Casting forming device for chemical pump casting

Abstract

The invention relates to the technical field of casting equipment, and discloses a chemical pump casting forming device which comprises a base, a turnover mechanism, a casting mold, a flow monitoring module, a liquid level monitoring module, a temperature monitoring module, an alarm module and a control module. The turnover mechanism is arranged on the base; the casting mold is detachably installed on the turnover mechanism and provided with a pouring gate groove body used for injecting pouring liquid. And the flow monitoring module is used for acquiring flow data when the pouring liquid flows through the pouring gate groove body in a non-contact manner so as to estimate the instantaneous flow. According to the invention, all-around real-time sensing and intelligent judgment of the pouring process are realized by fusing data of multiple sensors such as temperature, flow and liquid level; the pouring completion moment can be automatically and accurately identified, and the overturning action is immediately triggered, so that the problem of improper overturning opportunity caused by manual operation difference or fixed time sequence lag is fundamentally solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of casting equipment, more particularly, it relates to a chemical pump casting forming device. BACKGROUND

[0002] In the production process of chemical pump castings, gravity pouring is a common casting forming method. The existing gravity pouring machine usually includes a base, a turnover mechanism and a casting mold. The turnover mechanism is used to turn over the mold after pouring is completed to complete the forming of the casting. At present, the control of the turnover mechanism mainly depends on manual operation or preset fixed timing. In the manual control mode, the operator manually starts the turnover switch after pouring is completed according to experience; in the fixed timing mode, the system automatically turns over after the preset time arrives.

[0003] However, in the actual production process, both of the above-mentioned methods have certain deficiencies. The manual control is affected by the subjective judgment and operation speed of the operator, and there are differences between different operators, which leads to inconsistent turnover time and affects the quality of the casting. The fixed timing mode cannot adapt to the change of pouring speed, and due to the fluctuation of the flow rate, flow volume and solution content inside the mold of the pouring liquid, the fixed timing may start the turnover too early or too late, resulting in incomplete pouring or overflow and other problems. In addition, there is a time interval between the end of pouring and the start of the turnover switch, which may cause casting defects such as cold shut or shrinkage.

[0004] Therefore, there is an urgent need for a chemical pump casting forming device which can adaptively perceive the pouring process and automatically determine the optimal turnover start time. SUMMARY

[0005] The present application aims to provide a chemical pump casting forming device to solve the above-mentioned technical problems.

[0006] The present application solves the above-mentioned technical problems by the following technical solutions: The present application provides a chemical pump casting forming device, comprising: a base; a turnover mechanism arranged on the base; a casting mold detachably installed on the turnover mechanism, which is provided with a sprue groove body for injecting pouring liquid; a flow monitoring module for non-contact acquisition of flow data of the pouring liquid flowing through the sprue groove body to estimate the instantaneous flow volume; a liquid level monitoring module for monitoring whether the pouring liquid has filled to a key preset position in the mold cavity; a temperature monitoring module for real-time monitoring of temperature changes in the sprue groove body area to identify the pouring start time; an alarm module for issuing an audible and visual prompt signal; a control module, in communication connection with the flow monitoring module, the liquid level monitoring module, the temperature monitoring module, the alarm module and the overturning mechanism respectively, and configured to: identify the pouring starting moment based on the temperature change data output by the temperature monitoring module, and start timing; real-time integral estimation of the cumulative pouring weight according to the flow data output by the flow monitoring module; when the liquid level monitoring module detects that the pouring liquid has reached the preset position of the key area of the cavity, and the cumulative pouring weight reaches the preset range, it is determined that the pouring is about to be completed; immediately control the alarm module to issue an audible and visual prompt signal to notify the operator to stop pouring the pouring liquid container; and after issuing the prompt signal, delay for a preset time, if no abnormal interruption instruction is received, control the overturning mechanism to perform the overturning action.

[0007] Preferably, the flow monitoring module comprises an adjustable support frame and a speed sensor mounted on the support frame, and the speed sensor is aligned with the pouring liquid flow area in the pouring slot body.

[0008] Preferably, the liquid level monitoring module comprises at least one embedded thermocouple, which is embedded in the inner gate end of the casting mold.

[0009] Preferably, the temperature monitoring module comprises at least one temperature sensor embedded in the inner wall of the pouring slot body inlet, for monitoring the temperature jump signal when the pouring liquid flows for the first time.

[0010] Preferably, the alarm module comprises a buzzer and a double-color LED warning light arranged on the base, and the audible and visual prompt signal is continuous buzzing combined with green flashing light.

[0011] Preferably, the overturning mechanism comprises an overturning frame hinged to the base and an overturning driving member for driving the overturning frame to rotate around the horizontal axis, and the overturning frame is provided with an upper mold mounting member and a lower mold mounting member for fixing the casting mold.

[0012] Preferably, the overturning driving member is a servo cylinder hinged to the base, and the telescopic end is hinged to one side of the overturning frame.

[0013] Preferably, the delay preset time satisfies: ensuring that the operator has enough time to move away the pouring liquid container.

[0014] Preferably, the preset range is 95%-99% of the theoretical pouring weight.

[0015] Preferably, the control module is built-in with a filling time cumulative quality mapping model, which is calibrated based on historical qualified pouring mold temperature trigger time and actual pouring weight data, and used to dynamically correct the flow integral result.

[0016] The present application has the advantages of: The present application realizes all-round real-time sensing and intelligent judgment of the pouring process by fusing temperature, flow and liquid level multi-sensor data; can automatically and accurately identify the pouring completion time and immediately trigger the overturning action, fundamentally eliminating the problem of improper overturning timing caused by manual operation differences or fixed time lag; at the same time, the built-in alarm prompt and safety delay mechanism of the present application ensures smooth automatic process while taking into account operation safety. BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure 1 is a structural schematic view of a chemical pump casting forming device of the present application; Figure 2 is a structural schematic view of a turnover mechanism in a chemical pump casting forming device of the present application; Figure 3 is a structural schematic view of a chemical pump casting forming device of the present application; Figure 2 is a local enlarged schematic view of position A in the present application; Figure 4 is a side view of a chemical pump casting forming device of the present application; Figure 5 is a relationship block diagram between each module in a chemical pump casting forming device of the present application.

[0018] In the figure: 10, base; 20, turnover mechanism; 201, turnover frame; 202, servo electric cylinder; 203, upper mold mounting; 204, lower mold mounting; 30, casting mold; 301, sprue groove body; 40, flow monitoring module; 401, support frame; 402, speed sensor; 50, liquid level monitoring module; 60, temperature monitoring module; 70, alarm module. DETAILED DESCRIPTION

[0019] The subject matter described herein will now be discussed with reference to example implementations. It should be understood that discussions of these implementations are merely provided to enable those skilled in the art to better understand subject matter in order to better implement the subject matter described herein, and variations of elements discussed can be made by one skilled in the art without departing from the scope of the present specification. Various examples can omit, substitute, or add various procedures or components as appropriate, or in appropriate combination. Also, it will be understood that the placing of relative terms or descriptions such as "above," "below," "left," "right," "behind," "in front of," etc. is in reference to the positions of items as shown in the figures.

[0020] Reference should be made to both drawings throughout this description. Figures 1 to 5The application discloses a chemical pump casting forming device, which comprises a base 10, a turnover mechanism 20, a casting mold 30, a flow monitoring module 40, a liquid level monitoring module 50, a temperature monitoring module 60, an alarm module 70 and a control module.

[0021] The base 10 provides a support structure for the whole device, is usually welded by steel materials and has sufficient stability and strength. The turnover mechanism 20 is arranged on the base 10 and comprises a turnover frame 201 and a turnover driving part. The turnover frame 201 is connected with the base 10 through a hinge shaft and can rotate around a horizontal axis. The turnover driving part is a servo cylinder 202 in the embodiment, the cylinder body of which is hinged to the base 10, and the telescopic end is hinged to one side of the turnover frame 201. The servo cylinder 202 is used for driving the turnover frame 201 to turn through telescopic extension and contraction. The turnover frame 201 is provided with an upper mold mounting part 203 and a lower mold mounting part 204, and the casting mold 30 is fixed on the upper mold mounting part 203 and the lower mold mounting part 204 through bolts or clamps. The casting mold 30 is detachable and usually comprises an upper mold and a lower mold. A sprue groove body 301 is arranged on the lower mold through bolts, and the sprue groove body 301 has a rectangular structure and is used for guiding the pouring liquid to flow into a mold cavity.

[0022] The flow monitoring module 40 comprises an adjustable support frame 401 and a speed measuring sensor 402 arranged on the support frame 401. The support frame 401 is a telescopic or rotatable mechanical arm, the fixed end of which is connected with the base 10, so that the position and angle of the speed measuring sensor 402 can be adjusted. The speed measuring sensor 402 is a non-contact sensor, for example, a laser Doppler velocimeter or an ultrasonic flowmeter, which is aligned with the area through which the pouring liquid flows in the sprue groove body 301 and is used for acquiring the flow speed of the pouring liquid in real time. Based on the flow speed and the sectional area of the sprue groove body 301, the control module can estimate the instantaneous flow and calculate the cumulative pouring weight through integration.

[0023] The liquid level monitoring module 50 comprises at least one embedded thermocouple which is embedded in the inner gate end of the casting mold 30. When the pouring liquid fills the inner gate end, the thermocouple detects a sharp temperature rise, and the signal is transmitted to the control module, indicating that the pouring liquid has reached a key preset position. The key preset position is determined according to the casting design and is usually a critical point of cavity filling.

[0024] The temperature monitoring module 60 is a temperature sensor, for example, a K-type thermocouple or an infrared temperature sensor, which is embedded in the inner wall of the entrance of the sprue groove body 301. The temperature sensor monitors the temperature of the area of the sprue groove body 301 in real time. When the pouring liquid flows through for the first time, the temperature jumps from the ambient temperature to the pouring liquid temperature, and the control module identifies the temperature jump signal as the pouring starting time and starts an internal timer.

[0025] The alarm module 70 includes a buzzer and a dual-color LED warning light, which are installed on the base 10 in a conspicuous position. The buzzer is used to emit a continuous buzzing sound, and the LED warning light is used to emit a green flashing light, which together constitute an audible and visual prompt signal to inform the operator to stop pouring the pouring liquid containing container.

[0026] The control module is a PLC (Programmable Logic Controller) or an industrial computer, which is communicatively connected with the flow monitoring module 40, the liquid level monitoring module 50, the temperature monitoring module 60, the alarm module 70, and the overturning drive. The control module has built-in programs and execution logic, which are specifically configured as follows: Real-time monitoring of temperature sensor data, when the temperature exceeds the preset threshold (e.g. higher than the ambient temperature by 50°C), it is identified as the pouring start time, and the internal timer and flow integration program are started; Receiving flow rate data from the speed sensor 402, combining the cross-sectional area parameter of the sprue groove body 301, calculating the instantaneous flow rate, and integrating the time to obtain the cumulative pouring weight. The estimation formula of the cumulative pouring weight is: ; Where W is the cumulative weight, p is the pouring liquid density, A is the cross-sectional area of the sprue groove body, and v is the flow rate; Receiving the signal of the embedded thermocouple, when the pouring liquid is detected to reach the end of the inner gate, the liquid level state is recorded; When the liquid level monitoring module 50 detects that the pouring liquid has reached the critical position and the cumulative pouring weight is within the range of 95%-99% of the theoretical pouring weight, it is determined that the pouring is about to be completed. The theoretical pouring weight is pre-calculated based on the casting model and stored in the control module; Immediately control the alarm module 70 to issue an audible and visual prompt signal to prompt the operator to stop pouring the pouring liquid containing container; After issuing the prompt signal, delay for a preset time (e.g. 2-5 seconds), which ensures that the operator has enough time to move away the pouring liquid containing container; if no abnormal interruption instruction (such as an emergency stop button signal or a manual cancellation signal) is received within the delay time, control the overturning drive to start, driving the overturning frame 201 to overturn by a certain angle (usually 90°), completing the casting molding.

[0027] In order to further improve the control accuracy, the control module has a filling time cumulative quality mapping model built in; this model is obtained based on the data calibration of historical qualified pouring mold times, that is, collecting parameters such as temperature trigger time, actual pouring weight, flow integration result, etc. of multiple successful pouring, and establishing a mapping relationship through regression analysis or neural network training. In real-time control, the model dynamically corrects the flow integration result according to the current pouring conditions, such as compensating for measurement errors or environmental changes.

[0028] Regarding the design of the filling time cumulative mass mapping model, since the flow monitoring module estimates the cumulative pouring weight by integrating the flow rate, in actual application, errors may exist in the estimation. The sources of errors include: Flow field unevenness: the flow rate of the pouring liquid in the sprue groove body is not absolutely uniform, and the sensor may measure the local velocity; Liquid level fluctuation: splashing and turbulence in the pouring process can affect the stability of the measurement; Environmental interference: vibrations, dust, and the like in the field can cause subtle interference to the non-contact sensor; Process variation: slight differences in the temperature and viscosity of different batches of pouring liquid can affect the flow characteristics.

[0029] Since simple flow integration may produce cumulative bias in long-term operation, the purpose of setting the filling time cumulative mass mapping model in the present application is to dynamically correct and verify the real-time flow integration result by introducing historical experience data, so as to obtain a more reliable estimated value that is closer to the actual pouring weight. The filling time cumulative mass mapping model is a data-driven empirical model that essentially establishes a mapping relationship from “filling time” to “actual pouring weight”.

[0030] Among them, the filling time refers to the time experienced from the start of pouring (triggered by the temperature module to start timing) to the time when the liquid level sensor detects that the critical position of the mold cavity is filled. This is a process time parameter that can be accurately measured. The actual pouring weight refers to the actual weight of the molten metal consumed in this pouring, which can be obtained by weighing the weight difference of the pouring liquid container before and after pouring. The core idea is that under stable production process, for a particular casting, there is a strong correlation between “filling time” and “actual pouring weight”. By learning and remembering this relationship of many successful pourings in history, the model can use the currently measured “filling time” to predict and verify whether the “flow integration estimated weight” is reasonable. The model needs to be calibrated before the system is put into use or regularly, and the specific steps are as follows: Data acquisition: during the equipment debugging stage or regular maintenance, collect a large amount of (for example, 50-100 mold times) historical qualified pouring mold times data. Each mold time needs to record the following key data: T start : the pouring start time triggered by the temperature module; T level : the time when the liquid level module triggers to indicate that the critical position of the mold cavity is filled; t fill =T level -T start : the “filling time” of this pouring is calculated; W actualActual pouring weight (measured by high-precision scale, the weight difference before and after pouring the pouring liquid into the container is obtained as the true value); W integral : Cumulative weight estimated by flow integration of the control module; Relationship establishment: take t fill as the horizontal coordinate and W actual as the vertical coordinate, plot all the collected data points in the coordinate system. Through mathematical methods (such as least squares method), curve fitting is performed on these data points to establish a function relationship: W predicted =f(t fill ); This function f is the mapping model, which can be a simple linear function, or a quadratic function or an exponential function, the specific form depends on the distribution of actual data. At the same time, the system analyzes the flow integration error of each shot: Error=W actual -W integral ; And can further analyze the relationship between the error and the filling time t fill or the average flow rate, forming an error compensation query table or compensation function. However, in the normal production process, the model works as follows: Real-time monitoring: when a new pouring starts, the system normally starts timing and flow integration; Trigger and prediction: when the liquid level sensor is triggered, the system immediately: a. Record the current filling time t fill-current ; b. Read the current integral estimated value W integral-current from the flow monitoring module; c. Substitute t fill-current into the calibrated mapping model f to calculate a time-based predicted weight W predicted-current .

[0031] Data fusion and decision: the system now has two weight estimates: one is based on flow rate W integral-current , the other is based on time W predicted-current ; the control module will fuse and compare these two values (for example, take the weighted average, or select the value closer to the historical pattern), and dynamically correct W integralcurrent according to the error correction table to obtain a final confirmed cumulative pouring weight W final ; Judgment logic becomes: when the liquid level signal is triggered, and W final enters the preset range of theoretical weight (95%-99%), it is determined that the pouring is about to be completed.

[0032] By introducing this model, the control system of the present application evolves from a simple rule executor to an intelligent system with process awareness, data analysis and self-optimization capabilities.

[0033] The working process of the chemical pump casting forming device is as follows: Step S100, the operator fixes the casting mold 30 on the turnover frame 201 through the upper mold mounting part 203 and the lower mold mounting part 204, the installed casting mold 30 is in a closed state, the sprue groove body 301 thereon is in a horizontal posture and faces the operation working position; then the theoretical pouring weight, the preset range and the delay preset time are input through the operation panel; Step S200, the operator pours the aluminum alloy pouring liquid into the sprue groove body 301 by hand holding the pouring liquid containing container, when the pouring liquid flows through the inlet of the sprue groove body 301 for the first time, the temperature sensor monitors the temperature jump signal, the control module recognizes the pouring starting moment, starts the timing, and starts the flow monitoring module 40; Step S300, the speed sensor 402 monitors the instantaneous flow rate of the pouring liquid in real time, the control module calculates the instantaneous flow rate in combination with the cross-sectional area of the middle part of the sprue groove body 301, and integrates the instantaneous flow rate to estimate the cumulative pouring weight; at the same time, the integral result is corrected through the filling time cumulative mass mapping model; Step S400, when the pouring liquid fills the key position of the cavity, the embedded thermocouple monitors the temperature jump signal in sequence, the control module determines that the pouring liquid has reached the key area of the cavity; when the cumulative pouring weight after correction reaches the preset range, and the liquid level monitoring module 50 monitors that the pouring liquid is in place, the control module determines that the pouring is about to be completed; Step S500, the control module immediately controls the buzzer to emit a continuous buzzing sound, and the double-color LED warning light emits a green flashing light to remind the operator to stop pouring the pouring liquid containing container; after receiving the prompt, the operator removes the pouring liquid containing container; after the delay preset time ends, the control module does not receive an abnormal interruption instruction, sends a control signal to the servo cylinder 202 driver, and the servo cylinder 202 drives the turnover frame 201 to rotate 90° around the horizontal axis to complete the turnover action, so that the pouring liquid fills the forming cavity inside the casting mold 30; Step S600, after the pouring liquid is cooled and formed, the servo cylinder 202 drives the turnover frame 201 to reset, controls the upper mold mounting part 203 to drive the casting mold 30 to open, and takes out the formed casting, completes one casting cycle, cleans the casting mold 30, closes the casting mold 30, and repeats the above operation to continue the next casting operation.

[0034] Through the above scheme, the present application realizes automatic sensing and intelligent control of the pouring process, ensures immediate entry into the overturning action after pouring is completed, and improves production efficiency and consistency of product quality. Compared with the prior art, the present application has the following beneficial effects: The present application avoids the subjectivity of manual observation and the limitations of fixed timing through temperature, flow rate, and liquid level multi-dimensional monitoring data fusion judgment, can adapt to the pouring speed differences of different operators, ensures immediate start of overturning after pouring is completed, reduces the standing time of the pouring liquid in the mold cavity, effectively reduces casting defects such as air holes, slag inclusion, and shrinkage holes, and improves the forming quality and qualification rate of the chemical pump casting; In addition, the present application identifies from the start of pouring, estimates the cumulative weight, alarms when pouring is completed, and automatically overturns, without manual control of the overturning time throughout the process, only requiring the operator to move away the pouring liquid container after receiving the alarm, reducing the labor intensity of the operator, and avoiding production accidents caused by human operation errors; At the same time, the present application uses non-contact laser speed measurement for flow rate monitoring, avoiding damage to the sensor by high-temperature pouring liquid; the liquid level monitoring uses an embedded thermocouple to directly monitor the pouring liquid filling position, with high monitoring accuracy; the built-in filling time cumulative quality mapping model can dynamically correct the cumulative weight estimation result, improving control accuracy; the device can adapt to the production of chemical pump castings of different specifications by replacing the casting mold 30, with strong versatility; Finally, the present application sets the alarm module 70 to clearly remind the operator through audible and visual signals, avoiding pouring liquid overflow; the overturning mechanism 20 is driven by a servo cylinder 202, with accurate and controllable overturning angle, and sets an abnormal interruption function, facilitating handling of unexpected situations and improving the safety of the production process.

[0035] The embodiments of the present application are described above, but the present application is not limited to the above specific embodiments, which are only illustrative and not limiting, and many forms can be made by those of ordinary skill in the art under the inspiration of the present application, all of which are within the protection of the present application.

Claims

1. A casting and molding device for chemical pump castings, characterized in that, The application relates to a casting device, comprising: a base; a turnover mechanism arranged on the base; a casting mold which is detachably arranged on the turnover mechanism and is provided with a sprue groove for pouring liquid; a flow monitoring module for non-contact acquisition of flow data of the pouring liquid flowing through the sprue groove to estimate instantaneous flow; the flow monitoring module comprises an adjustable support frame and a speed sensor arranged on the support frame, and the speed sensor is aligned with the area through which the pouring liquid flows in the sprue groove; a liquid level monitoring module for monitoring whether the pouring liquid has filled to a key preset position in a cavity of the casting mold; the liquid level monitoring module comprises at least one embedded thermocouple which is embedded in the inner end of the inner sprue of the casting mold; a temperature monitoring module for monitoring the temperature change of the area of the sprue groove in real time to identify the starting moment of pouring; the temperature monitoring module comprises at least one temperature sensor embedded in the inner wall of the entrance of the sprue groove for monitoring the temperature jump signal when the pouring liquid flows through for the first time; an alarm module for issuing an audible and visual prompt signal; a control module which is in communication connection with the flow monitoring module, the liquid level monitoring module, the temperature monitoring module, the alarm module and the turnover mechanism, and is configured to: identify the starting moment of pouring based on the temperature change data output by the temperature monitoring module and start timing; integrate and estimate the cumulative pouring weight in real time according to the flow data output by the flow monitoring module; when the liquid level monitoring module monitors that the pouring liquid has reached the preset position of the key area of the cavity and the cumulative pouring weight reaches a preset range, it is determined that the pouring is about to be completed; immediately control the alarm module to issue an audible and visual prompt signal to inform the operator to stop pouring the pouring liquid container; and after issuing the prompt signal, delay for a preset time, if no abnormal interruption instruction is received, control the turnover mechanism to perform a turnover action; the control module is provided with a filling time cumulative weight mapping model which is obtained based on the temperature trigger time and actual pouring weight data calibration of historical qualified pouring mold times and is used for dynamically correcting the flow integration result.

2. The chemical pump casting molding apparatus according to claim 1, wherein The alarm module comprises a buzzer and a double-color LED warning light arranged on the base, and the audible and visual prompt signal is continuous buzzing combined with green flashing light.

3. The chemical pump casting molding apparatus according to claim 1, wherein The turnover mechanism comprises a turnover frame hinged to the base and a turnover driving element for driving the turnover frame to rotate around a horizontal axis, and the turnover frame is provided with an upper mold mounting element and a lower mold mounting element for fixing the casting mold.

4. The chemical pump casting molding apparatus according to claim 1, wherein The turnover driving element is a servo cylinder hinged to the base, and the telescopic end is hinged to one side of the turnover frame.

5. The chemical pump casting molding apparatus according to claim 1, wherein The delay preset time ensures that the operator has enough time to move away the pouring liquid container.

6. The chemical pump casting molding apparatus according to claim 1, wherein The preset range is 95%-99% of the theoretical pouring weight.

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