A fully automatic casting production line and a control system thereof

Abstract

This invention discloses a fully automated casting production line and its control system, relating to the field of casting production technology. The production line consists of a mold-raising unit, a separate demolding unit, sand removal, sand removal and mold fixing unit, water-cooled heating unit, molding unit, mold closing and unmolding unit, a precise positioning and pouring device, a trolley fixing device, a running track, and a control system, realizing the integration of the entire casting process. The trolley fixing device includes a trolley body, a self-positioning mechanism, a linkage anti-vibration component, and a cleaning and protection mechanism. The mold's own weight triggers the pallet to press down, which, through the linkage of guide rods and pull rods, drives the positioning table to automatically center, and with the help of the transmission pressure rod to rotate and tighten, a double locking is achieved. This control system supports switching between fully automatic, semi-automatic, and manual modes, as well as independent operation of a single mold. It can monitor parameters such as temperature control, positioning, and mold closing in real time, and automatically alarms and stops the machine in case of abnormalities. This invention features precise positioning, strong stability, and a high degree of automation, adapting to the production of castings of various specifications, effectively improving casting quality and production efficiency.

Description

Technical Field

[0001] This invention relates to the field of casting production technology, specifically to a fully automated casting production line and its control system. Background Technology

[0002] Sand casting is currently the most widely used forming process in casting production. Traditional automated casting production lines mostly use track-type conveyor trolleys with fixed molds to complete continuous processes such as mold removal, demolding, sand cleaning, molding, mold closing, and pouring. These production lines use a circulating conveyor track as a carrier, with trolleys carrying the molds moving between workstations. Independent actuators complete single-process actions, achieving semi-automatic or automated operation of the casting process. This is the mainstream technical solution for the mass production of small and medium-sized castings.

[0003] Existing casting production lines generally suffer from insufficient positioning accuracy of the trolley and mold, and passive positioning methods. When the mold is placed on the trolley platform, it often relies on manual alignment or simple guide grooves for positioning, which can only achieve rough positioning. Under the impact of the trolley running along the track and the operation of the process mechanism, the mold is prone to displacement, shaking, or even misalignment. During mold closing and pouring, the trolley cannot form an adaptive clamping and locking mechanism for the mold, and gaps or eccentricities are easily generated between the upper and lower molds, which directly reduces the sand molding accuracy and results in a high rate of defects such as flash, burrs, and dimensional deviations in the castings.

[0004] Meanwhile, the existing trolley platform lacks integrated positioning, shock absorption, and cleaning functions, further amplifying process defects. The positioning mechanism and mold are separate structures, unable to achieve automatic centering and clamping with the mold placement movement, requiring additional cylinder or motor-driven positioning components, resulting in complex structures and slow response. The sand and metal residue remaining on the trolley platform after casting is difficult to clean automatically, and long-term accumulation will exacerbate mold tilting and wear. Moreover, most trolleys only have a single load-bearing function and cannot adapt to the rapid change and stable clamping of molds of different specifications, resulting in poor production line flexibility, low debugging efficiency, and difficulty in meeting the automated production needs of high-precision, multi-variety castings.

[0005] Therefore, a fully automated casting production line and its control system are proposed to solve the above problems. Summary of the Invention

[0006] 1. The technical problem to be solved by the present invention

[0007] The purpose of this invention is to provide a fully automated casting production line and its control system to solve the following problems existing in the prior art: (1) Traditional casting production line trolleys and molds rely on manual alignment and simple positioning. The positioning is passive and the accuracy is low. The operation of the trolley and the impact of the process can easily cause the mold to deviate, shake, or misalign. The mold closing is prone to gaps or eccentricity, resulting in poor sand mold accuracy and high casting defect rate.

[0008] (2) The existing trolley does not integrate positioning, shock absorption and cleaning functions, and the platform residue is difficult to clean automatically, which aggravates mold wear and tilting; and it can only be adapted to a single mold, which is slow to change molds and has weak versatility, and cannot meet the automated production needs of multi-variety and high-precision castings.

[0009] 2. Technical Solution To achieve the above objectives, the present invention provides the following technical solution: a fully automated casting production line, comprising a mold-lifting device, a separate demolding device, a sand-cleaning device, a sand-cleaning and mold-fixing device, a water-cooling and heating device, a molding device, a mold-closing and demolding device, and a precision positioning and casting device, which are connected and work together in sequence. It also includes a trolley fixing device, a running track, and a control system. The running track runs through the entire line, and the trolley fixing device can move along the running track and is used to fix the mold. Each device is electrically connected to the control system, realizing the integration of the entire process of mold lifting, demolding, flipping, sand cleaning, water cooling, heating, molding, mold closing, mold dropping, and precision casting. The production line adopts a modular design, supports fully automatic, semi-automatic, and manual multi-mode operation, and can achieve independent operation of a single mold, adapting to multiple casting production scenarios. Each device can automatically complete temperature control, flipping, cleaning, and mold-closing positioning actions, ensuring continuous action and accurate positioning, improving sand mold accuracy and production stability.

[0010] Preferably, the sand cleaning device works in conjunction with the sand cleaning and fixing mold device. The sand cleaning and fixing mold device is used to fix the mold to be cleaned, and the sand cleaning device performs all-round sand cleaning operation on the fixed mold to remove residual sand from the mold surface and cavity.

[0011] Preferably, the water-cooled heating device integrates water cooling and heating functions, and can automatically switch working modes according to production process requirements to achieve precise temperature control of molds or sand molds and meet the forming temperature requirements of different castings.

[0012] Preferably, the mold closing and unclosing device integrates mold closing and unclosing functions, enabling precise positioning during mold closing and smooth operation during mold unclosing, thus avoiding damage to the sand mold or casting and ensuring production stability.

[0013] Preferably, the trolley fixing device includes a trolley body, with track wheels evenly installed at the bottom of the trolley body, and waste hoppers symmetrically installed in the middle of the trolley body. An upper mold and a lower mold for casting are respectively installed on the top of the trolley body. The trolley fixing device also includes a self-positioning mechanism and a cleaning and protection mechanism. The self-positioning mechanism is located below the upper mold and the lower mold, and the cleaning and protection mechanism is located in the trolley body. The self-positioning mechanism is used for automatic support and positioning of the upper mold and the lower mold when casting, and the cleaning and protection mechanism is used for shock absorption when supporting the upper mold and for slag removal from the trolley platform.

[0014] Preferably, the self-positioning mechanism includes a tray, with guide rods symmetrically fixedly mounted on the lower surface of the tray. The outer surfaces of the guide rods are slidably mounted on the upper surface of the vehicle body. A return spring is sleeved on the outer surface of the guide rod near the lower surface of the vehicle body. One end of the return spring is fixedly mounted on the guide rod, and the other end is fixedly mounted on the lower surface of the vehicle body. A pull rod is rotatably mounted on the end of the guide rod away from the tray, and a linkage block is rotatably mounted on the end of the pull rod away from the guide rod. A guide groove is formed around the circumference of the upper surface of the vehicle body, and the outer surface of the linkage block is slidably mounted in the guide groove. A positioning platform is fixedly mounted on the end of the linkage block away from the pull rod. Positioning bases are installed around the upper surface of the vehicle body, and the positioning platform is slidably mounted on the upper surface of the positioning base. The linkage block is fixedly mounted on the lower surface of the positioning platform through the positioning base. The self-positioning mechanism also includes a linkage anti-vibration component, which includes a transmission pressure rod. The outer surface of the middle part of the transmission pressure rod is slidably installed in the positioning platform. An L-shaped groove is formed on the outer surface of the middle part of the transmission pressure rod. A guide block is slidably installed in the L-shaped groove. The guide block is fixedly installed in the positioning platform. An auxiliary groove is formed near the bottom of the tray on the positioning platform. A sliding tooth is provided in the auxiliary groove. The lower end of the transmission pressure rod is installed on the sliding tooth. The transmission pressure rod is slidably installed in the sliding tooth through a limiting groove. An L-shaped guide plate is engaged with the tooth surface of the sliding tooth. The L-shaped guide plate is slidably installed in the middle of the positioning platform. A limiting groove is formed on the side of the positioning platform near the upper mold. A top plate is installed in the limiting groove. One end of the L-shaped guide plate passes through the limiting groove and is fixedly installed on the top plate. A tension spring is fixedly installed at the other end of the L-shaped guide plate. The end of the tension spring away from the L-shaped guide plate is fixedly installed on the positioning platform.

[0015] Preferably, the cleaning and protection mechanism includes a pressure shaft, which is fixedly installed in the middle of the lower surface of the tray. A turntable is rotatably installed below the middle of the upper surface of the vehicle body. A transmission sleeve is fixedly installed on the lower surface of the turntable. A semi-circular groove is symmetrically formed in the middle of the transmission sleeve. A pressing rod is fixedly installed in the middle of the pressure shaft. The pressing rod is slidably installed in the semi-circular groove on the inner surface of the transmission sleeve. An auxiliary spring is rotatably installed on the lower surface of the transmission sleeve. The auxiliary spring is sleeved on the outer surface of the pressure shaft, and the end of the auxiliary spring away from the transmission sleeve is fixedly installed on the pressure shaft. A linkage groove is formed on the circumference of the turntable. A slider is slidably installed in the linkage groove, and a power rod is fixedly installed on the slider. The end of the power rod away from the turntable is slidably installed through the vehicle body. A multi-functional plate is fixedly installed through the upper surface of the vehicle body. The multi-functional plate is slidably installed on the upper surface of the vehicle body. The upper surface of the multi-functional plate is covered with a high-temperature resistant flexible material. The multi-functional plate can be used for supporting and absorbing vibration of the lower mold, and can also be used for cleaning residue during casting on the upper surface of the vehicle body. The trolley fixing device can be adapted to molds of different specifications and has a locking and fixing structure to ensure that the mold does not shift during movement and operation of each process, further improving the positioning accuracy.

[0016] Preferably, the system includes a control host, an instruction input module, an execution module, a detection module, and a mode switching module. The control host is electrically connected to the instruction input module, the execution module, the detection module, and the mode switching module, and establishes a communication connection with each device on the production line. The mode switching module is used to switch between fully automatic, semi-automatic, and manual modes. The detection module is used to collect the operating parameters, mold status, and process completion status of each device on the production line in real time, and feeds back the collected signals to the control host. Based on the preset program and the signals fed back by the detection module, the control host controls the coordinated operation of each device through the execution module to automatically complete the entire process. At the same time, it can receive manual instructions from the instruction input module to realize independent operation, debugging, and model changeover of a single mold.

[0017] Preferably, the detection module includes a temperature sensor, a position sensor, a pressure sensor, and a sand detection sensor, which are used to detect the temperature of the water-cooled heating device, the operating position of each device, the mold closing pressure, and the sand cleaning effect, respectively, to ensure that the parameters of each process meet the production requirements; the control host has a built-in preset program that can store production process parameters for various castings, supports the modification, saving, and recall of process parameters, adapts to the production of castings of various specifications, and improves the compatibility of the production line.

[0018] Preferably, the control system also includes an alarm module. When the detection module detects abnormal operating parameters, device malfunction, or incomplete process, the alarm module issues an alarm signal and simultaneously controls the host to suspend the operation of the relevant process, facilitating troubleshooting and reducing the failure rate. The instruction input module includes a touch operation panel and a remote control interface. Staff can operate the system on-site via the touch operation panel or remotely debug, monitor, and input instructions via the remote control interface, making operation simple.

[0019] Compared with the prior art, the fully automated casting production line and its control system provided by the present invention have the following beneficial effects: This solution implements an integrated positioning mechanism that automatically centers the mold upon placement, completely changing the passive mode of traditional trolleys that rely on manual alignment and external drive positioning. The mold's own weight triggers the pallet to press down, and through the mechanical linkage of guide rods, pull rods, and linkage blocks, the positioning platform synchronously retracts towards the center, completing the rapid centering of the mold without additional power or manual intervention, thus solving the problems of inaccurate alignment and easy deviation between the trolley and the mold from the source.

[0020] The innovative design incorporates a circumferential positioning and top-surface clamping locking structure. Upon completion of centering, the linkage anti-vibration component is automatically triggered, and the transmission pressure rod rotates 90° downwards to achieve dual fixation of the mold's outer circumference and top surface. Compared to traditional single-point or single-sided limiting mechanisms, this method significantly improves mold stability under trolley movement and casting impacts, eliminates mold closing gaps and sand mold misalignment, and substantially enhances casting dimensional accuracy and product consistency.

[0021] The trolley integrates three functions: self-positioning, shock absorption and support, and automatic cleaning, achieving a modular design with multiple uses. When the mold is placed, the multi-functional plate automatically adheres to the bottom to provide shock absorption and cushioning. After the mold is removed, the multi-functional plate automatically pushes outward to scrape off the platform residue and collect it into the waste hopper. No manual cleaning is required throughout the process, which protects the mold and the trolley platform and maintains the cleanliness of the work area, solving the pain points of traditional trolleys that have limited functionality and cumbersome maintenance.

[0022] The production line and trolley device support multi-mode operation and independent single-mode operation, with a high degree of modularity and strong compatibility. The control system can switch between fully automatic, semi-automatic and manual modes with one click, adapting to different scenarios such as production, debugging and mold changing; the trolley can adapt to various mold specifications, with built-in locking and self-adaptive positioning structure, which enables fast mold change and good versatility, breaking through the limitations of traditional production lines that can only adapt to a single mold and lack flexibility.

[0023] The entire production line employs a closed-loop detection and intelligent linkage control system, which monitors parameters throughout the entire process, including positioning, temperature control, mold closing, and casting, in real time. Sensors for position, pressure, and temperature provide real-time feedback on any abnormalities, triggering an automatic alarm and suspending the corresponding process to prevent batch defects caused by positioning deviations or temperature anomalies. Compared to traditional manual inspections and extensive control, this solution offers higher stability and a lower failure rate, truly achieving high-precision, high-efficiency, and intelligent fully automated casting production. Attached Figure Description

[0024] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is an auxiliary schematic diagram of the three-dimensional structure of the present invention; Figure 3 This is a schematic diagram of the connection relationship of the self-positioning mechanism structure of the present invention; Figure 4 For the present invention Figure 3 Enlarged view of point A in the middle; Figure 5 This is an auxiliary schematic diagram showing the connection relationship of the self-positioning mechanism structure of the present invention; Figure 6 For the present invention Figure 5 Enlarged view at point B in the middle; Figure 7 This is a schematic diagram of the structural connection relationship of the cleaning and protection mechanism of the present invention; Figure 8 For the present invention Figure 7 Enlarged view of point C in the middle.

[0025] In the picture: 1. Car body; 11. Track wheels; 12. Waste hopper; 13. Upper mold; 14. Lower mold; 2. Self-positioning mechanism; 21. Tray; 22. Guide rod; 23. Return spring; 24. Pull rod; 25. Linkage block; 26. Guide groove; 27. Positioning base; 28. Positioning table; 3. Linkage anti-vibration component; 31. Transmission pressure rod; 32. Guide block; 33. L-shaped slide groove; 34. Sliding tooth; 35. L-shaped guide plate; 36. Tension spring; 37. Top plate; 4. Cleaning and protection mechanism; 41. Pressure shaft; 42. Turntable; 43. Transmission sleeve; 44. Auxiliary spring; 45. Extrusion rod; 46. Extrusion groove; 47. Linkage groove; 48. Power rod; 49. Multifunctional plate. Detailed Implementation

[0026] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0027] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0028] Example 1, please refer to Figures 1 to 8 As shown: To address the problems mentioned in the technical solutions, this application provides a fully automated casting production line and its control system. The system includes a sequentially connected and coordinated mold-lifting device, a separate demolding device, a sand-cleaning device, a sand-cleaning and mold-fixing device, a water-cooling and heating device, a molding device, a mold-closing and demolding device, and a precision-positioning and pouring device. It also includes a trolley fixing device, a running track, and a control system. The running track runs the entire production line, and the trolley fixing device can move along the track to fix the molds. Each device is electrically connected to the control system, realizing the integration of the entire process: mold lifting, demolding, flipping, sand cleaning, water cooling, heating, molding, mold closing, mold dropping, and precision pouring. This production line adopts a modular design, supporting fully automatic, semi-automatic, and manual operation modes, and can achieve independent operation of a single mold, adapting to various casting production needs. Each device can automatically complete temperature control, flipping, cleaning, and mold-closing positioning actions, ensuring continuous and precise positioning of each process, effectively improving sand mold accuracy and production stability.

[0029] The sand cleaning device and the sand cleaning and fixing mold device work together. The sand cleaning and fixing mold device is used to fix the mold to be cleaned. The sand cleaning device performs all-round sand cleaning operation on the fixed mold, thoroughly removing the sand material remaining on the mold surface and cavity, ensuring the cleanliness of the mold, and avoiding the sand material residue from affecting the casting quality.

[0030] The water-cooled heating device integrates water cooling and heating functions, and can automatically switch working modes according to production process requirements. It can accurately control the temperature of molds or sand molds, flexibly match the molding temperature requirements of different castings, and ensure that the molding effect of castings meets the standards.

[0031] The mold closing and unclosing device integrates mold closing and unclosing functions. During the mold closing process, it can achieve precise positioning to ensure mold closing accuracy; during the mold unclosing process, the action is smooth, effectively avoiding damage to the sand mold or casting, and further improving production stability.

[0032] The trolley fixing device includes a trolley body 1, with track wheels 11 evenly installed at the bottom of the trolley body 1 for easy movement along the running track; waste hoppers 12 are symmetrically installed in the middle of the trolley body 1 for collecting waste slag generated during the production process; an upper mold 13 and a lower mold 14 for casting are respectively installed on the top of the trolley body 1. The trolley fixing device also includes a self-positioning mechanism 2 and a cleaning and protection mechanism 4, wherein the self-positioning mechanism 2 is located below the upper mold 13 and the lower mold 14 for automatic support and positioning of the upper mold 13 and the lower mold 14 during mold closing and casting; the cleaning and protection mechanism 4 is located inside the trolley body 1 for shock absorption and buffering when the upper mold 13 is supported, and for slag removal and cleaning of the trolley body 1 platform.

[0033] Furthermore, such as Figure 4 As shown, guide rods 22 are symmetrically fixedly installed on the lower surface of the tray 21, and the outer surface of the guide rods 22 is slidably mounted on the upper surface of the vehicle body 1. A return spring 23 is sleeved on the outer surface of the guide rods 22 near the lower surface of the vehicle body 1. One end of the return spring 23 is fixedly installed on the guide rod 22, and the other end is fixedly installed on the lower surface of the vehicle body 1. A pull rod 24 is rotatably installed on the end of the guide rod 22 away from the tray 21, and a linkage block 25 is rotatably installed on the end of the pull rod 24 away from the guide rod 22. A guide groove 26 is opened in the circumferential direction on the upper surface of the vehicle body 1, and the outer surface of the linkage block 25 is slidably mounted in the guide groove 26. A positioning platform 28 is fixedly installed on the end of the linkage block 25 away from the pull rod 24. A positioning base 27 is installed around the upper surface of the vehicle body 1. The positioning platform 28 is slidably mounted on the upper surface of the positioning base 27, and the linkage block 25 passes through the positioning base 27 and is fixedly installed on the lower surface of the positioning platform 28.

[0034] When the upper mold 13 and lower mold 14 are closed and placed on the upper surface of the tray 21 for casting, the weight of the upper mold 13 and lower mold 14 will cause the tray 21 to move downward. During the downward movement of the tray 21, the return spring 23 is stretched on one hand, and the guide rod 22 drives the pull rod 24 to pull the linkage block 25 to move inward along the guide groove 26 on the other hand. When the linkage block 25 moves inward, it simultaneously drives the positioning table 28 to slide along the positioning base 27, which squeezes and centers the edge of the lower mold 14, effectively reducing the tilting and offset of the lower mold 14 and the upper mold 13 during the casting process and ensuring the casting accuracy.

[0035] Furthermore, such as Figure 6As shown, the outer surface of the transmission pressure rod 31 is slidably mounted in the positioning table 28. An L-shaped groove 33 is formed on its outer surface, and a guide block 32 is slidably installed within the L-shaped groove 33. The guide block 32 is fixedly mounted inside the positioning table 28. An auxiliary groove is formed at the bottom of the positioning table 28 near the tray 21. A sliding tooth 34 is provided in the auxiliary groove. The lower end of the transmission pressure rod 31 is fixedly mounted on the sliding tooth 34 and slidably mounted within the sliding tooth 34 through a limiting groove. An L-shaped guide plate 35 is slidably mounted in the middle of the positioning table 28. A limiting groove is formed on the side of the positioning table 28 near the upper mold 13. A top plate 37 is installed in the limiting groove. One end of the L-shaped guide plate 35 passes through the limiting groove and is fixedly mounted on the top plate 37. A tension spring 36 is fixedly mounted on the other end. The end of the tension spring 36 away from the L-shaped guide plate 35 is fixedly mounted on the positioning table 28.

[0036] When the positioning platform 28 comes into contact with the outer surfaces of the lower mold 14 and the upper mold 13, such as Figure 1 As shown, the top plate 37 contacts and moves relative to the lower mold 14 and the upper mold 13, thereby driving the L-shaped guide plate 35 to move outward; since the L-shaped guide plate 35 meshes with the sliding tooth 34, the outward movement of the L-shaped guide plate 35 will drive the sliding tooth 34 to rotate clockwise, and the rotation of the sliding tooth 34 will synchronously drive the transmission pressure rod 31 to rotate. Figure 5 and Figure 6 As shown, under the guiding and limiting action of the guide block 32 and the L-shaped slide groove 33, the sliding tooth 34 drives the transmission pressure rod 31 to rotate 90° clockwise and then simultaneously produces a downward pressing action. Since the sliding tooth 34 is rotatably assembled in the auxiliary groove, the transmission pressure rod 31 slides down along the sliding tooth 34 and completes the rotation under the guiding action of the L-shaped slide groove 33. Its upper end is finally pressed against the upper surface of the upper mold 13, realizing the multi-angle synchronous fixation of the upper mold 13 and the lower mold 14, ensuring the stability of the mold during translation and each process operation.

[0037] Specifically, the pressure shaft 41 is fixedly installed in the middle of the lower surface of the tray 21. A turntable 42 is rotatably installed below the middle of the upper surface of the vehicle body 1. A transmission sleeve 43 is fixedly installed on the lower surface of the middle of the turntable 42. A semi-circular groove is symmetrically opened in the middle of the transmission sleeve 43. An extrusion rod 45 is fixedly installed in the middle of the pressure shaft 41. The extrusion rod 45 is slidably fitted in the semi-circular groove opened in the inner surface of the transmission sleeve 43. An auxiliary spring 44 is rotatably installed on the lower surface of the transmission sleeve 43. The auxiliary spring 44 is sleeved on the outer surface of the pressure shaft 41, and the end away from the transmission sleeve 43 is fixedly installed on the pressure shaft 41. A linkage groove 47 is opened in the circumferential direction on the turntable 42. A slider is slidably installed in the linkage groove 47. A power rod 48 is fixedly installed on the slider. The end of the power rod 48 away from the turntable 42 passes through and is slidably fitted on the vehicle body 1. A multi-functional plate 49 is fixedly installed at the end that passes through the upper surface of the vehicle body 1. The multi-functional plate 49 is slidably mounted on the upper surface of the vehicle body 1. Its surface is covered with a high-temperature resistant flexible material, which can be used to support and dampen the lower mold 14, as well as to clean the casting residue on the upper surface of the vehicle body 1.

[0038] The waste hopper 12 is slidably mounted inside the vehicle body 1 and features a detachable and replaceable material box design for easy cleaning and transfer of waste residue. When the upper mold 13 and lower mold 14 are detached from the vehicle body 1 via the mold-lifting device, as... Figure 7 As shown, under the elastic reset action of the auxiliary spring 44, the cleaning and protection mechanism 4 drives the pressure shaft 41 to push the tray 21 upward. At this time, the extrusion rod 45 exerts an extrusion action on the extrusion groove 46 inside the transmission sleeve 43. Since the extrusion groove 46 is symmetrically opened at a 90° circumferential angle on the inner surface of the transmission sleeve 43, when the pressure shaft 41 slides upward, it will drive the transmission sleeve 43 to drive the turntable 42 to rotate clockwise. During the rotation of the turntable 42, the slider on the power rod 48 is extruded through the linkage groove 47, which drives the power rod 48 to drive the multi-functional plate 49 to slide outward along the upper surface of the vehicle body 1, pushing the metal debris splashed on the surface of the vehicle body 1 during the casting process to the outside, so that it falls into the waste hopper 12 for collection. Similarly, when the upper mold 13 and the lower mold 14 are placed on the upper surface of the tray 21 after the mold is closed, their own weight will drive the cleaning and protection mechanism 4 to drive the multi-functional plate 49 to move closer to the lower surface of the lower mold 14, thereby supporting and absorbing the vibration of the lower surface of the lower mold 14. The trolley fixing device can be adapted to molds of different specifications and has a reliable locking and fixing structure to ensure that the mold does not shift during movement and operation of each process, thereby further improving the positioning accuracy.

[0039] The control system includes a control host, an instruction input module, an execution module, a detection module, and a mode switching module. The control host is electrically connected to the instruction input module, execution module, detection module, and mode switching module, and establishes communication connections with each device on the production line. The mode switching module is used to switch between fully automatic, semi-automatic, and manual operating modes. The detection module is used to collect the operating parameters, mold status, and process completion status of each device on the production line in real time, and feeds back the collected signals to the control host in real time. Based on the preset program and the signals fed back by the detection module, the control host controls the coordinated operation of each device through the execution module to automatically complete the entire casting process. At the same time, it can receive manual instructions from the instruction input module to realize independent operation of a single mold, equipment debugging, and mold changeover operations.

[0040] The detection module includes temperature sensors, position sensors, pressure sensors, and sand detection sensors, which are used to detect the temperature parameters of the water-cooled heating device, the operating position of each device, the mold closing pressure, and the sand cleaning effect, respectively, to ensure that the parameters of each process meet the preset production requirements. The control host has built-in preset programs that can store production process parameters for various castings, support the modification, saving, and recall of process parameters, adapt to the production of castings of various specifications, and effectively improve the compatibility and flexibility of the production line.

[0041] The control system also includes an alarm module. When the detection module detects abnormal operating parameters, equipment malfunctions, or processes not being completed as required, the alarm module immediately issues an alarm signal. Simultaneously, the control host suspends the operation of the relevant process, facilitating timely troubleshooting and problem-solving by staff, thus reducing the production failure rate. The command input module includes a touch-screen control panel and a remote control interface. Staff can operate the equipment on-site via the touch-screen control panel or remotely debug, monitor operation, and input commands via the remote control interface. This convenient and efficient operation reduces the workload of manual labor.

[0042] Example 2: Based on Embodiment 1, but with some differences, the fully automated casting production line and its control system proposed in this invention will be described below with reference to specific examples and accompanying drawings. The specific content is as follows.

[0043] This embodiment provides a specific implementation plan for a fully automated casting production line that can be directly implemented, has a complete structure, and clearly defined operations. Figures 1 to 8 The device composition, workflow, mechanical linkage and control logic are described in detail.

[0044] This fully automated casting production line includes: a mold-lifting device, a separate demolding device, a sand-removing device, a sand-removing and mold-fixing device, a water-cooling and heating device, a molding device, a mold-closing and demolding device, a precision positioning and casting device, as well as a running track running through the entire line, a trolley fixing device moving along the track, and a control system. All devices on the line are connected sequentially and work together, driven by a unified control system to achieve fully automated integration of the entire process: mold lifting → demolding → flipping → sand removal → water cooling / heating → molding → mold closing → demolding → precision casting.

[0045] The production line adopts a modular design, supports switching between fully automatic, semi-automatic and manual modes, and can achieve independent operation of a single module, adapting to the production of multiple varieties and specifications of castings.

[0046] II. Specific structure of the trolley fixing device; The trolley fixing device includes a trolley body 1, track wheels 11, waste hopper 12, upper mold 13, lower mold 14, as well as a self-positioning mechanism 2, a linkage anti-vibration component 3, and a cleaning and protection mechanism 4.

[0047] The self-positioning mechanism 2 includes a tray 21, a guide rod 22, a return spring 23, a pull rod 24, a linkage block 25, a guide groove 26, a positioning base 27, and a positioning platform 28.

[0048] Below the tray 21, symmetrical guide rods 22 are fixed, and the guide rods 22 are slidably mounted on the vehicle body 1; a return spring 23 is sleeved on the lower end of the guide rod 22, and a pull rod 24 is hinged to the end; the other end of the pull rod 24 is hinged to a linkage block 25, and the linkage block 25 slides in the guide groove 26 of the vehicle body 1; the upper end of the linkage block 25 is connected to a positioning table 28, and the positioning table 28 slides along the positioning base 27.

[0049] Working process: When the upper and lower molds are closed and placed on the tray 21, the weight of the molds causes the tray 21 to press down, the guide rod 22 moves down and pulls the pull rod 24, which drives the linkage block 25 to move towards the center along the guide groove 26, so that the positioning table 28 clamps the outer periphery of the mold simultaneously, realizing automatic centering and one-time positioning, avoiding deviation during pouring and movement.

[0050] The linkage anti-vibration component 3 includes a transmission pressure rod 31, a guide block 32, an L-shaped slide groove 33, a sliding tooth 34, an L-shaped guide plate 35, a tension spring 36, and a top plate 37.

[0051] The transmission pressure rod 31 has an L-shaped groove 33, which cooperates with the guide block 32 fixed on the positioning table 28; the lower end of the transmission pressure rod 31 is connected to the sliding tooth 34, and the sliding tooth 34 meshes with the L-shaped guide plate 35; one end of the L-shaped guide plate 35 is connected to the top plate 37, and the other end is reset by the tension spring 36.

[0052] Working process: When the positioning table 28 clamps the mold, the top plate 37 is pressed and pushes the L-shaped guide plate 35 to move outward, which drives the sliding tooth 34 to rotate. This causes the transmission pressure rod 31 to complete a 90° rotation and press down under the guidance of the L-shaped slide groove 33, pressing the top surface of the upper mold 13 tightly. This achieves double locking of circumferential positioning and top surface pressing, greatly improving the stability of the mold.

[0053] The cleaning and protection mechanism 4 includes a pressure shaft 41, a turntable 42, a transmission sleeve 43, an auxiliary spring 44, a pressing rod 45, a linkage groove 47, a power rod 48, and a multi-functional plate 49.

[0054] A pressure shaft 41 is fixed below the tray 21. The pressure shaft 41 cooperates with the transmission sleeve 43 through the extrusion rod 45. The transmission sleeve 43 drives the turntable 42 to rotate. The turntable 42 drives the power rod 48 through the linkage groove 47. The power rod 48 drives the multi-functional plate 49 to slide on the vehicle body 1. The surface of the multi-functional plate 49 is provided with a high-temperature resistant flexible material.

[0055] Work process: When placing the mold: press down on the tray → the multi-functional plate 49 moves towards the center to support and absorb shock; After the mold is released: the auxiliary spring 44 rebounds → the tray rises → the turntable rotates → the multi-functional plate 49 pushes outward, scraping off the residue on the vehicle body surface and sweeping it into the waste hopper 12 for collection.

[0056] In this solution, the control system includes a control host, an instruction input module, an execution module, a detection module, a mode switching module, and an alarm module.

[0057] Command input module: Configured with touch operation panel and remote control interface, supporting on-site operation and remote debugging.

[0058] Detection module: Equipped with temperature sensor, position sensor, pressure sensor, and sand detection sensor to collect temperature, position, mold closing pressure, and sand cleaning effect in real time.

[0059] Mode switching module: Enables quick switching between fully automatic, semi-automatic and manual modes, and supports independent operation of a single mode.

[0060] Alarm module: Immediately sound and light alarm when parameters are abnormal, faults occur, or processes are not completed, and the control host automatically suspends the corresponding process.

[0061] Control host: Built-in multiple sets of casting process parameters, which can be stored, modified and recalled, automatically coordinate the actions of various devices to ensure continuous process, accurate positioning and stable temperature control.

[0062] The trolley, secured by a fixed device, carries the mold along a track to the mold-lifting device for mold removal; it then enters a separate demolding device to separate the mold from the sand mold; next, it enters a sand-cleaning and fixing device combined with a sand-cleaning device, where the mold is fixed and thoroughly cleaned of sand; it then enters a water-cooling and heating device, where it automatically heats or cools according to the process, achieving precise temperature control; finally, it enters a molding device to compact the sand mold; then, it enters a mold-closing and dropping device for precise mold closure and smooth dropping without damaging the sand mold; finally, it enters a precision positioning and pouring device, where the trolley's self-positioning mechanism and linked anti-vibration components automatically center and lock, completing high-precision pouring; after pouring, the trolley continues to circulate, and after the mold is removed, a cleaning and protection mechanism automatically cleans the trolley body of any residue; the entire line is monitored in real time by a control system, with automatic alarms and shutdowns in case of abnormalities, ensuring production safety and product quality.

[0063] Compared with the prior art, this embodiment features automatic mold centering and locking, high positioning accuracy, and no deviation during trolley movement and casting; linkage anti-vibration, strong stability during mold closing and casting, and high consistency of casting dimensions; integrated cleaning and decontamination, eliminating the need for manual cleaning and reducing dust and residue accumulation; multi-mode and modular design, adaptable to various casting specifications, fast changeover, and strong versatility; intelligent closed-loop control, high degree of automation, low failure rate, and significantly improved production efficiency.

[0064] Please refer to the above work process. Figures 1 to 8 .

[0065] It should be noted that the term "comprising" or any other variation thereof is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0066] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A fully automated casting production line, characterized in that, The system includes a sequentially connected and coordinated mold-lifting device, a separate demolding device, a sand-cleaning device, a sand-cleaning and mold-fixing device, a water-cooling and heating device, a molding device, a mold-closing and demolding device, and a precision-positioning and casting device. It also includes a trolley fixing device, a running track, and a control system. The running track runs the entire length of the line, and the trolley fixing device can move along the track and is used to fix the mold. Each device is electrically connected to the control system, realizing the integration of the entire process of mold lifting, demolding, flipping, sand cleaning, water cooling, heating, molding, mold closing, mold dropping, and precision casting. The production line adopts a modular design, supporting fully automatic, semi-automatic, and manual multi-mode operation, and can achieve independent operation of a single mold, adapting to various casting production scenarios. Each device can automatically complete temperature control, flipping, cleaning, and mold-closing positioning actions, ensuring continuous action and precise positioning, improving sand mold accuracy and production stability.

2. The fully automated casting production line according to claim 1, characterized in that, The sand cleaning device works in conjunction with the sand cleaning and fixing mold device. The sand cleaning and fixing mold device is used to fix the mold to be cleaned. The sand cleaning device performs all-round sand cleaning operation on the fixed mold to remove residual sand from the mold surface and cavity.

3. The fully automated casting production line according to claim 1, characterized in that, The water-cooled heating device integrates water cooling and heating functions, and can automatically switch working modes according to production process requirements to achieve precise temperature control of molds or sand molds and meet the forming temperature requirements of different castings.

4. The fully automated casting production line according to claim 1, characterized in that, The mold closing and unclosing device integrates mold closing and unclosing functions. It can achieve precise positioning when closing the mold and smooth operation when unclosing the mold, avoiding damage to the sand mold or casting and ensuring production stability.

5. The fully automated casting production line according to claim 1, characterized in that, The trolley fixing device includes a trolley body (1), with track wheels (11) evenly installed at the bottom of the trolley body (1), and waste hoppers (12) symmetrically installed in the middle of the trolley body (1). An upper mold (13) and a lower mold (14) for casting are respectively installed on the top of the trolley body (1). The trolley fixing device also includes a self-positioning mechanism (2) and a cleaning and protection mechanism (4). The self-positioning mechanism (2) is located below the upper mold (13) and the lower mold (14), and the cleaning and protection mechanism (4) is located in the trolley body (1). The self-positioning mechanism (2) is used for automatic support and positioning of the upper mold (13) and the lower mold (14) when casting. The cleaning and protection mechanism (4) is used for shock absorption when the upper mold (13) is supported and for slag removal from the platform of the trolley body (1).

6. The fully automated casting production line according to claim 5, characterized in that, The self-positioning mechanism (2) includes a tray (21). Guide rods (22) are symmetrically fixedly installed on the lower surface of the tray (21). The outer surface of the guide rods (22) is slidably installed on the upper surface of the vehicle body (1). A return spring (23) is sleeved on the outer surface of the guide rods (22) near the lower surface of the vehicle body (1). One end of the return spring (23) is fixedly installed on the guide rod (22), and the other end of the return spring (23) is fixedly installed on the lower surface of the vehicle body (1). A pull rod (24) is rotatably installed on the end of the guide rod (22) away from the tray (21). 4) A linkage block (25) is rotatably installed at the end away from the guide rod (22). A guide groove (26) is opened around the upper surface of the vehicle body (1). The outer surface of the linkage block (25) is slidably installed in the guide groove (26). A positioning platform (28) is fixedly installed at the end of the linkage block (25) away from the pull rod (24). A positioning base (27) is installed around the upper surface of the vehicle body (1). The positioning platform (28) is slidably installed on the upper surface of the positioning base (27). The linkage block (25) passes through the positioning base (27) and is fixedly installed on the lower surface of the positioning platform (28). The self-positioning mechanism (2) further includes a linkage anti-vibration component (3), which includes a transmission pressure rod (31). The outer surface of the middle part of the transmission pressure rod (31) is slidably installed in the positioning platform (28). An L-shaped groove (33) is provided on the outer surface of the middle part of the transmission pressure rod (31). A guide block (32) is slidably installed in the L-shaped groove (33). The guide block (32) is fixedly installed in the positioning platform (28). An auxiliary groove is provided near the bottom of the tray (21) of the positioning platform (28), and a sliding tooth (34) is provided in the auxiliary groove. The lower end of the transmission pressure rod (31) is installed on the sliding tooth (34). The transmission pressure rod (31) is slidably installed in the sliding tooth (34) through the limiting groove. The tooth surface of the sliding tooth (34) is engaged with an L-shaped guide plate (35). The L-shaped guide plate (35) is slidably installed in the middle of the positioning table (28). The positioning table (28) has a limiting groove on the side near the upper mold (13). A top plate (37) is installed in the limiting groove. One end of the L-shaped guide plate (35) is fixedly installed on the top plate (37) through the limiting groove. A tension spring (36) is fixedly installed on the other end of the L-shaped guide plate (35). The end of the tension spring (36) away from the L-shaped guide plate (35) is fixedly installed on the positioning table (28).

7. The fully automated casting production line according to claim 6, characterized in that, The cleaning and protection mechanism (4) includes a pressure shaft (41), which is fixedly installed in the middle of the lower surface of the tray (21). A turntable (42) is rotatably installed below the middle of the upper surface of the vehicle body (1). A transmission sleeve (43) is fixedly installed on the lower surface of the middle of the turntable (42). A semi-circular groove is symmetrically opened in the middle of the transmission sleeve (43). A pressing rod (45) is fixedly installed in the middle of the pressure shaft (41). The pressing rod (45) is slidably installed in the semi-circular groove opened in the inner surface of the transmission sleeve (43). An auxiliary spring (44) is rotatably installed on the lower surface of the transmission sleeve (43). The auxiliary spring (44) is sleeved on the outer surface of the pressure shaft (41). The end of the auxiliary spring (44) away from the transmission sleeve (43) is fixedly installed on the pressure shaft (41). The upper circle of the turntable (42) The circumferential opening is provided with a linkage groove (47), in which a slider is slidably installed. A power rod (48) is fixedly installed on the slider. The end of the power rod (48) away from the turntable (42) is slidably installed on the vehicle body (1). A multi-functional plate (49) is fixedly installed on the upper surface of the vehicle body (1). The multi-functional plate (49) is slidably installed on the upper surface of the vehicle body (1). A high-temperature resistant flexible material is installed on the upper surface of the multi-functional plate (49). The multi-functional plate (49) can be used for supporting and damping the lower mold (14) and for cleaning the residue during casting on the upper surface of the vehicle body (1). The trolley fixing device can be adapted to molds of different specifications and has a locking and fixing structure to ensure that the mold does not shift during movement and operation of each process, thereby further improving the positioning accuracy.

8. A control system for a fully automated casting production line according to any one of claims 1-7, characterized in that, The system includes a control host, an instruction input module, an execution module, a detection module, and a mode switching module. The control host is electrically connected to the instruction input module, execution module, detection module, and mode switching module, and establishes communication connections with each device on the production line. The mode switching module is used to switch between fully automatic, semi-automatic, and manual modes. The detection module is used to collect the operating parameters, mold status, and process completion status of each device on the production line in real time, and feeds back the collected signals to the control host. Based on the preset program and the signals fed back by the detection module, the control host controls the coordinated operation of each device through the execution module to automatically complete the entire process. At the same time, it can receive manual instructions from the instruction input module to realize independent operation, debugging, and model change operations of a single mold.

9. The control system for the fully automated casting production line according to claim 8, characterized in that, The detection module includes a temperature sensor, a position sensor, a pressure sensor, and a sand detection sensor, which are used to detect the temperature of the water-cooled heating device, the operating position of each device, the mold closing pressure, and the sand cleaning effect, respectively, to ensure that the parameters of each process meet the production requirements. The control host has a built-in preset program that can store production process parameters for various castings, supports the modification, saving and recall of process parameters, adapts to the production of castings of various specifications, and improves the compatibility of the production line.

10. The control system for the fully automated casting production line according to claim 8, characterized in that, The control system also includes an alarm module. When the detection module detects abnormal operating parameters, device malfunction, or incomplete process, the alarm module issues an alarm signal and simultaneously controls the host to suspend the operation of the relevant process, facilitating troubleshooting and reducing the failure rate. The instruction input module includes a touch operation panel and a remote control interface. Staff can operate the system on-site via the touch operation panel or remotely debug, monitor, and input instructions via the remote control interface, making operation simple.

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