Centrifugal casting apparatus and casting method

Abstract

The application relates to the technical field of casting devices, and discloses a centrifugal casting device and a casting method, the centrifugal casting device comprising a base, a rotary driving mechanism, a casting mold, an automatic feeding mechanism, a parameter acquisition mechanism and a control end; the rotary driving mechanism is arranged on the base, the casting mold is detachably arranged on a driving station of the rotary driving mechanism, and the mold is rotated by the rotary driving mechanism; the automatic feeding mechanism comprises a liquid storage container and a feeding piece; the liquid storage container has heat preservation and heating functions. The application sets the rotary driving mechanism, the automatic feeding mechanism, the parameter acquisition mechanism and the control end, constructs a closed-loop control system with real-time casting thickness as the only feedback signal, realizes intelligent self-adaptive regulation and control of the centrifugal casting process, can target-regulate the rotating speed and the feeding speed according to the position and size of the thickness deviation in the centrifugal casting process, and improves the control precision and efficiency.

Description

Technical Field

[0001] This invention relates to the field of casting equipment technology, and more specifically, to a centrifugal casting device and casting method. Background Technology

[0002] Centrifugal casting is a process that uses the centrifugal force generated by rotating a mold to distribute molten metal onto the inner wall of the mold cavity, forming hollow cylindrical or sleeve-like castings. This method is widely used in the production of precision castings such as hydraulic valve sleeves and automotive bearing housings.

[0003] In existing technologies, horizontal small and medium-sized centrifugal casting machines mostly use manual hand-held ladle pouring for casting. This method has obvious drawbacks: the pouring parameters (such as speed and angle) fluctuate greatly, resulting in an unstable metal filling process, which easily causes defects such as uneven casting wall thickness, incomplete pouring, and cold shut, resulting in a high scrap rate.

[0004] To address these issues, some equipment employs automatic feeding mechanisms. However, these traditional automatic mechanisms typically only execute preset, fixed programs and cannot adjust to real-time conditions during the casting process. When the properties of the molten metal (such as temperature and viscosity) or the mold condition change, these mechanisms fail to respond, still leading to inconsistent product quality.

[0005] Therefore, there is an urgent need in this field for a centrifugal casting equipment and casting method that can sense the forming state of castings in real time and adaptively adjust process parameters accordingly, so as to solve the problem of uneven wall thickness of castings from the root. Summary of the Invention

[0006] The purpose of this invention is to provide a centrifugal casting device and casting method to solve the aforementioned technical problems.

[0007] The present invention solves the above-mentioned technical problems through the following technical solutions: This invention provides a centrifugal casting device, comprising: a base, a rotary drive mechanism, a casting mold, an automatic feeding mechanism, a parameter acquisition mechanism, and a control terminal; The rotary drive mechanism is mounted on the base, and the casting mold is detachably mounted on the drive station of the rotary drive mechanism, which drives the mold to rotate. The automatic feeding mechanism includes: A liquid storage container with heat preservation and heating functions, used for storing molten metal; Feeding components are used to quantitatively deliver molten metal into the casting mold; The parameter acquisition mechanism includes: Solution state sensing device, which is used to monitor the flow state of molten metal and feeding speed data in real time; A speed sensor is used to obtain the spindle speed of the rotary drive mechanism. Thickness sensing components are used to acquire thickness data of castings inside casting molds; The control terminal is communicatively connected to both the automatic feeding mechanism and the parameter acquisition mechanism, and is configured as follows: Based on the real-time collection of casting thickness data from the thickness sensing component, it is determined whether the casting condition meets the preset thickness threshold. When the thickness data exceeds the normal threshold, targeted control commands are generated and executed for the feeding speed of the feeder and the spindle speed of the rotary drive mechanism, based on the magnitude and location of the thickness deviation.

[0008] Preferably, the feeding component includes a servo plunger pump connected to an insulated liquid storage container, and the output end of the servo plunger pump is connected to a feeding pipe extending into the casting mold.

[0009] Preferably, the solution state sensing element is an ultrasonic flow switch installed on the feed pipe.

[0010] Preferably, the thickness sensing element includes at least three ultrasonic thickness probes arranged along the axial direction of the casting mold, each of the ultrasonic probes being mounted on a base via a movable support frame.

[0011] Preferably, the speed sensing element is a speed encoder mounted on the main shaft of the rotary drive mechanism.

[0012] Preferably, the rotary drive mechanism includes a servo drive component and a mold drive component that is connected to the servo drive component for transmission.

[0013] Preferably, the control terminal is configured to execute the following judgment and control logic: Set thresholds for normal casting thickness, minor abnormality thresholds, and severe abnormality thresholds; When all thickness data at all measuring points are within the normal threshold, maintain the current feeding parameters and spindle speed. When the thickness data of any measuring point is within the slight abnormality threshold, determine whether the abnormality is too thin or too thick, and its axial position, and adjust the feeding speed and spindle speed according to the preset ratio. When the thickness data at any measuring point exceeds the severe anomaly threshold, an alarm is triggered and a safety shutdown procedure is executed.

[0014] Preferably, the control terminal is further configured to: simultaneously increase the feeding speed and spindle speed when the front end of the casting is too thin; reduce the feeding speed when the middle section of the casting is too thick; and simultaneously increase the feeding speed and spindle speed when the rear end of the casting is too thin.

[0015] Preferably, the control terminal is further configured to: based on the initial manually input parameter data related to the casting and casting mold, call the pre-stored process parameter data, and output the corresponding initial feeding parameters and spindle speed.

[0016] A centrifugal casting method includes the following steps: Step S100: Input the casting specifications, target thickness, and casting mold specifications. The control terminal calls the initial feeding parameters and spindle speed. Step S200: Start the rotary drive mechanism and automatic feeding mechanism to begin pouring; Step S300: Collect thickness data of different locations on the casting in real time using a thickness sensing component; Step S400: The control terminal compares the collected thickness data with the preset threshold and determines the casting status; Step S500: Based on the judgment result, dynamically adjust the feeding speed and spindle speed to bring the casting thickness back to the normal threshold range; Step S600: After pouring is completed, store the thickness and parameter data of this production, and remove the casting.

[0017] The beneficial effects of this invention are as follows: This invention constructs a closed-loop control system with real-time casting thickness as the sole feedback signal by setting up a rotary drive mechanism, an automatic feeding mechanism, a parameter acquisition mechanism, and a control terminal. This achieves intelligent adaptive control of the centrifugal casting process. During centrifugal casting, the rotation speed and feeding speed can be targeted and controlled according to the location and magnitude of the thickness deviation, improving the accuracy and efficiency of control. It can accurately suppress defects such as uneven casting wall thickness and significantly improve product quality stability. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of a centrifugal casting device according to the present invention; Figure 2 This is a partial structural schematic diagram of a centrifugal casting device according to the present invention; Figure 3 This is a schematic diagram of the automatic feeding mechanism in a centrifugal casting equipment according to the present invention; Figure 4 This is a block diagram showing the relationship between the components in a centrifugal casting device according to the present invention; Figure 5 This is a schematic flowchart of a centrifugal casting method according to the present invention.

[0019] In the diagram: 10, base; 20, rotary drive mechanism; 201, servo motor; 202, positioning chuck; 203, transmission shaft; 30, casting mold; 40, automatic feeding mechanism; 401, insulated liquid storage container; 402, servo plunger pump; 403, feeding pipe; 50, parameter acquisition mechanism; 501, ultrasonic flow switch; 502, incremental photoelectric encoder; 503, ultrasonic thickness probe; 504, support frame. Detailed Implementation

[0020] The subject matter described herein will now be discussed with reference to exemplary embodiments. It should be understood that these embodiments are discussed only to enable those skilled in the art to better understand and implement the subject matter described herein, and changes may be made to the function and arrangement of the elements discussed without departing from the scope of this specification. Various processes or components may be omitted, substituted, or added as needed in the examples. Furthermore, features described in some examples may be combined in other examples.

[0021] Please refer to the following: Figures 1 to 5 A centrifugal casting device includes: a base 10, a rotary drive mechanism 20, a casting mold 30, an automatic feeding mechanism 40, a parameter acquisition mechanism 50, and a control terminal. The rotary drive mechanism 20 is mounted on the base 10 and includes a servo drive component and a mold drive component. The servo drive component is preferably a permanent magnet synchronous servo motor 201. The mold drive component includes a retractable positioning chuck 202 and two drive shafts 203 that are rotatably mounted side by side on the base 10. One of the drive shafts 203 is connected to the output shaft of the synchronous servo motor 201 through a pulley and belt drive structure. The positioning chuck 202 is located above the two drive shafts 203. When installing the casting mold 30, the casting mold 30 is first placed between the two drive shafts 203. Then, the positioning chuck 202 moves down so that its bottom contacts the top of the casting mold 30, thereby positioning the casting mold 30 and preventing it from shifting. During the pouring operation, the synchronous servo motor 201 drives the drive shafts 203 to rotate, thereby causing the casting mold 30 to rotate.

[0022] The automatic feeding mechanism 40 includes a liquid storage container with heat preservation and heating functions, which is connected to a servo plunger pump 402 via a pipe. The servo plunger pump 402 is driven by an absolute value servo motor 201, and its outlet is connected to a feeding pipe 403 that extends into the casting mold 30.

[0023] The parameter acquisition mechanism 50 includes a solution state sensor, a rotation speed sensor, and a thickness sensor. The solution state sensor is an ultrasonic flow switch 501, which is installed at the end of the feed pipe 403 to monitor the flow state of the molten metal in real time. The rotation speed sensor is an incremental photoelectric encoder 502, which is installed on the spindle of the synchronous servo motor 201 to accurately measure the spindle speed. The thickness sensor includes three ultrasonic thickness probes 503, which are evenly arranged along the axial direction of the casting mold 30, corresponding to the front, middle, and rear ends of the casting, respectively. Each ultrasonic probe is mounted on the base 10 via a movable support frame 504. When the mold type changes, the position of the ultrasonic probe can be adjusted by adjusting the position of the support frame 504.

[0024] The control unit, serving as the system's intelligent decision-making center, employs an industrial PLC controller and communicates with both the automatic feeding mechanism 40 and the parameter acquisition mechanism 50. Its core lies in its built-in process parameter database, parameter matching model, and real-time control strategy, collectively forming an adaptive control algorithm. The control unit is crucial for achieving equipment intelligence; it internally constructs a complete decision-making and optimization system, the specific design details of which are as follows: a. Process Parameter Database: This is a structured, dynamically updated knowledge base, primarily composed of three interconnected data tables: a casting specification database, a successful process parameter database, and a thickness-control mapping database. The casting specification database stores key information about historical castings (material, target wall thickness, mold dimensions, etc.) as an index for parameter matching. The successful process parameter database corresponds to entries in the specification database, storing production-verified sets of process parameters (such as initial feeding speed, spindle speed, etc.) that can stably produce qualified castings. The thickness-control mapping database stores detailed control strategies, defining specific control actions corresponding to thickness deviations at different locations and directions. For example: Anomaly type: Front end too thin, control action: Feeding speed increased by 6%, spindle speed increased by 4%; Anomaly type: Middle section too thick, control action: Feeding speed decreased by 4%, spindle speed unchanged.

[0025] b. Parameter Matching Model: When the operator inputs new casting specifications via the touchscreen, this model operates according to the following process: Exact match query: Search for a record that is exactly the same in the casting specification library. If found, directly call the corresponding success parameter. Fuzzy matching and calculation: If there is no perfect match, find the record with the same material and mold size and the closest target wall thickness, and calculate a set of recommended initial parameters through the built-in interpolation algorithm; Parameter output: Displays the finalized initial parameter set and distributes it to each actuator.

[0026] c. Real-time control strategy: During the pouring process, the control unit executes multi-level decisions: Data fusion and status judgment: The thickness probe data is filtered (e.g., by moving average method) and trend analysis is performed, and compared with preset thresholds. The thresholds are set as follows: normal (±0.1mm), slight abnormality (±0.1mm-±0.2mm), and severe abnormality (>±0.2mm). The system will only trigger an action after two consecutive cycles of consistent judgment to avoid misjudgment.

[0027] Targeted control command generation: Once a "minor anomaly" is determined, the preset control ratio is immediately retrieved from the "thickness-control mapping library" based on the location and direction of the anomaly, and the new target parameters are calculated and sent to the actuator within 20ms.

[0028] d. Process self-optimization function: After each batch of production is completed, the system automatically performs optimization: Data recording: The final stable process parameters and quality indicators for this batch are linked to form new process data; Effect evaluation and knowledge update: If a process data is marked as a high-quality process solution multiple times, the system will prompt the user to use it to successfully update the initial parameters in the process parameter library, thereby achieving continuous iterative improvement of production effect.

[0029] The specific process of the casting method of the centrifugal casting equipment of the present invention is as follows: Step 1, Task Startup and Parameter Preset: Operators input the core parameters of this production task on the touch screen at the control end, including: casting material, target wall thickness, and casting mold specification 30. After receiving the instruction, the control terminal immediately searches its process parameter database. It first looks for a historical successful case that is completely consistent with the input specifications. If found, it automatically calls up the complete set of process parameters of that case (including initial feeding speed, spindle speed, etc.). If not found, it calculates a set of recommended initial parameters through an interpolation algorithm. The control unit displays the matched or calculated initial parameters (e.g., feeding speed 1.2L / s, spindle speed 850r / min) on the interface and sends them to each actuator, and is ready.

[0030] Step 2, Pouring Start and Real-time Monitoring: After the operator confirms that the parameters are correct, the operator issues a start command. The synchronous servo motor 201 of the rotary drive mechanism 20 starts first, driving the casting mold 30 to accelerate to the set initial speed. After the speed of the casting mold 30 stabilizes, the automatic feeding mechanism 40 starts, and the servo plunger pump 402 smoothly feeds the molten metal in the heat preservation liquid container 401 into the high-speed rotating mold through the feeding pipe 403 according to the set initial speed. At the moment the pouring begins, the parameter acquisition mechanism 50 is activated, and the wall thickness data of the front, middle and rear of the casting are collected in real time through three ultrasonic thickness probes 503; the flow rate of the molten metal is continuously monitored through the ultrasonic flow switch 501, and the actual speed of the synchronous servo motor 201 is continuously monitored through the speed encoder.

[0031] Step 3, Intelligent Decision-Making and Targeted Regulation: The control unit performs real-time filtering and trend analysis on the collected thickness data and compares it with preset thresholds (normal: ±0.1mm; slight abnormality: ±0.1-0.2mm; severe abnormality: >±0.2mm). If the thickness data are all within the normal threshold, it is judged as normal, and the system maintains all current parameters and continues to operate smoothly. If a minor anomaly is detected, the system immediately initiates targeted control. For example, if the thickness of the casting front end is detected to be 10.16mm (too thin), the control terminal generates and executes a linkage command based on the preset strategy: increasing the feeding speed by 6% and the spindle speed by 4%. This combined action aims to use the enhanced centrifugal force and molten metal flow rate to accurately correct the problem of the thin front end. The system continues to monitor after adjustment until the thickness returns to the normal range. If a serious anomaly is detected, i.e. the thickness at any measuring point suddenly exceeds the serious anomaly threshold, the system will determine it as a major process failure, immediately trigger an audible and visual alarm, and execute a safety shutdown procedure (stop feeding, reduce spindle speed) to await manual intervention and inspection.

[0032] Step 4: Process Completion and Data Archiving: When the ultrasonic flow switch 501 reports that the feeding amount has reached the set value, the servo plunger pump 402 stops working, the pouring stage ends, and the synchronous servo motor 201 decelerates and stops after the casting is completely solidified. Meanwhile, all key data from this batch of production, including the final stable process parameters, the thickness variation curve throughout the process, and all executed control records, are automatically packaged and stored in the database, and bound to the unique number of the casting.

[0033] As can be seen from the above, the beneficial effects of the present invention are as follows: This invention constructs a closed-loop control logic that directly addresses the root cause of the problem (uneven wall thickness) by using the real-time thickness of the casting as the core evaluation indicator and control basis. By targeting and controlling according to the location and magnitude of the thickness deviation, the accuracy and efficiency of control are greatly improved. In addition, through real-time intervention, the problem of uneven wall thickness can be eliminated from the nascent stage, which can reduce the scrap rate and effectively improve product quality and pass rate. This invention has self-learning and self-optimization capabilities, and can accumulate successful process parameters and automatically apply them to subsequent production. Operators only need to input basic specifications, which greatly reduces the dependence on operator experience and allows new employees to get started quickly. Compared to complex multi-sensor systems, this invention features an extremely simplified hardware configuration, focusing on the core thickness monitoring and actuator. This significantly reduces equipment modification costs and maintenance costs, making it ideal for the technological transformation and upgrading of small and medium-sized foundry enterprises.

[0034] The embodiments of the present invention have been described above, but the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the present invention, all of which are within the protection scope of the present invention.

Claims

1. A centrifugal casting device, characterized in that, include: Base, rotary drive mechanism, casting mold, automatic feeding mechanism, parameter acquisition mechanism, and control terminal; The rotary drive mechanism is mounted on the base, and the casting mold is detachably mounted on the drive station of the rotary drive mechanism, which drives the mold to rotate. The automatic feeding mechanism includes: A liquid storage container with heat preservation and heating functions, used for storing molten metal; Feeding components are used to quantitatively deliver molten metal into the casting mold; The parameter acquisition mechanism includes: Solution state sensing device, which is used to monitor the flow state of molten metal and feeding speed data in real time; A speed sensor is used to obtain the spindle speed of the rotary drive mechanism. Thickness sensing components are used to acquire thickness data of castings inside casting molds; The control terminal is communicatively connected to both the automatic feeding mechanism and the parameter acquisition mechanism, and is configured as follows: Based on the real-time collection of casting thickness data from the thickness sensing component, it is determined whether the casting condition meets the preset thickness threshold. When the thickness data exceeds the normal threshold, targeted control commands are generated and executed for the feeding speed of the feeder and the spindle speed of the rotary drive mechanism, based on the magnitude and location of the thickness deviation.

2. The centrifugal casting equipment according to claim 1, characterized in that, The feeding component includes a servo plunger pump connected to an insulated liquid storage container, and the output end of the servo plunger pump is connected to a feeding pipe extending into the casting mold.

3. The centrifugal casting equipment according to claim 2, characterized in that, The solution state sensing device is an ultrasonic flow switch installed on the feed pipe.

4. The centrifugal casting equipment according to claim 1, characterized in that, The thickness sensing element includes at least three ultrasonic thickness probes arranged along the axial direction of the casting mold, each of which is mounted on a base via a movable support frame.

5. A centrifugal casting device according to claim 1, characterized in that, The speed sensing element is a speed encoder installed on the main shaft of the rotary drive mechanism.

6. A centrifugal casting device according to claim 1, characterized in that, The rotary drive mechanism includes a servo drive component and a mold drive component that is connected to the servo drive component for transmission.

7. The centrifugal casting equipment according to claim 1, characterized in that, The control terminal is configured to execute the following judgment and control logic: Set thresholds for normal casting thickness, minor abnormality thresholds, and severe abnormality thresholds; When all thickness data at all measuring points are within the normal threshold, maintain the current feeding parameters and spindle speed. When the thickness data of any measuring point is within the slight abnormality threshold, determine whether the abnormality is too thin or too thick, and its axial position, and adjust the feeding speed and spindle speed according to the preset ratio. When the thickness data at any measuring point exceeds the severe anomaly threshold, an alarm is triggered and a safety shutdown procedure is executed.

8. A centrifugal casting device according to claim 7, characterized in that, The control terminal is further configured to: simultaneously increase the feeding speed and spindle speed when the front end of the casting is too thin; reduce the feeding speed when the middle section of the casting is too thick; and simultaneously increase the feeding speed and spindle speed when the rear end of the casting is too thin.

9. A centrifugal casting device according to claim 1, characterized in that, The control terminal is also configured to: based on the initial manually input parameter data related to the casting and casting mold, call the pre-stored process parameter data, and output the corresponding initial feeding parameters and spindle speed.

10. A centrifugal casting method, using the centrifugal casting equipment as described in any one of claims 1-9, characterized in that, The following steps are included: Step S100: Input the casting specifications, target thickness, and casting mold specifications. The control terminal calls the initial feeding parameters and spindle speed. Step S200: Start the rotary drive mechanism and automatic feeding mechanism to begin pouring; Step S300: Collect thickness data of different locations on the casting in real time using a thickness sensing component; Step S400: The control terminal compares the collected thickness data with the preset threshold and determines the casting status; Step S5 00: Based on the judgment results, dynamically adjust the feeding speed and spindle speed to bring the casting thickness back to the normal threshold range; Step S600: After pouring is completed, store the thickness and parameter data of this production, and remove the casting.

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