A cylinder head casting sand cleaning device and method

Abstract

This invention belongs to the field of casting post-treatment technology and discloses a sand removal device and method for cylinder head castings, including a frame, an ultrasonic sand removal tank, a contact ultrasonic component, a high-pressure jet component, and a water circulation component. The ultrasonic sand removal tank is installed on the top surface of the frame, and ultrasonic transducers are arranged on the inner wall of the ultrasonic sand removal tank. The contact ultrasonic component includes a clamp support, a contour clamp, and ultrasonic units. The clamp support is fixedly connected to the frame, and the contour clamp is detachably connected to the clamp support and suspended in the ultrasonic sand removal tank. The casting is placed at the bottom of the contour clamp, and multiple ultrasonic units are installed on the top of the contour clamp and are in contact with the surface of the casting. The high-pressure jet component includes a high-pressure jet nozzle arranged on the inner wall of the ultrasonic sand removal tank, which sprays water into the inner cavity opening of the casting. The water circulation component includes a water storage tank, which is connected to the ultrasonic sand removal tank and the high-pressure jet nozzle. This invention does not produce toxic substances that pollute the environment and has the technical effect of improving the sand removal quality of cylinder head castings.

Description

Technical Field

[0001] This invention belongs to the field of casting post-treatment technology, specifically relating to a sand removal device and method for cylinder head castings. Background Technology

[0002] The statements in this section are merely background information related to the present invention and do not necessarily constitute prior art.

[0003] Engine cylinder heads, cylinder blocks, and other parts with complex curved surfaces and internal water and oil passages are generally mass-produced using casting processes. After casting, it is necessary to remove the sand adhering to the cylinder head. Currently, commonly used sand removal methods include vibration sand removal, high-pressure jet cleaning, and ultrasonic cleaning. However, a single method usually has problems such as dead zones in sand removal, easy damage to castings, or low efficiency.

[0004] To address the aforementioned technical problems, existing technology discloses a sand core cleaning device for aluminum or magnesium alloy castings, which employs a composite sand cleaning scheme. The device includes a casting clamping assembly, a mechanical vibration assembly, and an ultrasonic cleaning assembly. First, the casting is immersed in a cleaning solution to soften the sand core; then, the mechanical vibration assembly drives the cleaning tank and the casting to vibrate as a whole, using mechanical impact force to break the sand core; finally, an ultrasonic concentrator is inserted into the cleaning solution to clean residual sand through ultrasonic cavitation.

[0005] The above solution has the following drawbacks: The above-mentioned method of chemical immersion for thin-walled castings will release toxic substances and pollute the environment, and there is also the problem of waste liquid treatment. Mechanical vibration acting on the cleaning tank will gradually weaken its vibration and crushing ability, making it difficult to concentrate its effect on the stubborn sand core deep inside the casting cavity. The ultrasonic energy concentrator placed in the cleaning fluid will also be unable to effectively enter the narrow inner cavity to generate sufficient impact. There are technical problems with the limited ability to remove sand cores deep in the cylinder head, in bends and cross flow channels. Summary of the Invention

[0006] In view of this, the purpose of the present invention is to provide a sand removal device and method for cylinder head castings, which can solve the technical problem of limited ability to remove sand cores in the deep, curved and cross flow channels of the cylinder head in the prior art.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: In a first aspect, a cylinder head casting sand removal device is provided, including a frame, an ultrasonic sand removal tank, a contact ultrasonic component, a high-pressure jet component, and a water circulation component; An ultrasonic sand-shedding trough is installed on the top surface of the frame, and at least one ultrasonic transducer is provided on the inner wall of the ultrasonic sand-shedding trough. The contact ultrasound assembly includes a clamp support, a contour clamp, and multiple ultrasound units. The clamp support is fixedly connected to the frame, and the contour clamp is detachably connected to the clamp support. The contour clamp is suspended in the ultrasound sand drop tank. The casting is placed at the bottom of the contour clamp, and the multiple ultrasound units are installed on the top of the contour clamp and are in contact with the surface of the casting. The high-pressure jet assembly includes at least one high-pressure jet nozzle disposed on the inner wall of the ultrasonic sand-falling tank, which jets water into the inner cavity opening of the casting. The water circulation component includes a water storage tank, which is connected to an ultrasonic sand removal trough and a high-pressure jet nozzle.

[0008] Furthermore, the sand removal device also includes a control cabinet, which is connected to the ultrasonic unit, ultrasonic transducer, and water circulation assembly respectively. The control cabinet is pre-set with the vibration intensity of the ultrasonic transducer and ultrasonic unit for different castings.

[0009] Furthermore, the ultrasonic sand removal tank is an inverted stepped tank with a rectangular top and a frustum-shaped stepped bottom. Several ultrasonic transducers are connected to the walls of the frustum-shaped stepped tank. The walls of the rectangular tank are connected to a circulating water inlet pipe and a high-pressure jet nozzle.

[0010] Furthermore, the water circulation component also includes a sand separator, a circulation pump, and a booster pump; The sand-water separator is connected between the water storage tank and the ultrasonic sand removal tank. The circulation pump is located between the water storage tank and the ultrasonic sand removal tank, and the pressurization pump is located between the water storage tank and the high-pressure jet nozzle. The circulating pump, booster pump, sand separator, and control cabinet are electrically connected.

[0011] Furthermore, the sand-water separator is connected to the ultrasonic sand removal tank via a recovery pipe, and the sand-water separator is connected to the water storage tank via a circulating return water pipe; a sand outlet pipe is installed at the bottom of the sand-water separator.

[0012] Furthermore, the contouring fixture includes a basket, an array plate, and a support plate. The bottom of the basket is open and the basket can be detachably suspended from the fixture bracket. The support plate is fixedly connected to the bottom of the basket, and the casting with its opening facing downwards is placed on the top of the support plate. The array plate is detachably connected to the top of the basket, and multiple ultrasonic units are detachably connected to the array plate.

[0013] Furthermore, the ultrasonic unit includes a sleeve, guide pin, transducer, amplitude transformer, and spring; The sleeve is threaded to the array plate, and a slot is opened at the top of the sleeve. The top of the sleeve passes through the array plate and is connected to the locking nut. The guide pin is fixedly connected to the top of the transducer, the amplitude rod is fixedly connected to the bottom of the transducer, the lower spring seat is fixed to the outer periphery of the bottom of the transducer, the upper spring seat is fixed to the bottom of the sleeve, the guide pin is slidably connected to the inner wall of the sleeve, the spring is sleeved on the outer periphery of the transducer, and the two ends of the spring are respectively connected to the upper spring seat and the lower spring seat. A vibration plate is fixed at the bottom of the amplitude transformer, and multiple sand discharge grooves are evenly opened on the bottom surface of the vibration plate.

[0014] Furthermore, the bottom of the suspended platform is provided with symmetrical positioning brackets. The positioning brackets include a positioning bracket body fixedly connected to the bottom of the suspended platform, an adjusting pressure plate bolt, and a pressure plate. The pressure plate bolt is threadedly connected to the positioning bracket body, and the end of the pressure plate bolt is rotatably connected to the pressure plate, and the pressure plate is centered.

[0015] Furthermore, a mass sensor is installed between the fixture bracket and the suspended platform. The mass sensor is connected to the control cabinet to monitor the total mass of the beam, the suspended platform, and the casting. The control cabinet can determine the sand removal endpoint based on the change in total mass and control the shutdown of each component equipment.

[0016] Secondly, a sand-removal method for the aforementioned cylinder head casting sand-removal device is provided, the specific steps of which include: The casting is clamped and positioned in the conformal fixture, and the position of the ultrasonic unit on the array plate and the preload of the ultrasonic unit are adjusted according to the type of casting to make the transducer plate fit against the upper surface of the casting. The contour jig with the casting is mounted on the jig bracket, and the contour jig is suspended in the ultrasonic sand drop tank. Based on the type of casting, the ultrasonic intensity of the ultrasonic transducer and each ultrasonic unit and the number of cycles of sand removal are set through the control cabinet, and the suction speed of the circulating pump and the pressure of the pressurizing pump, as well as the start and stop interval of the pressurizing pump are set. One cycle of the sand cleaning process is as follows: the ultrasonic unit and the pressure pump work simultaneously, then the ultrasonic transducer works, and then the ultrasonic is stopped for weighing and measurement; the water circulation component runs continuously. When the rate of change of total mass is lower than the preset rate of change threshold in the control cabinet, the control cabinet controls the sand cleaning device to stop sand cleaning.

[0017] Compared with the prior art, the advantages and positive effects of this invention are: This invention discloses a cylinder head casting sand removal device that directly transmits ultrasonic vibration energy to the interior of the casting through a contact ultrasonic component, peeling off the sand core inside the casting. Combined with a high-pressure jet component to flush away the detached sand core from the inner cavity, the sand removal efficiency is improved. Ultrasonic transducers within the ultrasonic sand removal tank bombard the surface of the casting, peeling off external sand. Circulating water keeps the cleaning fluid flowing in the ultrasonic sand removal tank, saving water resources and removing waste sand from the tank. This invention solves the technical problem of limited sand core removal capability in deep, curved, and intersecting flow channels of the cylinder head due to mechanical vibration in the cleaning tank, and it does not produce toxic substances that pollute the environment, thus significantly improving the sand removal quality of cylinder head castings. Attached Figure Description

[0018] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0019] Figure 1 This is a schematic diagram of the sand-removing device according to Embodiment 1 or Embodiment 2 of the present invention; Figure 2 This is a schematic diagram of the contouring fixture of Embodiment 1 or Embodiment 2 of the present invention; Figure 3 This is a schematic diagram of the ultrasonic unit of Embodiment 1 or Embodiment 2 of the present invention; Figure 4 This is a schematic diagram of the vibration transmission plate of Embodiment 1 or Embodiment 2 of the present invention; Figure 5 This is a schematic diagram of the ultrasonic sand-shedding trough of Embodiment 1 or Embodiment 2 of the present invention; Figure 6 This is a schematic diagram of the arrangement of the high-pressure jet nozzle in Embodiment 1 or Embodiment 2 of the present invention; In the picture: 1. Control cabinet; 2. Frame; 3. Circulating return water pipe; 4. Water storage tank; 5. Circulating inlet water pipe; 6. High-pressure pipe; 7. Circulating pump; 8. Booster pump; 9. Sand separator; 10. Sand outlet pipe; 11. Recovery pipe; 12. Drive motor; 13. Ultrasonic sand removal trough; 14. Contouring clamp; 15. Clamp bracket; 16. Ultrasonic transducer harness; 17. Ultrasonic unit harness; 18. Lifting lug; 19. Suspension basket; 20. Positioning bracket; 21. Pressure plate screw. 21. Bolt; 22. Support plate; 23. Pressure plate; 24. Ultrasonic unit; 25. Positioning screw; 26. Unit mounting hole; 27. Locking nut; 28. Array plate; 29. ​​Sleeve; 30. Guide pin; 31. Transducer; 32. Spring lower seat; 33. Amplitude rod; 34. Vibration transducer; 35. Spring; 36. Ultrasonic transducer; 37. Sand drop port; 38. Frustum-shaped stepped groove; 39. Cylinder head water passage; 40. High-pressure jet nozzle; 41. Cylinder head air passage. Detailed Implementation

[0020] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0021] The present invention will now be described in detail with reference to the accompanying drawings.

[0022] Example 1 This embodiment discloses a sand-removing device for cylinder head castings, such as... Figure 1As shown, it includes a frame 2, an ultrasonic sand-falling tank 13, a contact ultrasonic component, a high-pressure jet component, and a water circulation component; wherein the frame 2 is used to support and fix the ultrasonic sand-falling tank 13, the contact ultrasonic component, the high-pressure jet component, and the water circulation component.

[0023] like Figure 1 As shown, the ultrasonic sand removal tank 13 is fixedly installed on the top surface of the frame 2 and is used to contain the cleaning fluid (water in this embodiment) and the casting to be cleaned. At least one ultrasonic transducer 36 is provided on the inner wall of the ultrasonic sand removal tank 13. The ultrasonic transducer 36 generates an ultrasonic field in the cleaning fluid and generates a cavitation effect in the cleaning fluid through ultrasonic waves, which helps to peel off the fine sand adhering to the casting or the sand adhering to part of the inner cavity.

[0024] like Figure 1 As shown, the contact ultrasonic assembly includes a clamp support 15, a contour clamp 14, and multiple ultrasonic units 24. The clamp support 15 is fixedly connected to the frame 2, and the contour clamp 14 is detachably connected to the clamp support 15, and the contour clamp 14 is suspended in the ultrasonic sand removal tank 13. The casting is placed at the bottom of the contour clamp 14, and the multiple ultrasonic units 24 are installed on the top of the contour clamp 14 and are in contact with the surface of the casting. It should be noted that placing the casting in the contour clamp 14 and together with it in the ultrasonic sand removal tank 13, immersing the casting in the cleaning solution, allows the ultrasonic units 24 to be in close contact with the surface of the casting, directly transmitting ultrasonic vibration energy to the interior of the casting, peeling off the sand core inside the casting, and avoiding the generation of a large amount of dust.

[0025] It is important to note that in this embodiment, the ultrasonic unit 24 is bonded to the surface of the casting, enabling direct and efficient transmission of ultrasonic energy into the interior of the casting. Compared to the existing technology where the ultrasonic concentrator is placed in the cleaning fluid, making it difficult for its cavitation effect to effectively penetrate narrow internal cavities, the contact ultrasonic method in this embodiment can more effectively act on stubborn sand cores deep within the casting cavity, thereby solving the technical problem of limited ability of traditional ultrasonic sand cleaning to remove sand cores in deep, curved, and intersecting flow channels.

[0026] Understandably, the clamp bracket 15 is used to fix and support the contact ultrasonic component, ensuring that the ultrasonic unit 24 can work stably during the sand removal process; the contour clamp 14 is used to fix the casting to be sand removed and to ensure that the ultrasonic unit 24 fits in contact with the surface of the casting.

[0027] like Figure 1 , Figure 6 As shown, the high-pressure jet assembly includes at least one high-pressure jet nozzle 40. In this embodiment, the high-pressure jet nozzle 40 is disposed on the inner wall of the ultrasonic sand-removing tank 13 for jetting water into the inner cavity opening of the casting. Figure 6As shown, multiple high-pressure jet nozzles 40 are provided, which respectively spray water flow onto the cylinder head water passage 39 and cylinder head air passage 41 of the casting. The high-pressure jet assembly is used to generate high-speed, high-pressure water flow to flush the inner cavity of the casting. It can be understood that through the impact force of the water flow, the sand core that has been ultrasonically peeled or loosened can be further impacted and peeled off, and carried away from the inner cavity of the casting.

[0028] Understandably, the ultrasonic sand removal tank is filled with water until it covers the casting, but does not contact the transducer of the ultrasonic unit 24. After the ultrasonic unit 24 peels off the sand core from the inner cavity of the casting, and the high-pressure jet assembly flushes the detached sand core from the inner cavity, the ultrasonic transducer 36 installed in the ultrasonic sand removal tank 13 bombards the fine sand on the surface of the casting or some of the sand adhering to the inner cavity through cavitation, thereby improving the sand removal efficiency.

[0029] like Figure 1 As shown, the water circulation assembly includes a water storage tank 4, which is connected to the ultrasonic sand removal tank 13 and the high-pressure jet nozzle 40. Specifically, the water storage tank 4 is connected to the ultrasonic sand removal tank 13 via a circulation water pipe (including a circulation inlet pipe 5 and a circulation return pipe 3), and to the high-pressure jet nozzle 40 via a high-pressure pipe 6. It can be understood that the water storage tank 4 supplies water to the ultrasonic sand removal tank 13 and the high-pressure jet nozzle 40, while simultaneously allowing the cleaning fluid in the ultrasonic sand removal tank 13 to circulate through the circulation water pipe. This not only saves water resources but also removes waste sand from the ultrasonic sand removal tank 13. This contrasts sharply with the environmental pollution and wastewater treatment burden caused by existing technologies that use chemical immersion.

[0030] like Figure 1 As shown, the sand removal device also includes a control cabinet 1, which is installed on the top surface of the frame 2 and located on one side of the ultrasonic sand removal trough 13; the control cabinet 1 is connected to the ultrasonic unit 24, the ultrasonic transducer 36, the high-pressure jet assembly, and the water circulation assembly, respectively, as shown. Figure 1 As shown, control cabinet 1 is connected to ultrasonic transducer 36 via ultrasonic transducer harness 16 and to ultrasonic unit 24 via ultrasonic unit harness 17. In this embodiment, control cabinet 1 is equipped with an ultrasonic control board for adjusting the vibration intensity of the transducer 31 in ultrasonic transducer 36 and ultrasonic unit 24. Specifically, the ultrasonic control board presets the vibration intensity of ultrasonic transducer 36 and ultrasonic unit 24 for different castings. For example, for castings with dense flow channels and stubborn sand adhesion, a higher ultrasonic intensity is set; for castings with fragile structures or less sand adhesion, the ultrasonic intensity is reduced to avoid damage and save energy.

[0031] like Figure 1 , Figure 5As shown, the ultrasonic sand removal tank 13 is an inverted stepped tank with a rectangular top and a frustum-shaped stepped tank 38 at the bottom. Several ultrasonic transducers 36 are connected to the walls of the frustum-shaped stepped tank 38. A circulating water inlet pipe 5 and a high-pressure jet nozzle 40 are connected to the walls of the rectangular tank, with the circulating water inlet pipe 5 installed at the top of the rectangular tank wall. It can be understood that installing the circulating water inlet pipe 5 at the top of the rectangular tank wall allows circulating water to flow downwards from the top of the ultrasonic sand removal tank 13, carrying away the waste sand.

[0032] like Figure 5 As shown, the cross-sectional dimensions of the inverted stepped groove decrease from top to bottom, which optimizes the propagation path and energy distribution of ultrasonic waves in the water medium and guides the movement direction of water flow and waste sand. For example, in this embodiment, the ultrasonic transducer 36 is welded onto the frustum-shaped stepped groove 38, which facilitates the focusing and reflection of ultrasonic waves, allowing them to act more concentratedly and evenly on the casting immersed in water, improving the efficiency of ultrasonic cavitation stripping of the sand core, and simultaneously guiding the waste sand to the bottom for easy discharge. In one specific embodiment, the frustum-shaped stepped groove 38 is a quadrangular frustum, and the angle between it and the rectangular groove is 45°.

[0033] In this embodiment, the sand removal process is as follows: ultrasonic unit operation - ultrasonic transducer operation - ultrasonic stop - weighing measurement cycle; during the sand removal process, the circulating water continues to operate, and the water jet is turned on synchronously when the ultrasonic unit is working.

[0034] In the actual sand removal process, the water storage tank 4 sends circulating water into the ultrasonic sand removal tank 13 through the circulating water pipe, and carries the waste sand and high-pressure water out of the ultrasonic sand removal tank 13 together. The waste sand entering the water storage tank 4 will cause the circulating water to become turbid, which will affect the sand removal effect.

[0035] Therefore, the water circulation component in this embodiment also includes a sand-water separator 9, a circulation pump 7, and a booster pump 8. The sand-water separator 9 is connected between the water storage tank 4 and the ultrasonic sand removal trough 13. Specifically, the top of the sand-water separator 9 is connected to the sand removal port 37 at the bottom of the ultrasonic sand removal trough 13, and the sand-water separator 9 is connected to the water storage tank 4. Circulating water containing waste sand enters the sand-water separator 9 for sand and water separation. The circulating water after separating the waste sand can be sent back to the water storage tank for recycling. It can be understood that by setting up the sand-water separator 9, water and waste sand can be effectively separated, enabling water resources to be recycled.

[0036] In addition, such as Figure 1 As shown, the water storage tank 4 and the ultrasonic sand removal tank 13 are connected by a circulating water inlet pipe 5. A circulating pump 7 is installed on the circulating water inlet pipe 5, which sends the circulating water in the water storage tank 4 into the ultrasonic sand removal tank 13. A pressurizing pump 8 is installed on the high-pressure pipe 6 to pressurize the circulating water and send it into the ultrasonic sand removal tank 13 to flush out the hard-to-reach detached sand cores in the inner cavity of the casting. The sand-water separator 9 is a spiral sand-water separator.

[0037] In this embodiment, the circulating pump 7, the booster pump 8, and the sand separator 9 are electrically connected to the control cabinet 1. The control cabinet 1 has a built-in programmable logic controller (PLC), which is electrically connected to a frequency converter. The frequency converter is connected to the circulating pump 7 and the booster pump 8 respectively. By changing the power supply frequency supplied to the motors of the circulating pump 7 and the booster pump 8, the speed of the motors is adjusted, thereby regulating the pressure and flow rate output by the circulating pump 7 and the booster pump 8.

[0038] like Figure 1 As shown, in this embodiment, the circulating pump 7, the booster pump 8, the water storage tank 4, and the sand-water separator 9 are all installed on the bottom surface of the frame 2. The circulating pump 7 pumps water from the water storage tank 4 to the ultrasonic sand removal tank 13 to maintain the liquid level in the tank and simultaneously remove the detached waste sand. The booster pump 8 draws water from the water storage tank 4 to provide high pressure to the water jet nozzles in the sand removal tank, forming a jet to flush away the detached sand core inside the cavity. It should be noted that this arrangement is beneficial for optimizing the spatial layout of the sand removal device, facilitating operation and maintenance; at the same time, this arrangement can lower the center of gravity of the sand removal device, improving the stability and safety of the device operation.

[0039] like Figure 1 As shown, the top of the sand-water separator 9 is connected to the ultrasonic sand-falling trough 13 via a recovery pipe 11, and the sand-water separator 9 is connected to the water storage tank 4 via a circulating return water pipe 3. The circulating water, after filtration, returns to the water storage tank 4 through the circulating return water pipe 3. A sand outlet pipe 10 is provided at the bottom of the sand-water separator 9. In this embodiment, the recovery pipe 11 is an arc-shaped pipe, and the sand outlet pipe 10 is a spiral conveying pipe.

[0040] It should be noted that the recovery pipe 11, which introduces the mixed water containing sand particles into the sand-water separator 9, is designed as an arc-shaped pipe. This allows the sand-water mixture to form a smooth vortex or guide flow when entering the sand-water separator 9, reducing turbulence and impact, and facilitating the initial sedimentation or centrifugal separation of particles. In some embodiments, the recovery pipe 11 may also be a spiral pipe.

[0041] It should also be noted that the sand outlet pipe 10 is a spiral conveying pipe, and a drive motor 12 with spiral blades is installed on the sand outlet pipe 10. The spiral blades rotate inside the pipe, conveying the separated wet sand from the bottom of the sand-water separator 9. The drive motor 12 is electrically connected to the control cabinet 1, and the control cabinet 1 can control the start and stop of the drive motor 12. In some embodiments, the sand outlet pipe 10 may be a vibrating conveying pipe.

[0042] In this embodiment, the ultrasonic unit 24 is installed on the casting by the conforming clamp 14. However, in actual sand removal operations, the internal cavity arrangement of the casting is diverse. The conforming clamp 14 needs to ensure that the ultrasonic unit 24 can effectively transmit vibration to the internal cavity of different castings.

[0043] In this regard, such as Figure 2As shown, the contour jig 14 includes a basket 19, an array plate 28, and a support plate 22. The bottom of the basket 19 is open and the basket 19 is detachably suspended from the jig bracket 15. The support plate is fixedly connected to the bottom of the basket 19, and the casting is placed on the top of the support plate with the opening facing down. The array plate 28 is detachably connected to the top of the basket 19, and the tops of multiple ultrasonic units 24 are detachably connected to the array plate 28.

[0044] In this embodiment, the basket 19 is frame-shaped with an open bottom, facilitating the discharge of sand and water during the sand removal process. The support plate 22 is used to limit and support the bottom surface of the casting. The array plate 28 is detachably connected to the top of the basket 19. This design is because the casting must first be placed on the support plate 22; if the array plate 28 were fixedly connected to the top of the basket 19, the ultrasonic unit 24 would interfere with the placement and removal of the casting. Figure 2 As shown, in this embodiment, positioning screws 25 are fixedly connected to the four corners of the top of the suspended basket 19, and ear plates with positioning holes are fixedly connected to the four corners of the array plate 28. After aligning the positioning holes of the array plate 28 with the positioning screws 25, it is put down and then the positioning nuts are tightened, so that the array plate 28 and the suspended basket 19 can be detachably connected.

[0045] It should be noted that the ultrasonic unit 24 is detachably connected to the array plate 28, for example, through a threaded connection or magnetic adsorption, thereby adjusting the number, position, and angle of the ultrasonic units 24 according to the geometric characteristics of the casting cavity. Considering the vibration characteristics of the ultrasonic unit 24, this embodiment adopts a threaded connection. Figure 2 As shown, the array plate 28 has multiple unit mounting holes 26 arranged in an array. It can be understood that multiple ultrasonic units 24 are detachably connected to their corresponding unit mounting holes 26. The position of the ultrasonic units 24 can be flexibly adjusted according to the internal structure of the casting, ensuring that ultrasonic energy is concentrated on the area requiring sand removal, thereby transmitting vibration energy to the internal cavities of different parts of the casting and achieving precise sand removal.

[0046] It should be noted that the basket 19 is detachably suspended from the fixture bracket 15. This design takes into account that the basket 19 carries the casting suspended in the ultrasonic sand removal tank, and it is inconvenient to install the casting in the ultrasonic sand removal tank. Therefore, the basket 19 and the fixture bracket 15 are detachably connected. Figure 1 , Figure 2As shown, the fixture support 15 includes two uprights fixedly connected to the frame 2. These two uprights are positioned on both sides of the ultrasonic sand removal tank 13. Semi-circular slots are cut at the top of each upright, accommodating a crossbeam. A lifting lug 18 is installed at the top of the basket 19. The crossbeam passes through the lifting lug 18 and is placed within the semi-circular slot, allowing the basket 19 to be detachably suspended from the fixture support 15. A slot is cut on the crossbeam, and the lifting lug 18 engages with the slot under gravity, preventing the basket 19 from moving along the crossbeam during sand removal. Alternatively, multiple baskets 19 can be prepared and pre-installed with castings. After cleaning one casting, the previous basket 19 can be removed and the next basket 19 installed, improving cleaning efficiency.

[0047] In this embodiment, the ultrasonic unit 24 is mounted on the casting using a contour-following clamp 14. However, in actual sand removal operations, the castings not only have diverse internal cavity arrangements but also varied shapes. The contour-following clamp 14 needs to ensure that the ultrasonic unit 24 effectively fits the surfaces of different castings. Therefore, as... Figure 2 , Figure 3 As shown, the ultrasonic unit 24 in this embodiment includes a sleeve 29, a guide pin 30, a transducer 31, an amplitude transformer 33, and a spring 35. The sleeve 29 is threaded to the array plate 28, and a slot is formed at the top of the sleeve 29. The top of the sleeve 29 passes through the array plate 28 and is connected to the locking nut 27.

[0048] It should be noted that the outer wall of the sleeve 29 is provided with a threaded section, which can be threaded into the single-unit mounting hole 26 of the array plate 28. A slot is opened at the top of the sleeve 29, and the top of the sleeve 29 passes through the array plate 28 and connects to the locking nut 27. This design takes into account the different shapes of the castings. By using a flathead screwdriver in conjunction with the slot, the movement of the sleeve 29 relative to the array plate 28 can be adjusted, thereby adjusting the distance between the ultrasonic unit 24 and the surface of the casting, so that the ultrasonic unit 24 can adapt to the shape of the casting. Then, the locking nut 27 is used to fix the position of the sleeve 29, thereby fixing the position of the ultrasonic unit 24.

[0049] like Figure 3 As shown, the guide pin 30 is fixedly connected to the top of the transducer 31, and the amplitude transformer 33 is fixedly connected to the bottom of the transducer 31. It should be noted that the guide pin 30, transducer 31, and amplitude transformer 33 are coaxially arranged. A lower spring seat 32 is fixedly connected to the outer periphery of the bottom of the transducer 31, and an upper spring seat is fixedly connected to the bottom of the sleeve 29. The guide pin 30 is slidably connected to the inner wall of the sleeve 29. The spring 35 is sleeved on the outer periphery of the transducer 31, and its two ends are respectively connected to the upper spring seat and the lower spring seat 32. In this embodiment, the guide pin is threadedly connected to the top of the transducer. The guide pin is cylindrical with a chamfered end, and the amplitude transformer is a slender conical structure.

[0050] It is understandable that the sleeve 29, in conjunction with the guide pin 30, guides the guide pin 30, transducer 31, and amplitude transformer 33, ensuring that the transducer 31 slides axially along the sleeve 29 and preventing lateral displacement. In this embodiment, a spring upper seat is provided at the bottom of the sleeve 29, and a spring lower seat 32 is provided at the bottom of the transducer 31. The spring 35 is sleeved around the outer periphery of the transducer 31, and both ends of the spring are fixedly connected between the spring upper seat and the spring lower seat 32, providing preload to the amplitude transformer 33, pressing it firmly against the casting surface, while allowing the amplitude transformer 33 to have floating space along the sleeve axial direction to accommodate unevenness and vibration on the casting surface. It is also understandable that the preload of the amplitude transformer 33 can be adjusted by adjusting the sleeve 29. Furthermore, the cooperation of the guide pin, sleeve, and spring enables the ultrasonic unit to compensate for axial displacement when sand disperses on the casting surface.

[0051] like Figure 3 As shown, the bottom end of the amplitude transformer 33 is fixedly connected (e.g., bonded) to the vibration transmission plate 34, as shown. Figure 4 As shown, multiple sand-removing grooves are evenly distributed on the bottom surface of the vibration transducer 34, and these grooves are inclined outwards from the axis of the vibration transducer 34. It can be understood that the amplitude transformer 33 amplifies or reduces the ultrasonic vibration generated by the transducer 31 and transmits it to the vibration transducer 34. The sand-removing grooves on the bottom surface of the vibration transducer 34 provide a smooth discharge path for the detached sand particles and water when the ultrasonic vibration peels off the sand core from the inner cavity or outer wall of the casting, preventing sand particles from accumulating at the bottom of the vibration transducer 34 and affecting the transmission of vibration energy. In this embodiment, the vibration transducer 34 is a flexible vibration transducer used to conduct vibration and protect the casting surface from wear and vibration reflection from burning out the oscillator; it is generally made of polyurethane.

[0052] In practice, castings often have complex shapes and varying sizes. To ensure stable positioning and clamping of castings of different sizes, such as... Figure 2 , Figure 6 As shown, in this embodiment, symmetrical positioning brackets 20 are provided at the bottom of the suspended platform 19. The positioning brackets 20 include a positioning bracket body fixedly connected (e.g., welded) to the bottom of the suspended platform, an adjusting pressure plate bolt 21, and a pressure plate 23. Figure 2 , Figure 6 As shown, the pressure plate bolt 21 is threadedly connected to the positioning bracket body, and the end of the pressure plate bolt 21 is rotatably connected to the pressure plate 23, which is centered. When the casting is placed on the support plate 22, rotating the two pressure plate bolts 21 causes the pressure plate 23 to move towards the casting, clamping and positioning it, thus applying clamping force to castings of different sizes. Rotating the two pressure plate bolts 21 the same number of turns also ensures that the casting is centered relative to the basket 19. In this embodiment, the rotatable connection between the pressure plate 23 and the pressure plate bolt 21 can be a ball joint connection or a universal joint connection.

[0053] It should be noted that in this embodiment, both the pressure plate 23 and the support plate 22 have flexible pads, such as rubber pads, on the side facing the casting. By setting flexible pads, flexible contact with the casting is achieved, avoiding scratches or damage to the surface of the casting caused by rigid clamping. At the same time, it also leaves space for slight vibration with the casting, ensuring that ultrasonic energy can be effectively transmitted to the interior of the casting and promoting the peeling off of the sand core.

[0054] To avoid over- or under-sanding during the sand removal process, a mass sensor is installed between the clamp support and the suspended platform in this embodiment. Specifically, a mass sensor is installed at the bottom of the semi-circular groove at the top of the upright. The mass sensor is communicatively connected to the control cabinet 1 and is used to monitor the total mass of the beam, the suspended platform, and the casting. The control cabinet 1 can determine the sand removal endpoint based on the change in total mass and control the shutdown of each component equipment.

[0055] It is understandable that by monitoring the dynamic changes in the total mass of the beam, basket, and casting, the peeling of the sand core and sand mold inside and on the surface of the casting can be indirectly reflected. After receiving the mass data, control cabinet 1 processes and analyzes the mass data to calculate the change in total mass per unit time, i.e., the rate of change. For example, when the sand cleaning operation is underway, the sand core and sand mold are peeled off, and the total mass will continue to decrease, and the rate of change will be relatively significant. As the sand cleaning is nearing completion, the amount of sand that can be peeled off decreases, and the rate of change in total mass will gradually decrease and tend to stabilize. Control cabinet 1 has a threshold for the rate of change. When the rate of change in total mass is lower than the threshold or the change is not obvious for a period of time, it is considered that the sand cleaning operation has reached the predetermined endpoint. Then, a stop command is immediately sent to the actuator of the sand cleaning device (such as ultrasonic transducer 36, ultrasonic unit 24, pressurization pump, circulation pump, drive motor 12, sand-water separator, etc.) to terminate the sand cleaning operation.

[0056] Understandably, real-time monitoring of the total mass change rate of beams, baskets, and castings can precisely control the duration of sand removal operations, thereby saving energy consumption and avoiding problems of over-sand removal or under-sand removal during the sand removal process.

[0057] In this embodiment, the transducer frequency of the ultrasonic unit 24 is 20kHz~22kHz, which enables the casting to obtain an amplitude of 20~50μm, resulting in a better balance between the sand removal effect and energy consumption in the inner cavity of the casting; the frequency of the ultrasonic transducer is 25kHz~30kHz, which can generate large-size, high-energy cavitation bubbles in the water medium in the sand drop tank, which has a strong impact effect on the sand residue on the surface of the casting; the working pressure of the pressure pump is 30~50MPa, and the pressure can be dynamically adjusted within this range.

[0058] Example 2 This embodiment discloses a method for cleaning sand from cylinder head castings, which applies methods such as... Figures 1 to 6 A disclosed cylinder head casting sand removal device includes the following specific steps: First, the casting is clamped and positioned in the contour jig 14 by the pressure plate 23, and the position of the ultrasonic unit 24 on the array plate is adjusted according to the characteristics of the inner cavity of the casting. At the same time, the axial position of the ultrasonic unit 24 relative to the array plate is adjusted according to the shape of the casting, and the preload in each ultrasonic unit 24 is adjusted so that the transmission plate 34 of the ultrasonic unit 24 is attached to the upper surface of the casting.

[0059] The conforming fixture 14 containing the casting is then mounted on the fixture support 15, suspending it in the ultrasonic sand removal tank 13. Simultaneously, based on the casting's shape and the complexity of its internal cavity, the control cabinet 1 sets the ultrasonic intensity and number of cycles for the ultrasonic transducer 36 and each ultrasonic unit 24, and also sets the suction speed of the circulation pump 7, the pressure of the pressurization pump 8, and the start / stop interval of the pressurization pump 8. It is understood that the control cabinet 1 can preset multiple sand removal programs, each corresponding to different casting models. For example, for castings with dense internal flow channels or tightly bonded sand cores, a higher ultrasonic intensity or longer action time is set, while for castings with less dense internal flow channels, a shorter action time is set.

[0060] Then, the circulating pump 7, the pressurizing pump 8, and the transducer 31 are started in the set sequence and number of cycles to clean the sand from the casting. The sand removal sequence is as follows: First, the ultrasonic unit 24 drives the entire casting to vibrate, while the high-pressure water jet washes away the detached sand core; then, the ultrasonic transducer 36 removes the adhering sand through cavitation; then, the ultrasonic treatment is stopped and the weight is measured. By detecting the dynamic changes in the total mass of the beam, basket, and casting, when the rate of change of the total mass is lower than the preset rate of change threshold in control cabinet 1 or when the change is not obvious over a period of time, it is considered that the sand cleaning operation has reached the predetermined endpoint, and control cabinet 1 controls the sand cleaning device to stop sand cleaning.

[0061] Throughout the process, the water circulation components operate continuously to ensure the recycling of the sand cleaning media and the effective separation of waste sand.

[0062] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A sand-removing device for cylinder head castings, characterized in that, Includes frame, ultrasonic sand removal tank, contact ultrasonic components, high-pressure jet components, and water circulation components; The ultrasonic sand-falling trough is installed on the top surface of the frame, and at least one ultrasonic transducer is provided on the inner wall of the ultrasonic sand-falling trough. The contact ultrasound assembly includes a clamp support, a contour clamp, and multiple ultrasound units. The clamp support is fixedly connected to the frame, and the contour clamp is detachably connected to the clamp support. The contour clamp is suspended in the ultrasound sand drop tank. The casting is placed at the bottom of the contour clamp, and the multiple ultrasound units are installed on the top of the contour clamp and are in contact with the surface of the casting. The high-pressure jet assembly includes at least one high-pressure jet nozzle disposed on the inner wall of the ultrasonic sand-falling tank, which jets water into the inner cavity opening of the casting. The water circulation component includes a water storage tank, which is connected to an ultrasonic sand removal trough and a high-pressure jet nozzle. The contouring fixture includes a basket, an array plate, and a support plate. The basket has an open bottom and is detachably suspended from the fixture bracket. The support plate is fixedly connected to the bottom of the basket, and the casting with its opening facing downwards is placed on the top of the support plate. The array plate is detachably connected to the top of the basket, and multiple ultrasonic units are detachably connected to the array plate. The ultrasonic unit includes a sleeve, a guide pin, a transducer, an amplitude transformer, and a spring. The sleeve is threaded to the array plate, and a slot is formed at the top of the sleeve. The top of the sleeve passes through the array plate and is connected to a locking nut. The guide pin is fixedly connected to the top of the transducer, and the amplitude transformer is fixedly connected to the bottom of the transducer. A lower spring seat is fixed to the outer periphery of the bottom of the transducer, and an upper spring seat is fixed to the bottom of the sleeve. The guide pin is slidably connected to the inner wall of the sleeve. The spring is sleeved on the outer periphery of the transducer, and the two ends of the spring are respectively connected to the upper spring seat and the lower spring seat. A vibration transducer is fixed to the bottom of the amplitude transformer, and multiple sand-removing grooves are evenly formed on the bottom surface of the vibration transducer.

2. The cylinder head casting sand removal device as described in claim 1, characterized in that, The sand removal device also includes a control cabinet, which is connected to the ultrasonic unit, ultrasonic transducer, and water circulation assembly respectively. The control cabinet is pre-set with the vibration intensity of the ultrasonic transducer and ultrasonic unit for different castings.

3. The cylinder head casting sand removal device as described in claim 2, characterized in that, The ultrasonic sand-removing trough is an inverted stepped trough, with a rectangular trough at the top and a frustum-shaped stepped trough at the bottom. Several ultrasonic transducers are connected to the wall of the frustum-shaped stepped trough. A circulating water inlet pipe and a high-pressure jet nozzle are connected to the wall of the rectangular trough.

4. The cylinder head casting sand removal device as described in claim 2, characterized in that, The water circulation assembly also includes a sand separator, a circulation pump, and a booster pump; The sand-water separator is connected between the water storage tank and the ultrasonic sand removal tank. The circulation pump is located between the water storage tank and the ultrasonic sand removal tank, and the pressurization pump is located between the water storage tank and the high-pressure jet nozzle. The circulating pump, booster pump, and sand separator are electrically connected to the control cabinet.

5. A sand-removing device for cylinder head castings as described in claim 4, characterized in that, The sand-water separator is connected to the ultrasonic sand-falling tank via a recovery pipe, and the sand-water separator is connected to the water storage tank via a circulating return water pipe; a sand outlet pipe is installed at the bottom of the sand-water separator.

6. The cylinder head casting sand removal device as described in claim 1, characterized in that, The bottom of the suspended platform is provided with symmetrical positioning brackets. The positioning brackets include a positioning bracket body fixedly connected to the bottom of the suspended platform, an adjusting pressure plate bolt, and a pressure plate. The pressure plate bolt is threaded to the positioning bracket body, and the end of the pressure plate bolt is rotatably connected to the pressure plate, and the pressure plate is centered.

7. The cylinder head casting sand removal device as described in claim 1, characterized in that, A mass sensor is installed between the clamp bracket and the suspended basket. The mass sensor is connected to the control cabinet to monitor the total mass of the beam, the suspended basket, and the casting. The control cabinet can determine the sand removal endpoint based on the change in total mass and control the shutdown of each component equipment.

8. The sand-removing method of the cylinder head casting sand-removing device as described in any one of claims 1-7, characterized in that, The specific steps include: The casting is clamped and positioned in the contour jig, and the position of the ultrasonic unit on the array plate and the preload of the ultrasonic unit are adjusted according to the type of casting so that the transducer plate is attached to the upper surface of the casting. The contour jig with the casting is mounted on the jig bracket, so that the contour jig is suspended in the ultrasonic sand drop tank; Based on the type of casting, the ultrasonic intensity of the ultrasonic transducer and each ultrasonic unit and the number of cycles of sand removal are set through the control cabinet, and the suction speed of the circulating pump and the pressure of the pressurizing pump, as well as the start and stop interval of the pressurizing pump are set. One cycle of the sand removal process is as follows: the ultrasonic unit and the pressure pump work simultaneously, then the ultrasonic transducer works, and then the ultrasonic is stopped for weighing measurement; the water circulation component runs continuously. When the rate of change of total mass is lower than the preset rate of change threshold in the control cabinet, the control cabinet controls the sand cleaning device to stop sand cleaning.

Images