angle. The molten metal in the melting groove 10 flows along the inner wall of the melting chamber 1 to the discharge storage area 11 under gravity. At this time, the operator can clean the accumulated molten metal through a dedicated drain port, eliminating the need for repeated rinsing of the melting chamber 1 to dilute the molten metal in the melting groove 10. The structural design of the discharge storage area 11 ensures concentrated outflow of molten metal, avoiding residue. This solution, by driving the melting chamber 1 to tilt with the tilting cylinder 9, allows the molten metal to actively flow to a designated area. Combined with the flow guiding structure of the discharge storage area 11, it significantly reduces operational difficulty, fundamentally improving the problems of low material replacement efficiency and long cleaning cycles caused by molten metal residue in existing technologies. It also avoids energy waste caused by repeated rinsing, significantly improving material replacement efficiency and reducing maintenance costs. In some specific embodiments, the pouring storage area 11 can be designed as a recessed area on one side wall of the melting chamber 1, with a volume of, for example, 5% to 10% of the total volume of the melting chamber 1. Furthermore, the inner wall surface of the pouring storage area 11 can be covered with a high-temperature resistant coating to reduce molten metal adhesion. By setting up the pouring storage area 11, the molten metal automatically gathers in a specific area during the pouring process, significantly reducing the operating range and simplifying cleaning.

[0039] This application further proposes that an automatic telescopic protective cover 12 be provided on the melting chamber 1. The automatic telescopic protective cover 12 refers to a movable protective structure covering the opening of the melting chamber 1. Specifically, it can be implemented by a foldable metal cover driven by a motor or hydraulically. The coverage area is adjusted by telescopic movement. Its function is to reduce the heat loss inside the melting chamber 1 and at the same time block foreign objects from entering the melting chamber 1.

[0040] Combination Figure 8 As shown, in a preferred embodiment, a horizontal continuous casting channel 17 is also provided on one side of the casting cavity 2. The horizontal continuous casting channel 17 is adapted to be opened during the horizontal continuous casting process, at which time the riser pipe 4 is not required. The horizontal continuous casting channel 17 is located on the lower side of the casting cavity 2, so that the molten material can flow directly out of the horizontal continuous casting channel 17 for the horizontal continuous casting process using its height potential energy. During the horizontal continuous casting process, a first pressure or other pressure value is applied to the melting cavity 1, so that the casting cavity 2 maintains a certain liquid level during the process. By maintaining the preset liquid level potential energy, the feeding capacity of the melt solidification can be enhanced, and the density of the casting can be improved. Furthermore, because the liquid level is maintained at a certain height, slag floating on the liquid surface cannot enter the casting through the horizontal continuous casting channel 17, which helps to improve the quality of the casting. In the horizontal continuous casting process, the casting cavity 2 acts as a holding furnace. This design improves the functionality of the casting equipment and improves the quality of castings produced by the horizontal continuous casting process.

[0041] Combination Figure 10As shown, in another embodiment, a low-pressure side-inclined casting channel 19 can be provided on one side of the casting cavity 2. The low-pressure side-inclined casting channel 19 is inclined on one side of the casting cavity 2 to use pressure to force molten metal into the mold connected to the outside of the low-pressure side-inclined casting channel 19. Here, since this device can achieve the liquid level suspension at a preset height, it can effectively prevent product defects caused by insufficient molten metal height. In addition, a robotic arm device 20 can be provided on the outside of the casting cavity 2. The robotic arm device can be equipped with a robotic arm or other structure to grip the mold and drive it to rotate along the axis of the injection port, so as to realize the mold flipping along the axis. In this way, the pre-cooled cavity can be flipped to the bottom to achieve feeding by the gravity of the molten metal itself. This method can achieve double feeding by pressure holding and gravity, which greatly reduces the problem of internal and external surface shrinkage of the parts; and its structure is simple and low cost. In addition, this side casting method can reduce the flow channel and the required filling pressure, and improve the yield of complex castings.

[0042] Continue to combine Figure 1 As shown, in another embodiment, a shaped riser pipe 24 can also be installed above the casting cavity 2. The shaped riser pipe includes a vertical section vertically disposed on the sealing cover and an inclined section inclinedly disposed on the vertical section. The inclined section is located above the sealing cover and is used to connect to the casting mold. An opening is formed at the upper end of the vertical section, and an openable cover is provided at the opening. A cleaning rod can be inserted through the opening and the end opening of the inclined section during cleaning of the shaped riser pipe to facilitate internal cleaning.

[0043] In one embodiment, the robotic arm device 20 is disposed outside the casting cavity 2. The robotic arm device 20 can clamp the casting mold and drive the casting mold 5 to rotate / flip, thereby causing the lower casting mold 5 to rotate and flip along its axis. This allows the pre-cooled cavity to be flipped to the bottom, so that the molten metal can compensate for shrinkage through its own gravity. This method can achieve dual compensation of pressure holding and gravity, greatly reducing the problem of shrinkage inside and outside the part; and its structure is simple and the cost is low. In addition, this side casting method can reduce the runner and the required filling pressure, and improve the yield of complex castings.

[0044] The robotic arm device 20 described here can be directly mounted on the base 21 at the bottom, and the base 21 can be directly mounted on a flat surface. A first drive 205 is provided on the base, which can drive the robotic arm to rotate along the axis of the injection port. In another embodiment, the robotic arm device 20 can be connected to one side of the casting cavity 2 via a suspension mechanism 22, for example, by directly mounting the base 21 onto the suspension mechanism 22. Both methods can achieve the fixation of the robotic arm device 20 and adapt to different working conditions.

[0045] Combination Figures 10 to 12 As shown, specifically, taking the base 21 directly mounted on the ground as an example, the base 21 is rotatably mounted on the base 23 on the ground. The robotic arm device 20 is mounted on the base and includes a first robotic arm 201 and a second robotic arm 202. A first fixture 203 and a second fixture 204 are respectively provided at their ends for clamping two molds capable of closing. A second drive 206 is provided on the base to drive the first robotic arm 201 and the second robotic arm 202 to move closer or further apart, thereby realizing mold closing and opening. The first fixture 203 and the second fixture 204 are rotatably mounted at the ends of the first robotic arm 201 and the second robotic arm 202, respectively. A third drive 207, a hydraulic cylinder, is provided on the first robotic arm 201 and the second robotic arm 202 to drive the fixtures to rotate, thereby causing the cavity opening of the mold to rotate outwards, facilitating demolding of the molded parts. The base is also equipped with a fourth drive 208, which drives the robotic arm to move vertically to adjust the height of the mold, facilitating the adjustment of the pouring gate to the same height as the injection port. The base is also equipped with a sixth drive 210, which drives the robotic arm 20 to move horizontally, ensuring a sealing contact between the pouring gate and the injection port. The base 21 is further equipped with a fifth drive 209, which drives the robotic arm 20 to rotate, cooperating with the fourth drive 208 to lower the mold into the cooling tank or graphite tank. The base is rotatably mounted on the base 23, and a seventh drive 211 drives the base to rotate along the vertical axis, allowing the mold to switch between loading / unloading and injection positions. The robotic arm enables basic processes such as loading / unloading, mold closing, and demolding, achieving automation in low-pressure casting.

[0046] During low-pressure casting, the robotic arm device 20 first drives the mold to close at the "loading and unloading station"; then the base 21 drives the robotic arm device to rotate along the vertical axis to the "filling station", and the fourth drive 208 adjusts the mold height to seal the mold gate with the casting channel; then the melting chamber 1 applies the third pressure P3, and the casting chamber 2 applies the second pressure P2 (P3>P2), and the molten liquid is pressed into the mold cavity through the casting channel; when the molten liquid fills 70% of the cavity, the robotic arm device 20 starts the rotation drive (along the casting channel axis) to flip the cooled far end cavity of the mold to the bottom; then the pressure holding state of P3>P2 is maintained for 5-10 seconds (adjusted according to the casting thickness), and the shrinkage porosity is eliminated by "pressure holding + gravity feeding"; finally, after depressurization, the base 21 drives the robotic arm device 20 back to the loading and unloading station, the third drive 207 drives the fixture to flip and demold, and the fourth drive 208 drives the mold to descend and cool, thereby improving the automation of casting.

[0047] It should be noted that the casting mold 5 described here can have various connection methods to the casting cavity, for example: Combination Figure 13 As shown, when the casting mold 5 is arranged horizontally and the casting gate is in the middle of the mold, only horizontal low-pressure casting is performed. This method has a low filling pressure head and a clean inner cavity of the casting, which can solve the problem of rough product quality. Combination Figure 14 As shown, when the casting mold 5 is rotated to a certain tilt angle for fixed casting, and the casting gate is in the middle position of the mold, only tilted low-pressure casting is carried out. By tilting the pouring, the filling pressure head is reduced, and mechanical sand adhesion of the casting is prevented. This can solve the problem of sand adhesion in the inner cavity of tall products. In addition, an exposed riser can be added to the valve core positioning hole. By tilting the pouring, the thick part of the valve core positioning hole and the thick part of the water outlet are filled with exposed risers to compensate for shrinkage, thus solving the shrinkage problem (such as the bathtub body).

[0048] Combination Figure 15 As shown, when the casting mold 5 rotates while casting, and the pouring gate is in the middle position of the mold, the robotic arm device 20 can be used to carry out rotary low-pressure casting. By tilting the plane of the pouring valve core and forming an exhaust channel with the direction of copper flow velocity, the copper flows through the valve core while the mold rotates. When the mold rotates to a vertical position, it meets the gravity feeding requirements of the riser of the casting and can solve the problem of poor polishing of the appearance of the casting during filling (such as side-opening valves and curved water nozzles). Combination Figure 16 As shown, when the casting mold 5 is arranged vertically and the sprue mold is at the bottom, only vertical low-pressure casting is performed, which solves the problem of simple mass production of products. The process is simple and efficient. Combination Figure 17 As shown, when the casting mold 5 is arranged vertically and the pouring gate is on the top of the mold, vertical gravity casting is implemented. Through automatic gravity casting, the problem of manual material scooping and casting is solved, and the labor intensity is reduced. Combination Figure 18 As shown, when performing rotational casting, the casting port is initially on the casting mold 5. Rotational gravity casting can be performed using a robotic arm device. Rotational gravity casting can solve the problems of low mold cost and low process yield for small tees, small crosses, and straight pipe products with a length of less than 200mm.

[0049] Example 2 Combination Figures 5 to 7 As shown, this embodiment provides a material changing method for a multi-functional casting furnace, including the following steps: S1, such as Figure 5 As shown, when changing materials, the casting chamber 2 is separated from the melting chamber, and then the remaining molten liquid in the melting chamber 1 is cast into the ingot mold 13 using the low-pressure casting production mode. The ingot mold does not contain a sand core, which is used to solidify the copper into an ingot and then remove it. S2, such as Figure 6 As shown, when the molten liquid level in the melting chamber 1 is lower than the preset height, the melting chamber 1 is tilted by the tilting cylinder 9, so that the molten liquid in the melting groove 10 and the molten liquid in the melting chamber 1 gather in the corner of the melting chamber 1. The molten liquid in the corner is then manually removed and cleaned. S3, such as Figure 7 As shown, a coreless induction furnace is used for the rapid melting of new materials. The molten new liquid is poured into a ladle 14 and then injected into the melting chamber 1 of the cored induction furnace through the feeding port 7 using the ladle. This allows the new liquid to enter the melting groove 10 for rapid material replacement.

[0050] The ingot mold refers to a forming container used to receive the remaining molten metal. It can be made of graphite or metal, and its internal cavity shape matches the shape of the ingot. The molten metal cools and solidifies within the mold to form a solid ingot for subsequent recycling. The coreless induction furnace refers to an induction heating device used for rapidly melting metal materials. It can be implemented using an open induction coil structure, directly heating the metal block through electromagnetic induction. The molten metal is then transferred through a ladle to the melting groove 10 of the melting chamber 1 to complete the material replacement.

[0051] During the material changeover process, the separation of the casting chamber 2 and the melting chamber 1 ensures that they do not interfere with each other. The remaining molten metal is pressed into the ingot mold to form ingots through low-pressure casting, preventing molten metal residue from remaining in the melting chamber 1. When the liquid level in the melting chamber 1 is lower than the preset height, the tilting cylinder 9 drives the melting chamber 1 to tilt, causing the residual molten metal in the melting groove 10 and the chamber to gather in the corner area for easy manual cleaning. The new material is rapidly melted into a liquid state through a coreless induction furnace and transferred to the melting chamber 1 through a ladle, allowing the new molten metal to quickly fill the melting groove 10, thus achieving direct material changeover without the need for cleaning.

[0052] Compared to existing technologies, material replacement in existing technologies requires repeated manual emptying of high-temperature molten liquid and cleaning of the molten groove 10, which is complex and poses safety hazards. This method separates the casting chamber 2 from the melting chamber 1, uses an ingot mold to solidify the remaining molten liquid, utilizes a tilting cylinder 9 to collect the residual molten liquid, and rapidly melts the new material using a coreless induction furnace. This eliminates the need for repeated cleaning of the molten groove 10 during material replacement, significantly shortening operation time and reducing the intensity of manual intervention. It solves the problems of difficult cleaning of the molten groove 10 and low material replacement efficiency in existing technologies, achieving rapid cleaning of residual molten liquid in the melting chamber 1 and seamless replacement of new material. It avoids the cumbersome process of molten liquid dilution and repeated operations in traditional cleaning processes, while also reducing the risks of manual operation in high-temperature environments.

[0053] It should be understood that the above are merely preferred embodiments of the present invention, and the scope of protection of the present invention is not limited to the above embodiments. All technical solutions that fall within the scope of the present invention are within the scope of protection of the present invention.

[0054] The accompanying drawings used in the above description of the embodiments only illustrate certain embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

Claims

1. A multifunctional casting furnace, characterized in that, The application relates to a multifunctional casting furnace. The multifunctional casting furnace comprises a melting cavity and a pouring cavity installed on one side of the melting cavity, and a connecting channel is arranged between the melting cavity and the pouring cavity. The melting cavity is provided with a feeding opening and a first air inlet and pressurizing port for applying a first pressure or a third pressure above the melting cavity, and a heating melting device is arranged in the melting cavity. The pouring cavity is adapted to be connected with a casting mold, and is provided with a second air inlet and pressurizing port for applying a second pressure above the molten metal in the pouring cavity. The multifunctional casting furnace is configured as follows: Before casting, the first pressure is applied to the melting cavity to press the molten metal in the melting cavity into the pouring cavity through the connecting channel, and the molten metal in the pouring cavity is lifted to a preset height. During casting, the second pressure is applied to the pouring cavity to keep the molten metal in the pouring cavity at a preset hovering height, and the third pressure greater than the second pressure is applied to the melting cavity to press the molten metal in the pouring cavity into the casting mold by using the pressure difference.

2. The multi-functional casting furnace according to claim 1, characterized by The casting mold is adapted to be connected with the pouring cavity through a liquid lifting pipe, the bottom of the liquid lifting pipe is located below the hovering height of the molten metal in the pouring cavity, and when the first pressure is applied to the melting cavity, the liquid level in the liquid lifting pipe is the same as the liquid level in the pouring cavity.

3. The multi-functional casting furnace according to claim 1, characterized by The heating melting device is a first heating induction body device arranged below the melting cavity, a molten channel communicated with the melting cavity is formed in the first heating induction body device, and the metal material is melted by electromagnetic induction.

4. The multi-functional casting furnace according to claim 3, characterized by The pouring cavity is detachably installed on one side of the melting cavity.

5. The multi-functional casting furnace according to claim 4, characterized by The side wall of the pouring cavity is provided with a horizontal continuous casting channel.

6. The multi-functional casting furnace according to claim 5, characterized by A tilting oil cylinder is arranged on the melting cavity, the tilting oil cylinder is configured to drive the melting cavity to tilt so that the molten metal in the molten channel flows out to the tilted melting cavity for taking out, and a molten material storage area is formed on the melting cavity to make the molten metal gather in the molten material storage area after the melting cavity is tilted to a certain angle.

7. The multi-functional casting furnace according to claim 1, characterized by A second heating induction body device is arranged below the pouring cavity to heat and keep the molten metal in the pouring cavity, so that the pouring cavity keeps a constant temperature.

8. The multi-functional casting furnace according to claim 1, characterized by A low-pressure side inclined pouring channel is arranged on one side of the pouring cavity.

9. The multi-functional casting furnace according to claim 6, characterized by Sealing covers are arranged on the melting cavity and the pouring cavity respectively, so that the melting cavity and the pouring cavity are communicated only through the connecting channel.

10. The multi-functional casting furnace according to claim 1, characterized by A mechanical hand device is arranged on the side or upper part of the pouring cavity to drive the casting mold to move.

11. The multi-functional casting furnace according to claim 10, characterized by The mechanical hand device is rotatably connected to one side of the pouring cavity through a base.

12. The multi-functional casting furnace according to claim 11, characterized by The base is rotatably connected to one side of the pouring cavity through a suspension mechanism.

13. The multi-purpose casting furnace according to claim 11 or 12, characterized in that A plurality of driving mechanisms are arranged on the base to drive the mechanical hand device to perform the processes of mold closing, moving, rotating and demolding on the casting mold.

14. The multi-functional casting furnace according to claim 10, characterized by The casting mold is horizontally arranged, and the pouring port is arranged at the middle position of the casting mold to realize horizontal low-pressure casting.

15. The multi-functional casting furnace according to claim 14, characterized by The mechanical hand device is adapted to drive the casting mold to rotate to realize rotary low-pressure casting.

16. The multi-functional foundry furnace of claim 1, wherein The casting mold is connected at the pouring gate in a preset inclination, and the pouring gate is arranged at the middle position of the casting mold to realize inclined low-pressure casting.

17. The multi-functional casting furnace according to claim 1, characterized by The casting mold is arranged vertically, and the pouring gate is arranged at the lower edge of the casting mold to realize vertical low-pressure casting.

18. The multi-functional foundry furnace of claim 1, wherein, The casting mold is arranged vertically, and the pouring gate is arranged at the upper edge of the mold to realize vertical gravity casting.

19. The multi-functional casting furnace according to claim 10, characterized by The casting mold is arranged vertically, and the mechanical arm device is adapted to drive the casting mold to rotate to realize rotary gravity casting.

20. A method of changing the material of the multifunctional casting furnace according to claim 6, characterized by, The method comprises the following steps: S1, when the material is replaced, the pouring cavity is separated from the melting cavity, and then the residual molten metal in the melting cavity is poured into the ingot mold by the mode of low-pressure casting, the ingot mold is not provided with a sand core, and is used for taking out after the copper water is solidified into an ingot; S2, when the liquid level of the molten metal in the melting cavity is lower than a preset height, the melting cavity is tilted by using a tilting oil cylinder, the molten metal in the melting channel and the molten metal gathered in the corner of the melting cavity are poured into the corner, the molten metal in the corner is manually taken out, and the corner is cleaned; S3, the new molten metal after melting is tilted into the pouring ladle, the new molten metal is poured into the melting cavity through the charging port by using the pouring ladle, and the new molten metal enters the melting channel to realize rapid material replacement.

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