An automatic casting machine system, a novel casting device, and a control method thereof

Abstract

This invention provides an automatic casting machine system, a novel casting device, and its control method. The casting device adopts a multi-cavity integrated structure, allowing multiple sets of molds to be used in parallel production within the same floor space, significantly increasing production capacity and saving workshop space and equipment investment. The furnace body is divided into multiple casting cavities, each equipped with an independent casting port, heating device, liquid level detection unit, and temperature detection unit. The furnace body has connecting channels and switching devices that connect all casting cavities. The control system uniformly adjusts the power of all heating devices based on the temperature of a single cavity. The remaining temperature detection units are used for monitoring the casting temperature of a single cavity. Combined with liquid level detection, it enables automatic shutdown in case of single-cavity abnormalities and automatically opens the stopper rods for material replenishment and temperature equalization when all cavities are not casting. This invention can achieve automatic switching between independent casting in multiple cavities and unified material replenishment and temperature adjustment throughout the furnace, resulting in uniform and stable temperature control, good casting consistency, and high automation and production efficiency.

Description

Technical Field

[0001] This invention relates to the field of casting technology, and more specifically, to an automatic casting machine system, a novel casting device, and a control method thereof. Background Technology

[0002] In the field of precision metal casting, processes such as low-pressure casting and rotary casting are widely used in the mass production of non-ferrous metal castings such as copper alloys and aluminum alloys. As the core equipment for supplying molten liquid, the casting equipment's temperature control accuracy, liquid level stability, and production efficiency directly determine the finished product quality and production capacity of the castings.

[0003] As market demand for casting capacity continues to increase, multiple casting units are typically required to operate simultaneously in order to accelerate product production and delivery.

[0004] However, different casting devices are prone to problems such as asynchronous power regulation and temperature oscillation overshoot, resulting in poor consistency of melt temperature among casting devices, large differences in the metallographic structure and mechanical properties of the product castings, and insufficient quality stability of the final delivered products; at the same time, multiple casting devices are costly, occupy a large area, have a high failure rate, and are inefficient.

[0005] In view of this, the applicant hereby submits this application after studying the existing technology. Summary of the Invention

[0006] The present invention provides an automatic casting machine system, a novel casting device and its control method, which aims to improve at least one of the above-mentioned technical problems.

[0007] To solve the above-mentioned technical problems, the present invention provides an automatic casting machine system, including a casting device and multiple casting coordination devices. The casting device includes a furnace body with multiple casting cavities. Multiple casting coordination devices are arranged around the casting cavities to realize multi-station automated casting. The casting coordination device includes a multi-degree-of-freedom manipulator unit, and a casting mold is installed on the manipulator unit.

[0008] Multiple casting cavities are isolated from each other and operate independently. The mold is connected and cooperated with the independently operating casting cavity under the operation of the robot unit to inject the molten metal into the mold to complete the automated casting.

[0009] As a further optimization, the furnace body is also provided with a connecting channel that connects all the casting cavities. A switch device is installed at the connecting channel. The switch device is used to open or close the connecting channel. When the switch device is in the closed state, each casting cavity is isolated from each other and operates independently.

[0010] As a further optimization, the casting coordination device is a base-type device, which also includes a base, a pedestal, and a rotary drive unit. The pedestal is used to place on the ground, and at least one set of the robotic arm units is provided on the pedestal. The pedestal is rotatably mounted on the pedestal, and the rotary drive unit drives the pedestal to rotate along the vertical axis, so that the mold can rotate and switch between the loading / unloading station and the injection station.

[0011] As a further optimization, the casting coordination device is a suspended type, which also includes a base, a suspension base and a rotary drive unit. At least one set of the robotic arm units is provided on the base. The base is rotatably mounted on the suspension base and is suspended and hoisted through the suspension base. The rotary drive unit drives the base to rotate along the vertical axis so that the mold can rotate and switch between the loading / unloading station and the injection station.

[0012] As a further optimization, the furnace body is a circular furnace body, and the multiple casting cavities are evenly distributed in a fan shape inside the circular furnace body; the connecting channel is set at the center of the circular furnace body, and all casting cavities are interconnected through the connecting channel at the center; the switching device is installed in the connecting channel at the center; the multiple casting coordination devices are distributed around the furnace body to realize multi-station automatic casting.

[0013] As a further optimization, the multiple casting cavities are arranged in a rectangular layout in a straight line, and a connecting channel is provided between every two adjacent casting cavities. Each connecting channel is equipped with a corresponding switch device. All switch devices are opened or closed synchronously to achieve interconnection or isolation of all casting cavities. The multiple casting coordination devices are arranged in a straight line to achieve multi-station automatic casting.

[0014] As a further optimization, the robotic arm unit includes: A rotating mechanism having a first output end, wherein the first output end is coaxially matched with the casting port of the casting cavity, and the axis of the first output end is defined as the rotating axis A; An adjustment mechanism is installed at the first output end of the rotating mechanism and is driven by the rotating mechanism to rotate around the rotating axis A; the adjustment mechanism has a second output end for connecting to the mold; The adjustment mechanism is configured to drive the mold to move in a radial direction perpendicular to the rotation axis A; The adjustment mechanism includes a hydraulic three-position cylinder, which can selectively position and hold the mold in a first position, a second position, and a third position, all of which are located on the same straight line.

[0015] The present invention also provides a novel casting apparatus, including a furnace body for supplying molten metal to an external mold. The furnace body is divided into multiple independent casting chambers, each of which is equipped with an independent casting port and a heating device. The heating device is used to heat and melt or heat the metal material in the corresponding casting chamber. The casting port is used to output molten metal to the external mold. At least one of the casting chambers is provided with a feeding port. Each of the casting cavities is equipped with an independent liquid level detection unit and a temperature detection unit; The furnace body is also provided with a connecting channel that connects all the casting cavities. A switch device is installed at the connecting channel to open or close the connecting channel. When the switch device is in the open state, each casting cavity is connected to the other through the connecting channel, and molten metal can flow and conduct temperature between the casting cavities. When the switch device is in the closed state, each casting cavity is isolated from the other and operates independently. The casting apparatus also includes a control system, which is connected to each of the temperature detection units, each of the liquid level detection units, the casting control module corresponding to each casting cavity, and the switching device. The control system is configured as follows: One of the temperature detection units is selected as the reference temperature detection unit. The output power of all heating devices is adjusted according to the detection signal of the reference temperature detection unit to achieve the melting or heating of the metal. The remaining temperature detection units are used to detect the casting temperature of the corresponding casting cavity in real time. When the casting temperature of any casting cavity is detected to be lower than the preset range value, the casting cavity is controlled to stop the casting operation. Based on the detection signals from each liquid level detection unit, when the liquid level in any casting cavity is detected to be lower than the preset liquid level threshold, the casting operation of that casting cavity is controlled to stop. When all casting cavities are in a non-casting state, the switch device is turned on to perform feeding, temperature adjustment and molten metal circulation. After the molten metal in each casting cavity reaches the preset casting temperature and preset liquid level value, the switch device is turned off and each casting cavity begins independent casting.

[0016] As a further optimization, each casting cavity is independently equipped with a feeding port that can be opened or closed. During the feeding operation, at least one feeding port can be opened to feed material, while the other feeding ports remain sealed.

[0017] As a further optimization, each casting cavity is also equipped with an independent air intake and pressurization device, which is connected to the control system via a signal. During the casting operation, the air intake and pressurization device introduces pressurized gas into the corresponding casting cavity to increase the air pressure inside the cavity, thereby driving the molten metal liquid to overflow from the side casting port and be injected into the external mold.

[0018] As a further optimization, the casting furnace of the casting device is a cored induction furnace, a gas furnace, an electric furnace, an induction furnace, a resistance furnace, or a coreless induction furnace.

[0019] The present invention also provides a control method for the novel casting apparatus as described above, comprising the following steps: S1 Feeding and Melting: The control system opens the control switch to connect the channels and make the casting cavities interconnected; feed material into the casting cavity through the feeding port and start the heating and melting device to heat and melt the added material; S2 parameter adjustment: Select one of the temperature detection units as a reference, and the control system adjusts the output power of the heating and melting device according to the detection signal of the reference temperature detection unit to raise the temperature of the molten metal to the preset casting temperature; detect the liquid level of each casting cavity through each liquid level detection unit, and add metal material until the liquid level of each casting cavity reaches the preset liquid level requirement; S3 Isolation for Casting: After the temperature of the molten metal in all casting cavities reaches the preset casting temperature and the liquid level reaches the preset requirements, the control system controls the switch to close, isolating each casting cavity from the others. S4 Independent Casting: Each casting chamber is independently pressurized and performs casting operations. During the casting process, each temperature detection unit monitors the casting temperature of the corresponding casting chamber in real time, and each liquid level detection unit monitors the liquid level of the corresponding casting chamber in real time. When the casting temperature of any casting chamber is detected to be lower than the preset range or the liquid level is lower than the preset threshold, the control system controls the casting chamber to stop casting operations. S5 Cycle Reset: When all casting cavities are in a non-casting state, the control system automatically turns on the switch to perform feeding, temperature adjustment and liquid level increase again. After all parameters meet the standards, the switch is turned off and the next round of casting production begins.

[0020] By adopting the above technical solution, the present invention can achieve the following technical effects: 1. By adopting a strategy of uniformly controlling the power of all heating devices with a single reference temperature, the power conflict and temperature oscillation problems that are prone to occur in multi-cavity independent temperature control are avoided from the root, and the temperature of the molten metal in the whole furnace is uniform and stable; at the same time, each cavity is equipped with an independent temperature monitoring unit, which can accurately intercept abnormal temperature conditions in a single cavity and ensure casting quality.

[0021] 2. Through the common connection channel, the molten liquid in each cavity can flow freely during the non-casting stage, and the liquid level can be evenly distributed automatically. There is no need for precise material replenishment in each cavity, and the material replenishment efficiency is high. The liquid level in each cavity is consistent before casting, the filling pressure is stable, and the casting quality is consistent.

[0022] 3. The stopper switch is automatically linked to the casting status. During casting, the cavity is completely isolated without interference. When not casting, it is automatically connected to replenish materials and equalize the temperature. If there is an abnormal cavity, the machine will automatically stop. No manual intervention is required throughout the process. The degree of automation is high and the production cycle is compact.

[0023] 4. Each cavity can be independently equipped with molds of different sizes, and the unified control logic is still followed during mixed production, without the need to adjust parameters separately; the matching three-dimensional robotic arm unit can quickly switch between top pouring, middle pouring and bottom pouring modes, with strong process adaptability.

[0024] 5. The integrated structure of multiple chambers in one furnace allows a single furnace to integrate multiple independently castable chambers. With the same floor space, multiple sets of molds can be used for parallel production, which greatly improves the equipment capacity. There is no need to configure multiple independent smelting furnaces, which effectively saves workshop space and reduces equipment procurement and civil engineering investment. With the help of automatic liquid equalization and unified temperature control linkage through the public connection channel, it takes into account both high production efficiency and space utilization. Attached Figure Description

[0025] To more clearly illustrate the technical solutions of the specific embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0026] Figure 1 This is a top view of the furnace body in Embodiment 1 of the present invention.

[0027] Figure 2 This is a cross-sectional structural diagram of the furnace body in Embodiment 1 of the present invention.

[0028] Figure 3 This is a schematic diagram of the structure of the robotic arm unit and the furnace body in Embodiment 2 of the present invention.

[0029] Figure 4 This is an exploded structural diagram of the robotic arm unit in Embodiment 2 of the present invention.

[0030] Figure 5 This is a schematic diagram illustrating an example of top-pouring casting in Embodiment 2 of the present invention.

[0031] Figure 6 This is a schematic diagram illustrating an example of casting by injection in Embodiment 2 of the present invention.

[0032] Figure 7 This is a schematic diagram illustrating an example of bottom-pouring casting in Embodiment 2 of the present invention.

[0033] Figure 8 This is a top view of the furnace body in Embodiment 3 of the present invention.

[0034] Figure 9 This is a cross-sectional structural diagram of the furnace body in Embodiment 3 of the present invention.

[0035] Figure 10 This is a schematic diagram of the arrangement of the casting coordination device in Example 4.

[0036] Figure 11 This is a schematic diagram of the arrangement of the double-arm base type and circular furnace body in Example 4.

[0037] Figure 12 This is a schematic diagram of the arrangement of the single-arm base type and rectangular furnace body in Example 4.

[0038] Figure 13 This is a schematic diagram of the single-arm base arrangement in Example 4.

[0039] Figure 14 This is a schematic diagram of the arrangement of the double-arm suspended casting coordination device in Example 5.

[0040] Figure 15 This is a schematic diagram of the arrangement of the single-arm suspended casting coordination device in Example 5.

[0041] The diagram shows the following components: 1. Furnace body; 2. Casting cavity; 3. Feed port; 4. Casting port; 5. Heating device; 6. Liquid level detection unit; 7. Temperature detection unit; 8. Connection channel; 9. Switching device; 10. Molten metal; 11. Air inlet and pressurization device; 12. Robotic arm unit; 121. Feeding mechanism; 122. Rotating mechanism; 1221. Rotating shaft A; 1222. Rotary motor; 1223. Rotary bearing support; 1224. Lifting fixed seat; 123. Adjustment mechanism; 1231. Linear slide rail; 1232. Linear slider; 1233. Hydraulic three-position cylinder; 1234. Lifting slide; 13. Mold; 131. Casting port; 14. Base; 15. Base; 16. Suspension base; 17. Rotary drive unit. Detailed Implementation

[0042] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0043] This invention provides an automatic casting machine system, including a casting device and multiple casting coordination devices. The casting device includes a furnace body with multiple casting cavities. The casting coordination devices are arranged around the casting cavities to realize multi-station automated casting. The casting coordination devices include a multi-degree-of-freedom manipulator unit, on which a casting mold is mounted. Multiple casting cavities are isolated from each other and operate independently. The mold is connected and cooperated with the independently operating casting cavity under the operation of the robot unit to inject the molten metal into the mold to complete the automated casting.

[0044] In a preferred embodiment, the furnace body is further provided with a connecting channel that connects all the casting cavities. A switching device is installed at the connecting channel. The switching device is used to open or close the connecting channel. When the switching device is in the closed state, each casting cavity is isolated from each other and operates independently.

[0045] Example 1 like Figure 1-2 As shown, this embodiment provides a novel casting device, including a furnace body 1. The furnace body 1 is a vertical circular structure. The interior of the furnace body 1 is divided into three independent casting cavities 2. The three casting cavities 2 are evenly distributed in a fan shape and arranged in a ring array around the center of the furnace body 1.

[0046] Each casting cavity 2 is equipped with a feeding port 3 at its top, and each feeding port 3 can be opened or sealed independently. In actual production, the feeding mode can be flexibly selected: only one feeding port 3 is opened to feed solid metal ingots such as brass, while the other feeding ports 3 remain sealed to reduce heat loss and molten metal oxidation in the furnace; or multiple or all feeding ports 3 can be opened simultaneously to feed materials according to the required feeding efficiency. The multi-mode feeding design can adapt to different production capacity rhythms and raw material specifications. The single-port sealed feeding method has low heat loss and is more suitable for long-term continuous heat preservation production; multi-port simultaneous feeding can significantly shorten the feeding time and improve the overall furnace production cycle.

[0047] Each of the casting cavities 2 is equipped with a heating device 5 at its bottom. In this embodiment, the heating device 5 is an induction heater, which can efficiently heat and melt the metal material in the casting cavity 2 into molten metal 10 and precisely maintain the temperature through the principle of electromagnetic induction. Each of the casting cavities 2 is provided with a casting port 4 on its side wall. The inlet end of the casting port 4 is located at the lower part of the side wall inside the casting cavity 2, and the outlet end extends obliquely upward to the outer side wall of the furnace body 1 for fitting and connecting with the pouring port 131 of the external mold 13.

[0048] Preferably, each of the casting cavities 2 is equipped with an independent air inlet pressurization device 11 at its top, and the air inlet pressurization device 11 is connected to the control system signal. During the casting operation, the air inlet pressurization device 11 introduces inert pressurized gas into the casting cavity 2, increasing the air pressure inside the cavity and driving the molten metal to overflow horizontally along the side casting port 4 and be injected into the cavity of the mold 13 to complete the filling. The side-mounted casting port 4 combined with the air pressure casting structure eliminates the need for additional riser pipes, resulting in a shorter molten metal flow path and smaller temperature drop, which can more stably ensure the casting inlet temperature. At the same time, the structure is simple, easy to maintain, and less prone to pipe blockage failure.

[0049] Preferably, each casting cavity 2 is equipped with an independent liquid level detection unit 6 and a temperature detection unit 7, both of which are connected to the control system signal. The liquid level detection unit 6 is used to collect the liquid level height data of the molten liquid in the cavity in real time, and the temperature detection unit 7 is used to collect the temperature data of the molten liquid in the cavity in real time.

[0050] A vertical connecting channel 8 is located at the center of the furnace body 1. All the inner walls of the casting cavities 2 have through holes that connect to this connecting channel 8, meaning the three casting cavities 2 are interconnected through the connecting channel 8 at the center. A switching device 9 is installed within the connecting channel 8. This switching device 9 uses a cylinder-driven structure; the extension and retraction of the cylinder piston rod causes a stopper rod to move vertically up and down, thereby opening or closing the connecting channel 8. In other embodiments, the switching device can be a valve, but details will not be elaborated here.

[0051] Specifically, when the switch device 9 is in the open state, each casting cavity 2 is interconnected through the connecting channel 8, allowing the molten metal to flow freely between the cavities, automatically achieving uniform liquid level distribution. Simultaneously, heat conduction rapidly brings the temperature of each cavity to a uniform level. When the switch device 9 is in the closed state, the connecting channel 8 is completely blocked, and each casting cavity 2 is independently isolated, allowing for independent casting operations without pressure interference. The structure employing a single-centered channel combined with a single-set stopper rod device minimizes the number of actuators, reducing equipment manufacturing costs and control complexity. Furthermore, the symmetrical flow channel layout ensures consistent flow resistance in each cavity, resulting in more uniform molten metal distribution and effectively preventing liquid level deviations between cavities.

[0052] Preferably, the casting apparatus further includes a control system, which is connected to the temperature detection unit 7, the liquid level detection unit 6, the casting control module corresponding to each casting cavity 2, the power adjustment module of each heating device 5, the air inlet pressurization device 11, and the switching device 9. The core control logic of the control system is configured as follows: Reference temperature control logic: One temperature detection unit 7 is selected as the reference temperature detection unit. This reference unit establishes a communication connection with the power adjustment module of all heating devices 5. Based solely on the molten temperature of the reference cavity, the output power of all heating devices 5 is automatically adjusted to achieve uniform heating, holding, and cooling of the entire furnace of molten metal. Taking brass casting as an example, the reference temperature range can be set to 1030℃±10℃. The control system automatically adjusts the power according to the deviation of the reference temperature to stabilize the entire furnace of molten metal within the target temperature range. The other non-reference temperature detection units 7 do not communicate with the heating power adjustment module and only perform two functions: first, to display the current casting temperature of the corresponding casting cavity 2 in real time for operator monitoring; second, to participate in the casting anomaly judgment. When the casting temperature of the corresponding cavity is detected to be lower than the preset lower limit, an abnormal signal is immediately sent to the control system, and the control system immediately triggers the cavity to stop casting operations. If the mold sizes matched to different casting cavities 2 are different, the temperature or liquid level in one cavity may drop more rapidly, resulting in a faster temperature change rate. This causes the temperature to quickly fall below the reference temperature, leading to differences in the products cast later compared to those produced in other cavities or an increased scrap rate. The single-reference unified power adjustment control mode fundamentally avoids the power conflicts and temperature oscillations that easily occur with independent temperature control in multiple cavities, resulting in higher temperature control stability and reduced energy consumption. Independent temperature monitoring for each cavity retains the quality control capability of a single cavity, accurately intercepting abnormal casting conditions and improving the overall yield.

[0053] Liquid level control logic: The liquid level detection unit 6 feeds back liquid level data to the control system in real time. When the liquid level of the molten metal 10 in any cavity is detected to be lower than the preset threshold, the control system controls that cavity to stop casting to prevent insufficient filling pressure and poor casting due to excessively low liquid level. The control system has preset casting trigger conditions: only when the temperature of the molten metal in the casting cavity 2 is within the preset casting temperature range, and the liquid level of the molten metal 10 is higher than the inlet of the connecting channel 8, meeting the minimum liquid level requirement for gas pressure liquid rise, is the cavity determined to be ready for casting, and the casting operation can be started.

[0054] Stopper rod linkage logic: The control system monitors the working status of all casting cavities 2 in real time. When all casting cavities 2 are in a non-casting state, the automatic control switch device 9 is turned on, and the material replenishment, temperature equalization and liquid level equalization stage is entered. After the molten temperature of each casting cavity 2 is consistent and reaches the preset casting temperature, and the liquid level of the molten metal 10 reaches the preset requirements, the automatic control switch device 9 is turned off, and each cavity enters an independent waiting-to-cast state.

[0055] Example 2 like Figure 3-7As shown, this embodiment is equipped with a casting coordination device, which includes a robotic arm unit 12 for clamping and controlling the mold 13, realizing automatic docking of the mold 13 and the casting port 4, rotational drive during the casting process, and switching of casting modes. The robotic arm unit 12 consists of three parts: a feeding mechanism 121, a rotating mechanism 122, and an adjusting mechanism 123. The feeding mechanism 121 is used to drive the robotic arm unit 12 to move back and forth along the axial (horizontal) direction of the casting port 4, realizing the fitting, pressing, and separation of the casting port 131 of the mold 13 and the casting port 4 of the furnace body 1; the feeding mechanism 121 can adopt a conventional linear drive structure such as a cylinder slide or a lead screw slider. The rotating mechanism 122 includes a rotary motor 1222, a rotary bearing support 1223, and a lifting fixed seat 1224. The fixed end of the rotary bearing support 1223 is fixedly connected to the output end of the feed mechanism 121, and its rotating end is fixedly connected to the rear end face of the lifting fixed seat 1224. The axis of the rotary bearing support 1223 is the rotating shaft A1221, which is a horizontal axis and can be coaxially aligned with the axis of the casting port 4. The rotary motor 1222 drives the rotating end of the rotary bearing support 1223 to rotate through a gear meshing structure, thereby driving the lifting fixed seat 1224, the adjustment mechanism 123, and the mold 13 to rotate uniformly around the rotating shaft A1221, meeting the process requirements of rotary casting. The adjustment mechanism 123 is installed on the front end face of the lifting fixed seat 1224 and includes a linear slide rail 1231, a linear slider 1232, a hydraulic three-position cylinder 1233, and a lifting slide 1234. The linear slide rail 1231 is fixed on the lifting base 1224 in a vertical direction perpendicular to the rotation axis A1221. The linear slider 1232 is slidably fitted on the linear slide rail 1231 and fixedly connected to the L-shaped lifting base 1234. The mold 13 is mounted and fixed on the front end of the lifting base 1234. The fixed end of the hydraulic three-position cylinder 1233 is connected to the lifting base 1224, and the moving end is connected to the linear slider 1232. The extension and retraction of the piston rod drives the linear slider 1232 to rise and fall along the linear slide rail 1231, thereby adjusting the vertical position of the mold 13.

[0056] The hydraulic three-position cylinder 1233 can precisely position and self-lock the mold 13 in three collinear working positions: the first position is the original position (both piston rods are not extended), corresponding to the top-pouring casting mode; the second position is the middle position (only the lower piston rod extends), corresponding to the middle-pouring casting mode; and the third position is the upper limit position (both piston rods extend simultaneously), corresponding to the bottom-pouring casting mode. All three positions are located on the same vertical line of the rotating axis A1221, and the pouring port 131 of the mold 13 at each position is exactly coaxially aligned with the rotating axis A1221. The use of the hydraulic three-position cylinder 1233 to achieve three-position switching relies on the mechanical structure for precise positioning and self-locking, eliminating the need for additional position sensors. It offers high positioning accuracy, strong impact resistance, and stable mold 13 position during casting, preventing easy displacement. Simultaneously, it allows for rapid switching between different casting processes, significantly improving the equipment's process adaptability, and the control system has low complexity and a low failure rate.

[0057] Example 3 like Figure 8-9 As shown, the core structure, control logic and working principle of this embodiment are basically the same as those of Embodiment 1. The main difference lies in the overall layout of the furnace body 1 and the arrangement of the connecting channel 8.

[0058] In this embodiment, the furnace body 1 has a rectangular structure, and multiple casting cavities 2 are arranged in a straight line side by side, forming a rectangular layout. A connecting channel 8 is provided on the partition wall between every two adjacent casting cavities 2, and a set of switching devices 9 is installed at each connecting channel 8. All switching devices 9 are connected to the control system signal, and the control system uniformly controls the synchronous execution of opening or closing actions, realizing the synchronous connection or isolation of all casting cavities 2. The long, straight layout is more suitable for linearly arranged automated production lines, facilitating the sequential operation of multi-station robotic arm units 12 along the length of the furnace body 1, increasing the flexibility of workshop layout, and better connecting upstream and downstream processes.

[0059] In this embodiment, two casting ports 4 are symmetrically arranged on the left and right side walls of each casting cavity 2. Depending on the arrangement of the robotic arm unit 12 in the production line, one side of the casting port 4 can be selected for operation, while the other side of the casting port 4 is sealed with a sealing structure and kept in a non-working state. The design of the symmetrical casting ports 4 on both sides supports the arrangement of double-sided workstations, and robotic arm unit 12 and mold 13 workstations can be arranged on both sides of the furnace body 1 at the same time, thereby avoiding positional conflicts of the robotic arm unit 12. It can also adapt to the modification needs of single-sided production line layout, making the equipment more versatile.

[0060] Example 4 like Figure 10-13In this embodiment, the casting coordination device can be arranged as a base type, with the base 14 rotatably mounted on the base 15. The base 14 is driven to rotate along the vertical axis by the rotation drive unit 17, thereby rotating the robot arm unit 12, so that the mold 18 can rotate and switch between the loading / unloading station and the injection station. The base 14 can be configured with a single robot arm unit 12 as a single-arm structure, or with two robot arm units 12 as a double-arm structure.

[0061] Example 5 like Figure 14-15 In this embodiment, the casting coordination device can be arranged in a suspended manner, using a hoisting method, with the base 14 hoisted by the suspension base 16; at the same time, only one robotic arm unit 12 can be set as a single-arm structure, or multiple robotic arm units 12 can be set on the same base 14 to form multiple arms and various coordinations, such as a double-arm structure. There are many ways to arrange them, and the specific arrangement can be based on the arrangement in a multi-functional casting machine disclosed in CN120325937A, which will not be elaborated here.

[0062] It should be noted that in the above embodiments, the casting furnace of the casting device is a cored induction furnace. In other embodiments, it may also be a gas furnace, electric furnace, induction furnace, resistance furnace or coreless induction furnace, etc., and there is no specific limitation on it here.

[0063] The present invention also provides a control method for the above-mentioned novel casting apparatus: Combining the two furnace body structures described above, the complete usage and control process of the casting device of this invention is as follows: S1 Charging and Melting Stage: In the initial state, the control system activates all switches 9, fully opening the connecting channel 8, and all casting cavities 2 are interconnected through the channel. The operator adds solid metal ingots into the cavities through the charging port 3, and then starts the heating device 5 to heat and melt the metal. During this stage, the molten metal 10 can flow freely between the cavities through the connecting channel 8, automatically achieving uniform liquid level distribution, and simultaneously making the temperature of each cavity more uniform through heat conduction.

[0064] S2 Parameter Adjustment Stage: The control system automatically adjusts the output power of all heating devices 5 based on the detection value of the pre-selected reference temperature detection unit, and gradually raises the temperature of the entire furnace of molten metal 10 to the preset casting temperature range; at the same time, each liquid level detection unit 6 monitors the liquid level height in real time, and replenishes the material in time when the liquid level is insufficient, until the liquid level of all casting cavities 2 reaches the preset safe casting height.

[0065] S3 Isolation and Waiting-for-Pouring Stage: After the control system determines that the temperature of the molten metal 10 in all casting cavities 2 meets the standard and the liquid level meets the requirements, it outputs a control signal to close all switching devices 9, the connecting channel 8 is blocked, and each casting cavity 2 forms an independent closed cavity, entering the waiting-for-casting state. Cutting off the cavity connection before casting can completely avoid pressure interference and molten metal crossflow between cavities during the casting process, ensuring stable single-cavity casting pressure, and making the filling speed and molding quality more controllable.

[0066] S4 Independent Casting Stage: Each casting cavity 2 independently starts casting operations according to the production rhythm. The air inlet pressurization device 11 introduces pressurized gas, driving the molten metal 10 to be injected from the casting port 4 into the docked mold 13. Throughout the casting process, each temperature detection unit 7 and liquid level detection unit 6 continuously monitors the parameters of the corresponding cavity in real time. If the temperature of any cavity falls below the lower limit or the liquid level falls below the threshold, the control system immediately stops the casting of that cavity to prevent the production of unqualified castings. The remaining normal cavities can continue to operate.

[0067] S5 Cycle Reset Stage: When all casting cavities 2 have completed their current casting and are in a non-casting state, the control system automatically turns on the switch device 9 to re-enter the process of material replenishment, temperature adjustment, and melt equilibration; after the temperature and liquid level of all cavities have returned to the casting requirements, the switch device 9 is turned off and the next round of casting production is started.

[0068] The aforementioned fully automated cyclic control logic enables unattended continuous production. Stopper switch, power adjustment, and abnormal shutdown are all executed automatically without manual intervention. Regardless of whether the mold 13 matching each cavity is the same size or the casting time of a single cavity is the same, the temperature and liquid level control rules and stopper switch logic are uniformly followed. This supports mixed production of castings of multiple specifications, greatly improving the production flexibility and adaptability of the equipment.

[0069] Obviously, the above detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to describe preferred embodiments, not all embodiments, and is not intended to limit the invention. Various modifications and variations can be made to the invention by those skilled in the art. Based on the embodiments of the invention, any modifications, equivalent substitutions, improvements, etc., made by those skilled in the art to all other embodiments obtained without inventive effort are within the scope of protection of the invention.

Claims

1. An automatic casting machine system, comprising a casting device and multiple casting coordination devices, characterized in that, The casting device includes a furnace body with multiple casting cavities, and multiple casting coordination devices are arranged around the casting cavities to realize multi-station automated casting. The casting coordination device includes a multi-degree-of-freedom manipulator unit, and a casting mold is installed on the manipulator unit. Multiple casting cavities are isolated from each other and operate independently. The mold is connected and cooperated with the independently operating casting cavity under the operation of the robot unit to inject the molten metal into the mold to complete the automated casting.

2. The automatic casting machine system according to claim 1, characterized in that, The furnace body is also provided with a connecting channel that connects all the casting cavities. A switch device is installed at the connecting channel. The switch device is used to open or close the connecting channel. When the switch device is in the closed state, each casting cavity is isolated from each other and operates independently.

3. The automatic casting machine system according to claim 1, characterized in that, The casting coordination device is a base-type device, which also includes a base, a pedestal, and a rotary drive unit. The pedestal is used to place on the ground. At least one set of the robotic arm units is provided on the pedestal. The pedestal is rotatably mounted on the pedestal and is driven by the rotary drive unit to rotate along the vertical axis, so that the mold can rotate and switch between the loading / unloading station and the injection station.

4. The automatic casting machine system according to claim 1, characterized in that, The casting coordination device is a suspended type, which also includes a base, a suspension base and a rotary drive unit. At least one set of the robotic arm units is provided on the base. The base is rotatably mounted on the suspension base and is suspended and hoisted through the suspension base. The rotary drive unit drives the base to rotate along the vertical axis so that the mold can rotate and switch between the loading / unloading station and the injection station.

5. The automatic casting machine system according to any one of claims 1-4, characterized in that, The furnace body is circular, and multiple casting cavities are evenly distributed in a fan shape inside the circular furnace body; the connecting channel is located at the center of the circular furnace body, and all casting cavities are interconnected through the connecting channel at the center; the switching device is installed in the connecting channel at the center; the multiple casting coordination devices are distributed around the furnace body to realize multi-station automatic casting.

6. The automatic casting machine system according to any one of claims 1-4, characterized in that, The multiple casting cavities are arranged in a rectangular layout in a straight line. A connecting channel is provided between every two adjacent casting cavities, and a corresponding switch device is provided at each connecting channel. All switch devices are opened or closed synchronously to realize the interconnection or synchronous isolation of all casting cavities. The multiple casting coordination devices are arranged in a straight line to realize multi-station automatic casting.

7. The automatic casting machine system according to claims 1-4, characterized in that, The robotic arm unit includes: A rotating mechanism having a first output end, wherein the first output end is coaxially matched with the casting port of the casting cavity, and the axis of the first output end is defined as the rotating axis A; An adjustment mechanism is installed at the first output end of the rotating mechanism and is driven by the rotating mechanism to rotate around the rotating axis A; the adjustment mechanism has a second output end for connecting to the mold; The adjustment mechanism is configured to drive the mold to move in a radial direction perpendicular to the rotation axis A; The adjustment mechanism includes a hydraulic three-position cylinder, which can selectively position and hold the mold in a first position, a second position, and a third position, all of which are located on the same straight line.

8. A novel casting apparatus, comprising a furnace body for supplying molten metal to an external mold, characterized in that: The furnace body is divided into multiple independent casting chambers. Each casting chamber is equipped with an independent casting port and a heating device. The heating device is used to heat and melt or heat up the metal material in the corresponding casting chamber. The casting port is used to output molten metal to an external mold. At least one of the casting chambers is provided with a feeding port. Each of the casting cavities is equipped with an independent liquid level detection unit and a temperature detection unit; The furnace body is also provided with a connecting channel that connects all the casting cavities. A switch device is installed at the connecting channel to open or close the connecting channel. When the switch device is in the open state, each casting cavity is connected to the other through the connecting channel, and molten metal can flow and conduct temperature between the casting cavities. When the switch device is in the closed state, each casting cavity is isolated from the other and operates independently. The casting apparatus also includes a control system, which is connected to each of the temperature detection units, each of the liquid level detection units, the casting control module corresponding to each casting cavity, and the switching device. The control system is configured as follows: One of the temperature detection units is selected as the reference temperature detection unit, and the output power of all heating devices is adjusted according to the detection signal of the reference temperature detection unit to achieve the melting or heating of the metal. The remaining temperature detection units are used to detect the casting temperature of the corresponding casting cavity in real time. When the casting temperature of any casting cavity is detected to be lower than the preset range value, the casting operation of that casting cavity is controlled to stop. Based on the detection signals from each liquid level detection unit, when the liquid level in any casting cavity is detected to be lower than the preset liquid level threshold, the casting operation of that casting cavity is controlled to stop. When all casting cavities are in a non-casting state, the switch device is turned on to perform feeding, temperature adjustment and molten metal circulation. After the molten metal in each casting cavity reaches the preset casting temperature and preset liquid level value, the switch device is turned off and each casting cavity begins independent casting.

9. The novel casting apparatus according to claim 8, characterized in that, Each casting cavity is independently equipped with a feeding port that can be opened or closed. During the feeding operation, at least one feeding port can be opened to feed material, while the other feeding ports remain sealed.

10. The novel casting apparatus according to claim 8, characterized in that, Each of the casting cavities is also equipped with an independent air inlet pressurization device, which is connected to the control system via a signal. During the casting operation, the air inlet pressurization device introduces pressurized gas into the corresponding casting cavity to increase the air pressure inside the cavity, thereby causing the molten metal to overflow from the side casting port and be injected into the external mold.

11. The novel casting apparatus according to claim 8, characterized in that, The casting furnace of the casting device is a cored induction furnace, a gas furnace, an electric furnace, an induction furnace, a resistance furnace, or a coreless induction furnace.

12. A control method for the novel casting apparatus as described in any one of claims 8-11, characterized in that, Includes the following steps: S1 Feeding and Melting: The control system opens the control switch to connect the channels and make the casting cavities interconnected; feed material into the casting cavity through the feeding port and start the heating and melting device to heat and melt the added material; S2 parameter adjustment: Select one of the temperature detection units as a reference, and the control system adjusts the output power of the heating and melting device according to the detection signal of the reference temperature detection unit to raise the temperature of the molten metal to the preset casting temperature; detect the liquid level of each casting cavity through each liquid level detection unit, and add metal material until the liquid level of each casting cavity reaches the preset liquid level requirement; S3 Isolation for Casting: After the temperature of the molten metal in all casting cavities reaches the preset casting temperature and the liquid level reaches the preset requirements, the control system controls the switch to close, isolating each casting cavity from the others. S4 Independent Casting: Each casting chamber is independently pressurized and performs casting operations. During the casting process, each temperature detection unit monitors the casting temperature of the corresponding casting chamber in real time, and each liquid level detection unit monitors the liquid level of the corresponding casting chamber in real time. When the casting temperature of any casting chamber is detected to be lower than the preset range or the liquid level is lower than the preset threshold, the control system controls the casting chamber to stop casting operations. S5 Cycle Reset: When all casting cavities are in a non-casting state, the control system automatically turns on the switch to perform feeding, temperature adjustment and liquid level increase again. After all parameters meet the standards, the switch is turned off and the next round of casting production begins.

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