Foundry based on an additive manufacturing process

Abstract

A kind of foundry based on additive manufacturing process, belong to the field of casting technology, to solve the problem of complex process layout, insufficient automation level of foundry, including linearly arranged forming unit along any wall of foundry, vertically wall and setting by core pouring unit close to forming unit in the direction away from forming unit, further away from forming unit direction close to core pouring unit and set side by side with shakeout unit and cooling unit, melting unit is provided at one end of cooling unit and core pouring unit, and melting unit is set on the other side of cooling unit relative to shakeout unit, and post-processing unit is set close to cooling unit in the direction away from forming unit. Realize the mode of process separation and fixed-point operation combination, improve the space utilization of foundry, reduce cross operation, improve the safety between processes and within processes.

Description

Technical Field

[0001] This invention relates to the field of casting technology, and in particular to a foundry. Background Technology

[0002] In the traditional resin sand casting industry, factory layouts typically revolve around discrete processes such as core making, molding, mold assembly, melting, pouring, sand removal, and cleaning. This layout model generally faces the following technical problems in practical applications: 1) Complex logistics organization: The materials in the workshop rely heavily on overhead cranes for transportation, and the logistics routes are circuitous and intersecting, which not only results in low efficiency but also brings certain safety management challenges. 2) Difficulty in controlling the production environment: The high-temperature and high-dust processes such as box assembly, casting, and cooling are concentrated in the area, resulting in poor efficiency in the collection and treatment of smoke and dust, and making it difficult to maximize the effectiveness of environmental protection facilities; 3) Insufficient automation and informatization: Key processes rely on manual operation, and production data is difficult to collect in real time, which restricts the consistency control of product quality and the traceability of the whole process. 4) Poor layout flexibility: The existing fixed layout is difficult to adapt to the flexible production needs of multiple varieties and small batches, and also limits the integrated application of efficient logistics systems and energy-saving and environmental protection technologies.

[0003] Therefore, there is a lack of foundry layout solutions in the existing technology that can systematically optimize logistics, improve environmental friendliness, and adapt to the needs of intelligent production. Summary of the Invention

[0004] In view of the problems caused by the process layout of traditional foundries, such as complex logistics organization, difficulty in production environment control, insufficient automation and informatization, and poor layout flexibility, it is necessary to propose a foundry based on additive manufacturing technology, which realizes the green, safe and efficient nature of foundry.

[0005] A foundry based on additive manufacturing technology includes several process units and a logistics unit. The logistics unit is used to transfer objects between the various process units. The process units include a forming unit, a core casting unit, a melting unit, a cooling unit, a sand removal unit, and a post-processing unit. This achieves the purpose of process separation and fixed-point operation, and improves the safety and environmental protection of production operations.

[0006] Furthermore, to ensure the shortest cycle time, shortest object transfer path, and fewest transfers, the core assembly and casting unit includes sand core assembly, box embedding, and core package casting. The sand cores completed in the molding unit are transferred to the core assembly and casting unit. After core assembly and box embedding, the core package is cast. The core package consists of sand cores that form the inner and outer contours of the casting, or it consists of sand cores and a sand box embedded in a sand box that form the inner and outer contours of the casting.

[0007] Furthermore, the logistics unit includes several rail-guided transfer vehicles, which are connected to each work process via rails to complete the transfer of products between processes and realize the logistics of products within the entire foundry.

[0008] Furthermore, the molding unit includes several 3D printing devices for printing sand cores, a first track set on the common path of the entrance and exit of several 3D printing work boxes and a first rail-mounted transfer vehicle running on it, a work box buffer line at the end of the first track, a core output station and a first gantry robot set at the core output station in the direction away from the 3D printing devices, a sand cleaning line and an automatic sand cleaning room, a manual sand cleaning room and an intelligent testing room set in the sand cleaning line, an impregnation and coating area immediately after the sand cleaning line, a second rail-mounted transfer vehicle between the sand cleaning line and the impregnation and coating area, a second gantry robot set in the impregnation and coating area, a third track and a third rail-mounted transfer vehicle spanning the impregnation and coating area in the direction away from the sand cleaning line in the impregnation and coating area, and a drying area with drying equipment adjacent to the impregnation and coating area; through the various processes of the molding unit arranged above, the molding unit realizes fully automated production from molding sand to sand cores that can be directly used later.

[0009] Furthermore, the automatic sand cleaning chamber is equipped with an air knife for automatically cleaning the surface of the sand core. The air knife is mounted on a two-dimensional mounting frame that can move horizontally and vertically, located on the top of the automatic sand cleaning chamber. The air knife provides strong airflow, cleaning the surface of the sand core by blowing strong air onto it. The robotic arm sand cleaning chamber is equipped with a robotic arm, which is slidably mounted on a crossbeam located on the top of the manual sand cleaning chamber. An air outlet is located at the end of the robotic arm away from the crossbeam. By placing the air outlet at the outlet or inlet of the internal cavity of the sand core, high-pressure gas is used to blow away the sand core. The internal cavity is used to clean the floating sand in the internal cavity of the sand core. An optical detector is installed in the intelligent testing room to scan the sand core to form a point cloud map. The point cloud map is then compared with the sand core model to determine whether the sand core cleaning meets the cleaning requirements. The optical detector performs a full-area optical scan on the sand core after the sand cleaning operation, generating a three-dimensional point cloud model of the sand core. The three-dimensional point cloud model is compared with the original three-dimensional design model of the sand core in terms of contour and surface features. Based on the comparison results, it is determined whether the sand cleaning effect of the sand core meets the preset sand cleaning technical requirements.

[0010] Furthermore, to avoid mutual dust interference between the automatic sand cleaning room, the manual sand cleaning room, and the intelligent testing room, the three rooms are relatively independent and enclosed, and the sand core is conveyed by the sand cleaning roller conveyor through the roller shutter door located at the sand cleaning roller conveyor.

[0011] Furthermore, to facilitate the recycling of the trays used to hold sand cores and reduce the number of trays, the sand cleaning roller conveyor is configured as a two-layer structure, including an upper roller conveyor, a lower roller conveyor, and roller conveyor lifting devices at both ends. The upper roller conveyor is used to transport sand cores placed on the trays, and the lower roller conveyor is used to transport empty trays. The roller conveyor lifting device consists of a lifting platform, a scissor fork bracket, a servo electric push rod drive unit, and a guide limit mechanism. The lifting platform is equipped with conveying rollers of the same specifications as the roller conveyor to ensure smooth tray transition. The mounting base of the lifting device is fixed to the frame beams at both ends of the upper and lower roller conveyors with bolts, so that the lifting platform is flush with the upper roller conveyor when raised to the upper limit and flush with the lower roller conveyor when lowered to the lower limit.

[0012] Furthermore, the method for realizing the process from molding sand to core in the molding unit is as follows: S01, after the 3D printing equipment completes printing based on the printing data of the sand core to be produced, it issues a command to summon the first rail-guided transfer vehicle. The first rail-guided transfer vehicle transports the printed sand core from the sand core work box to the work box buffer line, where the sand core waits for curing. At the same time, the first rail-guided transfer vehicle picks up the empty work box from the work box buffer line and returns it to the corresponding 3D printing equipment, realizing the automatic replacement of the 3D printing equipment work box. S02, after the curing is completed, the work box containing the sand core is transferred by the first rail transfer vehicle to the core exit platform of the core exit station. The core exit platform is lifted and the sand core is pushed out of the sand box. The first truss robot grabs the sand core and places it on the sand cleaning roller. S03, the sand core placed on the sand cleaning roller conveyor enters the automatic sand cleaning room, then the manual sand cleaning room, and then the intelligent testing room to achieve sand cleaning and inspection of the sand core; S04, the sand core after sand cleaning is placed at one end of the sand cleaning roller conveyor opposite the immersion coating tank. The second rail-guided transfer car transfers the sand core after sand cleaning to the first receiving roller conveyor. The second gantry robot grabs the sand core from the first receiving roller conveyor and places it into the immersion coating tank for coating / immersion coating. In order to coat / immerse the sand core well, the sand core can be rotated at least two times in the immersion coating tank. After coating / immersion coating, the sand core is placed on the second receiving roller conveyor again, and the coating condition of the coated sand core placed on the second receiving roller conveyor is checked and the excess coating is allowed to stand and drain. S05, the coated sand cores are transferred by the second truss robot to the third rail-mounted transfer vehicle. The third rail-mounted transfer vehicle then transfers the coated sand cores to the drying equipment for drying. The dried sand cores are then transferred by a crane to the sand core automated storage and retrieval system.

[0013] Furthermore, the core assembly and casting unit includes a traveling crane, a sand core storage unit, a fourth rail-guided transfer vehicle, a core assembly station, a third gantry robot, a fifth rail-guided transfer vehicle, a mortise casting line, and a sand mixer and a casting machine installed within the mortise casting line. The sand core storage unit is arranged linearly parallel to the process direction of the molding unit, with at least one row of such storage units. A fourth track and a fifth track are arranged in a direction away from the molding unit and perpendicular to the sand core storage unit. A fourth rail-guided transfer vehicle is installed on the fourth track, and a fifth rail-guided transfer vehicle is installed on the fifth track. A core assembly station is located between the fourth and fifth tracks. The fourth rail-guided transfer vehicle transports sand cores from the sand core storage unit to the core assembly station, and the fifth rail-guided transfer vehicle transports the assembled sand cores to the mortise casting line. The mortise casting line is equipped with a mortise casting roller conveyor. The assembled sand cores and sand boxes are placed on the mortise casting roller conveyor by the traveling crane for sand core mortise casting and casting operations.

[0014] Furthermore, the operation process of the core casting unit is as follows: S11, the fourth rail-guided transfer vehicle transfers the corresponding sand cores from the automated warehouse to the core assembly platform at the core assembly station according to the core assembly plan; S12, the workers complete the assembly of the sand cores of the product to be produced on the core assembly platform according to the core assembly process; S13, after the sand core assembly is completed, the fifth rail-guided transfer car will take the sand core to the sand box casting line's sand box casting roller conveyor. S14, the operators, with the cooperation of the overhead crane and the sand mixer, complete the embedding of the sand core of the product to be produced according to the embedding process, forming the core package of the product to be produced with the sand box. S15. After the embedded molding sand in the core package has solidified, the core package is poured by the casting machine. S16, the completed core package is transferred to the cooling unit by a crane.

[0015] Furthermore, the smelting unit is located on one side of the core casting unit and in a direction adjacent to the buried box casting line, thereby minimizing the ladle transfer distance.

[0016] Furthermore, the cooling unit is arranged linearly adjacent to the buried box casting line and away from the sand core three-dimensional warehouse to achieve the shortest transfer distance of the core package after casting. In order to facilitate the transfer of the core package after casting, the fifth track spans the buried box casting line and the cooling unit, so that the fifth rail transfer car can transfer the cast core package to the cooling unit, and then the trolley of the cooling unit can transfer the cast core package to the cooling unit, where the molten metal to be produced is condensed.

[0017] Furthermore, the sand removal unit is located at the end of the cooling unit away from the melting unit. The sand removal unit is equipped with a core ladle storage platform and a sand removal vibration device. The solidified core ladle is transferred from the cooling unit to the core ladle storage platform by a crane, and then the crane is transferred to the sand removal vibration device according to the box-making plan to perform vibration sand removal operation on the casting.

[0018] Furthermore, the post-processing unit is arranged linearly in the direction away from the cooling unit and forming unit, and has several post-processing stations to achieve the purpose of cleaning several castings at the same time, so as to improve post-processing efficiency.

[0019] The beneficial effects of the technical solution of this invention: Achieve process separation and fixed-point operation: Through automated logistics systems such as RGV and automated warehouses, the processes of molding, core assembly, casting, and cooling are reasonably separated in space to reduce cross-operations and improve safety and environmental protection. Enhance automation and intelligence: Introduce fully automated systems for core extraction, sand cleaning, core assembly, core embedding, casting, and post-processing, significantly reducing manual intervention and improving production efficiency and product quality consistency; A traceable casting circulation system that allows castings to be transferred without touching the ground: By combining an automated warehouse with a conveyor system, castings can be transferred from sand removal to final inspection without touching the ground, ensuring information traceability and efficient use of space. Building a green, safe, and efficient modern foundry: Through overall layout optimization and intelligent equipment integration, we achieve a systematic improvement in environmental protection, safety, and production management. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall layout of the foundry for this patent. Figure 2 This is a schematic diagram of the molding unit layout; Figure 3 This is a schematic diagram of the sand removal line layout; Figure 4 This is a schematic diagram of the core casting unit layout; Figure 5 This is a schematic diagram of the layout of the core casting unit for the bare casting process; Figure 6 This is a schematic diagram of the overall layout of a casting plant using the bare casting process; The components are as follows: 1-3D printing equipment; 2-First track; 3-First rail-guided transfer vehicle; 4-Work box buffer line; 5-Core output station; 6-First gantry robot; 7-Sand cleaning line; 8-Sand cleaning roller conveyor; 9-Second track; 10-Second rail-guided transfer vehicle; 11-Immersion coating area; 12-Second gantry robot; 13-Third track; 14-Third rail-guided transfer vehicle; 15-Sand core automated storage; 16-Fourth track; 17-Fourth rail-guided transfer vehicle; 18-Fifth track; 19-Fifth rail-guided transfer vehicle; 20-Core assembly station; 21-Core assembly table; 22-Third gantry robot; 23-Buried box casting line. Detailed Implementation

[0021] To more clearly illustrate the technical solution of the present invention, the technical solution of the invention will be described in detail with reference to the accompanying drawings. Obviously, the following description is some typical embodiments of the present invention. For those skilled in the art, other solutions can be obtained based on these embodiments without creative effort.

[0022] One implementation scheme for a foundry layout based on additive manufacturing processes achieves a combination of process separation and fixed-point operation by setting up rail-guided transfer vehicles and automated warehouses between processes. This improves the space utilization of the foundry, reduces cross-operations, and enhances the safety of operations between and within processes. By combining overhead cranes with gantry robots and rail-guided transfer vehicles in the process, the non-ground transfer of sand cores and castings is achieved, improving operational efficiency.

[0023] Note: Molding units along the process travel direction are defined as linearly aligned, and those perpendicular to the process travel direction of the molding unit are defined as perpendicular. Similarly, the linear alignment and perpendicular direction of the relative positional relationship between other processes are the same as the direction and position of the molding units defined above.

[0024] In this embodiment, such as Figure 1The diagram shows the layout of a foundry according to this embodiment. A foundry based on 3D printing equipment 1 includes several process units and a logistics unit. The logistics unit is used to transfer objects, such as sand cores and core packages, between the various process units. The process units include a molding unit, a core assembly and casting unit, a melting unit, a cooling unit, a sand removal unit, and a post-processing unit. This achieves the purpose of process separation and fixed-point operation, and improves the safety and environmental protection of production operations. The molding unit is linearly arranged along any wall of the foundry. The core assembly and casting unit is arranged perpendicular to the wall and adjacent to the molding unit in the direction away from the molding unit. The sand removal unit and the cooling unit are arranged side by side adjacent to the core assembly and casting unit in the direction away from the molding unit. The melting unit is located at one end of the cooling unit and the core assembly and casting unit and is located on the other side of the cooling unit relative to the sand removal unit. The post-processing unit is located adjacent to the cooling unit in the direction away from the molding unit. Through the arrangement of the above process units, the logistics operation with the shortest logistics distance and no product touching the ground is achieved, which improves the overall operation efficiency of the foundry and shortens the cycle time of logistics operations.

[0025] As a supplement to this embodiment, in order to achieve continuous and fixed-point operation of the process, the core assembly and casting unit includes the processes of sand core assembly, box embedding, and core package casting. The sand cores completed in the molding unit are transferred to the core assembly and casting unit. After core assembly and box embedding, the core package is cast. The core package consists of sand cores that form the inner and outer contours of the casting, or it consists of sand cores that form the inner and outer contours of the casting and a sand box embedded in a sand box.

[0026] As a supplement to this embodiment, the logistics unit includes several tracks and rail-mounted transfer vehicles. Each rail-mounted transfer vehicle is connected to each work process via tracks to complete the transfer of products between processes, thereby realizing the logistics of products throughout the entire foundry. Specifically, the logistics unit includes a first track 2, a second track 9, a third track 13, a fourth track 16, and a fifth track 18, as well as a first rail-mounted transfer vehicle 3, a second rail-mounted transfer vehicle 10, a third rail-mounted transfer vehicle 14, a fourth rail-mounted transfer vehicle 17, and a fifth rail-mounted transfer vehicle 19 running on the five tracks. The first rail-mounted transfer vehicle 3, the second rail-mounted transfer vehicle 10, and the third rail-mounted transfer vehicle 14 are arranged in the molding unit, while the fourth rail-mounted transfer vehicle 17 and the fifth rail-mounted transfer vehicle 19 are arranged in the core casting unit, realizing the transfer of objects within the two units and between the two major processes.

[0027] As a supplement to this embodiment, the molding unit includes several 3D printing devices 1 for printing sand cores, a first track 2 set on the common path of the entrance and exit of several 3D printing work boxes, and a first rail-guided transfer vehicle 3 running on it. A work box buffer line 4 is provided at the end of the first track 2 extending outside the 3D printing devices 1. A core output station 5 and a first gantry robot 6 set on the core output station 5 are also provided at the outer end of the first track 2 with the work box buffer line 4. Immediately following the track 2, a sand cleaning line 7 is provided, as well as an automatic sand cleaning room, a manual sand cleaning room, and an intelligent testing room set on the sand cleaning line 7. Following the linear sand-cleaning line 7 is an impregnation and coating zone 11. Between the sand-cleaning line 7 and the impregnation and coating zone 11 is a second rail-guided transfer vehicle 10. A second gantry robot 12 is located in the impregnation and coating zone 11. A third track 13 and its third rail-guided transfer vehicle 14 span the impregnation and coating zone 11 away from the sand-cleaning line 7. Adjacent to the impregnation and coating zone 11, in a linear direction perpendicular to the molding unit and away from the wall, is a drying zone containing drying equipment. Through the various processes of the molding unit arranged above, the molding unit achieves fully automated production from molding sand to sand cores that can be directly used later. Specifically, as shown... Figure 2As shown, several 3D printing devices 1 are arranged in two rows on one side of the forming unit. A first track 2 for carrying a first rail-mounted transfer vehicle 3 is provided between the two rows of 3D printing devices 1. The first track 2 is parallel to the two rows of forming lines of the 3D printing devices 1. The work box entry / exit track of the 3D printing devices 1 is perpendicularly connected to the first track 2, enabling the first rail-mounted transfer vehicle 3 to transfer the work box into and out of the 3D printing devices 1. At both ends of the first track 2, work box buffer lines 4 are also provided for storing work boxes. The work box buffer lines 4 are formed by… Several roller conveyors are arranged side-by-side on both sides of the first track 2. More specifically, one roller conveyor is used to store work boxes containing sand cores, and the other roller conveyor is used to store empty work boxes. The first rail-guided transfer vehicle 3 is responsible for transferring work boxes between the work box buffer line 4 and the 3D printing equipment 1, realizing automatic replacement of work boxes in the 3D printing equipment 1. The next step is the core ejection station 5, which is equipped with a first gantry robot 6. The first gantry robot 6 transfers the work box containing sand cores from the work box buffer line 4 to the core ejection platform of the core ejection station 5, and ejects the sand cores from the work box on the core ejection platform. The core is then removed from the core outlet; the next step is the sand cleaning line 7. The automatic sand cleaning room, manual sand cleaning room, and intelligent testing room within the sand cleaning line 7 are connected by a sand cleaning roller conveyor 8 that runs through the sand cleaning line 7. This allows the sand cores from the core outlet station 5 to automatically and smoothly travel from the automatic sand cleaning room to the manual sand cleaning room and then to the intelligent testing room. The sand cleaning roller conveyor 8 not only runs through the sand cleaning line 7 but also has a working box-like length between the sand cleaning line 7's enclosed space and the preceding core outlet station 5 and the following immersion coating tank. This facilitates the temporary storage of sand cores awaiting sand cleaning and those that have been cleaned, thus making it easier to feed the sand cores into the immersion coating tank. The sand cleaning line 7 and the sand cleaning roller conveyor 8 extend into the core exit station 5 to facilitate the first gantry robot 6 placing the extracted sand cores onto the sand cleaning roller conveyor 8, thereby facilitating the transfer of sand cores from the core exit station 5 to the sand cleaning line 7. In the direction opposite to the sand cleaning line 7 and the immediately following dip coating area 11, the sand cleaning roller conveyor 8 also extends into the dip coating area 11 to accommodate at least one sand core, facilitating the transfer of sand cores from the sand cleaning line 7 to the dip coating area 11. Furthermore, to improve sand cleaning efficiency, three sand cleaning roller conveyors 8 are arranged parallel to the sand cleaning line 7, meaning that three sand cores can be sanded simultaneously.The next step is the dip coating zone 11. A second track 9 is provided in a direction perpendicular to the sand-cleaning line 7 and the advance direction of the dip coating zone 11. A second rail-mounted transfer vehicle 10 is mounted on the second track 9. At least one first receiving roller conveyor is also provided in the direction opposite to the sand-cleaning line 7 in the dip coating zone 11. The second rail-mounted transfer vehicle 10 transfers the cleaned sand cores from the sand-cleaning roller conveyor 8 to the first receiving roller conveyor. At least one second receiving roller conveyor is also provided in the direction away from the exit of the sand-cleaning line 7 in the dip coating zone 11. The second receiving roller conveyor is used to temporarily store the dip-coated sand cores to check whether the dip coating is qualified and to allow excess coating to flow away from the sand cores. A second gantry robot 12 is provided in the dip coating tank area. The second gantry robot 12 is responsible for picking up the sand cores stored on the first receiving roller conveyor and immersing them in the coating tank for coating. The coated sand cores are then placed on the second receiving roller conveyor, and the second gantry robot 12 transfers the qualified coated sand cores stored on the second receiving roller conveyor to the third rail-guided transfer vehicle 14. The third rail 13, which carries the third rail-guided transfer vehicle 14, is set perpendicular to the process travel direction and in the direction of the coating tank outlet. The immediate following step is the drying process, which includes drying equipment arranged linearly parallel to the first rail 2 and alongside the coating tank. This ensures the shortest possible transfer distance for the coated sand cores to the drying equipment. After drying, the sand cores can then proceed to the subsequent core casting unit.

[0028] As a further supplement to this embodiment, the sand cleaning room is divided into three independent spaces: an automatic sand cleaning room, a manual sand cleaning room, and an intelligent testing room. Each independent space is connected by a roller shutter door. The automatic sand cleaning room is equipped with an air knife for automatically cleaning loose sand from the surface of the sand core. The air knife is mounted on a two-dimensional mounting frame located at the top of the automatic sand cleaning room, which can move horizontally and extend vertically. The air knife provides strong airflow, cleaning the loose sand from the surface of the sand core by blowing strong air onto it. The manual sand cleaning room is equipped with a robotic arm, which is slidably mounted on a horizontal... The beam includes a robotic arm, which can be a three-axis robotic arm. An air outlet is located at the end of the robotic arm furthest from the beam. By placing the air outlet at the outlet or inlet of the internal cavity of the sand core, high-pressure gas is used to blow away the floating sand within the sand core cavity, thus cleaning the floating sand. An optical detector is installed in the intelligent testing room. This optical detector performs a full-area optical scan of the sand core after the sand cleaning operation, generating a three-dimensional point cloud model of the sand core. This three-dimensional point cloud model is compared with the original three-dimensional design model of the sand core in terms of contour and surface features. Based on the comparison results, it is determined whether the sand cleaning effect of the sand core meets the preset sand cleaning technical requirements.

[0029] As a further supplement to this embodiment, to facilitate the recycling of the trays used to hold sand cores and reduce the number of trays, the sand cleaning roller conveyor 8 is configured as a two-layer structure, including an upper roller conveyor, a lower roller conveyor, and roller conveyor lifting devices at both ends. The upper roller conveyor is used to transport sand cores placed on the trays, and the lower roller conveyor is used to transport empty trays. The roller conveyor lifting device structure consists of a lifting platform, a scissor fork bracket, a servo electric push rod drive unit, and a guide limit mechanism. The lifting platform is equipped with conveying rollers of the same specifications as the roller conveyor to ensure smooth tray transition. The mounting base of the lifting device is fixed to the frame beams at both ends of the upper and lower roller conveyors with bolts, so that the lifting platform is flush with the upper roller conveyor when raised to the upper limit and flush with the lower roller conveyor when lowered to the lower limit, and is connected to the main control system for linkage.

[0030] As a further supplement to this embodiment, the method for realizing the process from molding sand to core in the molding unit is as follows: S01, after printing the sand core according to the issued printing data, the 3D printing equipment 1 issues a command to summon the first rail-guided transfer vehicle 3. The first rail-guided transfer vehicle 3 transfers the printed sand core from the sand core work box to the work box buffer line 4, where the sand core waits for curing. At the same time, the first rail-guided transfer vehicle 3 picks up the empty work box from the work box buffer line 4 and returns it to the corresponding 3D printing equipment 1, realizing the automatic replacement of the work box of the 3D printing equipment 1. S02, after the curing is completed, the work box containing the sand core is transferred by the first rail transfer car 3 to the core outlet platform of the core outlet station 5. The core outlet platform is lifted to push the sand core out of the sand box. The first truss robot 6 grabs the sand core and places it on the sand cleaning roller conveyor 8. S03, the sand core placed on the sand cleaning roller conveyor 8 enters the automatic sand cleaning room, then the manual sand cleaning room, and then the intelligent testing room to achieve sand cleaning and inspection of the sand core; S04, the sand core after sand cleaning is placed at one end of the sand cleaning roller conveyor 8 opposite the dip coating tank. The second rail-guided transfer car 10 transfers the sand core after sand cleaning to the first receiving roller conveyor. The second gantry robot 12 grabs the sand core from the first receiving roller conveyor and places it into the dip coating tank for coating / dipping. In order to coat / dip the sand core well, the sand core can be rotated at least two times in the dip coating tank. After dipping / coating, the sand core is placed on the second receiving roller conveyor again, and the coated sand core placed on the second receiving roller conveyor is inspected for coating status and allowed to stand to allow the paint to seep in and flow away excess paint. S05, the coated sand cores are transferred by the second gantry robot 12 to the third rail-mounted transfer vehicle 14. The third rail-mounted transfer vehicle 14 transfers the coated sand cores to the drying equipment for drying. The dried sand cores are then transferred by the overhead crane to the sand core automated storage and retrieval system 15.

[0031] As a supplement to this embodiment, the core assembly and casting unit includes a traveling crane, a sand core storage unit 15, a fourth rail-guided transfer vehicle 17, a core assembly station 20, a third gantry robot 22, a fifth rail-guided transfer vehicle 19, a buried box casting line 23, and a sand mixer and a casting machine installed within the buried box casting line 23. Specifically, as... Figure 4 As shown, at least one row of the sand core storage unit 15 is arranged linearly parallel to the process direction of the molding unit. In this embodiment, two rows of sand core storage units 15 are arranged in parallel. In order to transfer sand cores between the two rows of sand core storage units 15, a palletizing robot is also arranged between the two rows of sand core storage units 15 to facilitate the transfer of sand cores between the two rows of sand core storage units 15. A fourth track 16 and a fifth track 18 are arranged in the direction away from the molding unit and perpendicular to the sand core storage unit 15, and a fourth rail-guided transfer vehicle 1 is provided on the fourth track 16. 7. A fifth rail-mounted transfer vehicle 19 is provided on the fifth track 18, and a core assembly station 20 is provided between the fourth track 16 and the fifth track 18. In this embodiment, the core assembly station 20 is provided with three core assembly platforms. The fourth rail-mounted transfer vehicle 17 transports sand cores from the sand core storage 15 to the core assembly station 20, and the fifth rail-mounted transfer vehicle 19 transports the assembled sand cores to the embedded box casting line 23. The embedded box casting line 23 is provided with an embedded box casting roller conveyor. The assembled sand cores and sand boxes are placed on the embedded box casting roller conveyor by a crane for sand core embedded box operation and casting operation.

[0032] As a further supplement to this embodiment, the operation process of the core casting unit is as follows: S11, the fourth rail-guided transfer vehicle 17 transfers the corresponding sand cores from the automated warehouse to the core assembly platform of the core assembly station 20 according to the core assembly plan; S12, the workers complete the assembly of the sand cores of the product to be produced on the core assembly platform according to the core assembly process; S13, the sand core after core assembly is transferred from the fifth rail-guided transfer car 19 to the buried box casting line 23 via the buried box casting roller conveyor. S14, the operators, with the cooperation of the overhead crane and the sand mixer, complete the embedding of the sand core of the product to be produced according to the embedding process, forming the core package of the product to be produced with the sand box. S15. After the embedded molding sand in the core package has solidified, the core package is poured by the casting machine. S16, the completed core package is transferred to the cooling unit by a crane.

[0033] As a supplement to this embodiment, the smelting unit is located on one side of the core casting unit and adjacent to the embedded casting line 23, thereby minimizing the ladle transport distance. Specifically, the smelting unit includes a ladle baking machine, a spheroidizing station, a slag removal platform, and an intermediate frequency furnace. During molten metal smelting, after the ladle is baked at the baking machine, it is carried by the casting machine to the intermediate frequency furnace to receive the molten metal. The casting machine carries the ladle containing the molten metal to the spheroidizing station to spheroidize the molten metal, and then transports it to the slag removal platform to remove slag from the surface of the molten metal in the ladle. Finally, the casting machine carries the qualified molten metal to the embedded casting line 23 to complete the casting of the core ladle.

[0034] As a supplement to this embodiment, the cooling unit is arranged linearly in the direction away from the sand core storage 15, adjacent to the buried box casting line 23, to achieve the shortest transfer distance of the core package after casting. In order to facilitate the transfer of the core package after casting, the fifth track 18 spans the buried box casting line 23 and the cooling unit, so that the fifth rail transfer car 19 can transfer the cast core package to the cooling unit, and then the trolley of the cooling unit can transfer the cast core package to the cooling unit, where the molten metal to be produced is condensed.

[0035] As a supplement to this embodiment, the sand removal unit is located at the end of the cooling unit away from the melting unit. The sand removal unit is equipped with a core ladle storage platform and a sand removal vibration device. The solidified core ladle is transferred from the cooling unit to the core ladle storage platform by a crane, and then the crane is transferred to the sand removal vibration device to perform vibration sand removal operation on the casting according to the box-making plan.

[0036] As a supplement to this embodiment, the post-processing unit is arranged linearly in the direction away from the cooling unit and forming unit, and has several post-processing stations to achieve the purpose of cleaning several castings simultaneously, thereby improving post-processing efficiency. Specifically, the post-processing unit is provided with a heat treatment area, a shot blasting area, a casting transfer warehouse, and a painting area to realize the post-processing of castings after sand removal.

[0037] Another implementation scheme is a foundry layout based on cast iron casting and additive manufacturing technologies, such as... Figure 6As shown, the system includes molding units arranged linearly along any wall of the foundry; core assembly stations 20 arranged linearly in the same row as the molding units; a core package storage unit located adjacent to the core assembly station 20 in a direction perpendicular to the molding units and away from the wall; a sand removal unit and a pouring line arranged linearly in the same row on the side of the core package storage unit away from the molding units in a vertical direction; a post-processing unit located adjacent to the molding units in a linear row with the core package storage unit; and a melting unit located in a direction perpendicular to the pouring line away from the core package storage unit. The core assembly station 20 is connected to the drying area of ​​the molding units via roller conveyors to facilitate the transfer of sand cores. Two roller conveyors connect the core assembly station 20 to the core package storage unit to transfer the assembled core packages to the first row of the core package storage unit. The material flow between the two rows of core package storage units is carried by a palletizing robot. The poured core packages are transferred again via roller conveyors to the second row of core package storage units for cooling. The cooled core packages are then transferred via roller conveyors to the sand removal unit.

[0038] As a supplement to this embodiment, the core assembly and casting unit includes a core package storage unit, a core assembly station 20, a casting line, and a casting machine, such as... Figure 5 As shown, the core assembly station 20 is located adjacent to the third track 13 and the molding unit. The core assembly station 20 is equipped with three core assembly platforms 21 and a third gantry robot 22 to facilitate the handling of sand cores during the core assembly process. The casting line is located adjacent to the core assembly station 20 in a direction away from the third track 13. A sixth track is also provided at the casting line. The sixth track is used to support the casting machine and runs through the casting line and the melting unit, so as to transfer the molten metal from the melting unit to the casting line for casting the core package. A parallel core package storage unit is located in a position away from the molding unit and the third track 13. The core package storage unit is used to store the core packages from the core assembly station 20.

[0039] As a supplement to this embodiment, the two rows of core package automated storage units can not only store assembled core packages, but also store sand cores that do not need to be assembled temporarily and are waiting for production scheduling, realizing multiple uses of one automated storage unit and saving space.

[0040] As a supplement to this embodiment, the two rows of core packaging storage units can also be set up separately, with one row located adjacent to the molding unit for storing sand cores that are not currently needed for core assembly; the other row is located in a... Figure 5 The location shown is used to store core packages awaiting production scheduling.

[0041] As a supplement to this embodiment, such as Figure 5 The operation process of the core casting unit under the bare casting process shown is as follows: S21, the dried sand core is transported to the core assembly station 20 by the third rail transfer car 14. After the sand core is assembled into a core package on the core assembly table 21 of the core assembly station 20, it is transferred to the core package automated warehouse by the sixth rail transfer car running on the third track 13. S22, for core packages that are already waiting to be poured, the fifth rail transfer car 19 directly transfers the core packages to the pouring line; for the remaining core packages, the sixth rail transfer car transfers them into the core package automated warehouse to wait for the pouring production schedule.

[0042] By implementing the technical solution of this invention, the main casting processes such as core making, molding, box assembly, pouring, and cooling are separated, and each process is operated at a fixed location. Through process separation and fixed-location operation, the problems of cross-flow logistics and difficulty in dust and fume collection in traditional casting are fundamentally solved, greatly improving operational safety and environmental protection efficiency. By setting up a three-level sand cleaning and inspection line, a perfect combination of automatic and manual sand cleaning is achieved, and automatic detection of sand cleaning effect is realized, further improving the automation level and intelligence of the molding unit. Core assembly, box embedding, and pouring are integrated into a single production line, shortening the production cycle and improving production efficiency. Furthermore, the assembly line operation enhances the specialization of operations and reduces the error rate of operational tasks.

[0043] The above embodiments are merely descriptions of a typical application of the technical solution of the present invention. Reasonable extensions can be made without requiring creative effort.

Claims

1. A foundry based on additive manufacturing technology, characterized in that, It includes several process units and a logistics unit, wherein the logistics unit is used to transfer objects between the various process units, and the process units include a molding unit, a core casting unit, a melting unit, a cooling unit, a sand removal unit and a post-processing unit. A molding unit is arranged linearly along any wall of the foundry. A core casting unit is set up perpendicular to the wall and in the direction away from the molding unit. A sand removal unit and a cooling unit are set up side by side in the direction away from the molding unit and in the direction of the core casting unit. A melting unit is set up at one end of the cooling unit and the core casting unit and is located on the other side of the cooling unit relative to the sand removal unit. A post-processing unit is set up in the direction away from the molding unit and in the direction of the cooling unit.

2. The foundry based on additive manufacturing process as described in claim 1, characterized in that, The logistics unit includes several tracks and rail-mounted transfer vehicles, each rail-mounted transfer vehicle being connected to various work processes via tracks. The logistics unit includes a first track, a second track, a third track, a fourth track, and a fifth track, as well as a first rail-mounted transfer vehicle, a second rail-mounted transfer vehicle, a third rail-mounted transfer vehicle, a fourth rail-mounted transfer vehicle, and a fifth rail-mounted transfer vehicle running on the five tracks. The first rail-mounted transfer vehicle, the second rail-mounted transfer vehicle, and the third rail-mounted transfer vehicle are arranged in the molding unit, while the fourth rail-mounted transfer vehicle and the fifth rail-mounted transfer vehicle are arranged in the core casting unit, realizing the transfer of objects within the two units and between the two major processes.

3. The foundry based on additive manufacturing process as described in claim 1, characterized in that, The molding unit includes several 3D printing devices for printing sand cores, a first track set on the common path of the entrance and exit of several 3D printing work boxes, and a first rail-mounted transfer vehicle running on it. At the end of the first track extending outside the 3D printing devices, there is a work box buffer line. At the outer end of the first track with the work box buffer line, there is also a core exit station and a first gantry robot set at the core exit station. Immediately following the linear path, there is a sand cleaning line and an automatic sand cleaning room, a manual sand cleaning room, and an intelligent testing room set within the sand cleaning line. Immediately following the linear sand cleaning line, there is an impregnation zone. Between the sand cleaning line and the impregnation zone, there is a second rail-mounted transfer vehicle and a second gantry robot set in the impregnation zone. A third track and a third rail-mounted transfer vehicle are set across the impregnation zone and the drying zone in a direction away from the sand cleaning line in the impregnation zone. Immediately adjacent to the impregnation zone and in a linear direction perpendicular to the molding unit and away from the wall, there is also a drying zone, in which drying equipment is set.

4. The foundry based on additive manufacturing process as described in claim 3, characterized in that, The sand cleaning line is equipped with an automatic sand cleaning room, a manual sand cleaning room, and an intelligent testing room in sequence from the core exit station toward the immersion coating area. A sand cleaning roller conveyor runs through the three rooms. The sand cores pass through the roller shutters above the sand cleaning roller conveyor in various areas of the sand cleaning line. The sand cleaning roller conveyor has a reserved space outside the automatic sand cleaning room toward the core exit station to accommodate at least one sand core. The sand cleaning roller conveyor also has a reserved space outside the intelligent testing room toward the immersion coating area to accommodate at least one sand core.

5. The foundry based on additive manufacturing process as described in claim 3, characterized in that, A second track and a third track are provided in a direction perpendicular to the advancing direction of the sand-cleaning line and the dip-coating zone. A second rail-mounted transfer car is provided on the second track, and a third rail-mounted transfer car is provided on the third track. The second track is located between the sand-cleaning line and the dip-coating zone, and the third track is located at the end of the dip-coating zone away from the sand-cleaning line.

6. The foundry based on additive manufacturing process as described in claim 5, characterized in that, At least one first receiving roller conveyor is provided in the direction opposite to the sand removal line in the immersion coating area. The second rail transfer car transfers the sand core that has been cleaned from the sand removal roller conveyor to the first receiving roller conveyor. At least one second receiving roller conveyor is provided in the direction away from the sand removal line in the immersion coating area. The second receiving roller conveyor is used to temporarily store the sand core after immersion coating.

7. The foundry based on additive manufacturing process as described in claim 6, characterized in that, The operation process of the molding unit includes, S01, after the 3D printing equipment completes printing based on the printing data of the sand core to be produced, it issues a command to summon the first rail-guided transfer vehicle. The first rail-guided transfer vehicle transports the printed sand core from the sand core work box to the work box buffer line, where the sand core waits for curing. At the same time, the first rail-guided transfer vehicle picks up the empty work box from the work box buffer line and returns it to the corresponding 3D printing equipment, realizing the automatic replacement of the 3D printing equipment work box. S02, after the curing is completed, the work box containing the sand core is transferred by the first rail transfer vehicle to the core exit platform of the core exit station. The core exit platform is lifted and the sand core is pushed out of the sand box. The first truss robot grabs the sand core and places it on the sand cleaning roller. S03, the sand core placed on the sand cleaning roller conveyor enters the automatic sand cleaning room, then the manual sand cleaning room, and then the intelligent testing room to achieve sand cleaning and inspection of the sand core; S04, the sand core after sand cleaning is placed at one end of the sand cleaning roller conveyor opposite the immersion coating tank. The second rail-guided transfer car transfers the sand core after sand cleaning to the first receiving roller conveyor. The second gantry robot grabs the sand core from the first receiving roller conveyor and places it into the immersion coating tank for coating / immersion coating. In order to coat / immerse the sand core well, the sand core can be rotated at least two times in the immersion coating tank. After coating / immersion coating, the sand core is placed on the second receiving roller conveyor again, and the coating condition of the coated sand core placed on the second receiving roller conveyor is checked and the excess coating is allowed to stand and drain. S05, the coated sand cores are transferred by the second truss robot to the third rail-mounted transfer vehicle. The third rail-mounted transfer vehicle then transfers the coated sand cores to the drying equipment for drying. The dried sand cores are then transferred by a crane to the sand core automated storage and retrieval system.

8. The foundry based on additive manufacturing process as described in claim 1, characterized in that, The core assembly and casting unit includes a traveling crane, a sand core storage unit, a fourth rail-guided transfer vehicle, a core assembly station, a third gantry robot, a fifth rail-guided transfer vehicle, a buried box casting line, and a sand mixer and a casting machine installed within the buried box casting line. The sand core storage unit is arranged in at least one row, linearly parallel to the process direction of the molding unit. A fourth track and a fifth track are arranged in the direction away from the molding unit and perpendicular to the sand core storage unit. A fourth rail-guided transfer vehicle is installed on the fourth track, and a fifth rail-guided transfer vehicle is installed on the fifth track. A core assembly station is located between the fourth track and the fifth track.

9. The foundry based on additive manufacturing process as described in claim 8, characterized in that, The operation process of the core casting unit includes, S11, the fourth rail-guided transfer vehicle transfers the corresponding sand cores from the automated warehouse to the core assembly platform at the core assembly station according to the core assembly plan; S12, the workers complete the assembly of the sand cores of the product to be produced on the core assembly platform according to the core assembly process; S13, after the sand core assembly is completed, the fifth rail-guided transfer car will take the sand core to the sand box casting line's sand box casting roller conveyor. S14, the operators, with the cooperation of the overhead crane and the sand mixer, complete the embedding of the sand core of the product to be produced according to the embedding process, forming the core package of the product to be produced with the sand box. S15. After the embedded molding sand in the core package has solidified, the core package is poured by the casting machine. S16, the completed core package is transferred to the cooling unit by a crane.

10. A foundry based on additive manufacturing technology, characterized in that, Several process units and logistics units, wherein the logistics units are used to transfer objects between the various process units, and the process units include a molding unit, a core casting unit, a melting unit, a cooling unit, a sand removal unit, and a post-processing unit; The factory consists of molding units arranged linearly along the wall, core assembly stations aligned with the molding units, a core package storage unit located perpendicular to the molding units, a sand removal unit and a casting line on the side of the core package storage unit furthest from the molding units, a post-processing unit located linearly adjacent to the molding units and aligned with the core package storage unit, and a melting unit located on the casting line furthest from the core package storage unit. The drying area of ​​the molding units and the core assembly stations are connected by roller conveyors to facilitate the transfer of sand cores. Two roller conveyors connect the core assembly stations and the core package storage unit to transfer the assembled core packages to the first row of the core package storage unit. The logistics between the two rows of core package automated storage and retrieval systems are carried out by palletizing robots. After the core packages are poured, they are transferred again to the second row of core package automated storage and retrieval systems via roller conveyors for cooling. After cooling, the core packages are transferred to the sand removal unit via roller conveyors.

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