Intelligent foundry sand casting pouring process molten metal skimming mechanism and method

Abstract

The present application relates to the technical field of slag-iron separation before casting pouring, in particular to a molten metal skimming mechanism and method for intelligent casting sanding pouring process. The existing skimmer relies on the linkage force of the bottom metal liquid flow on the top floating slag to realize slag removal, lacks reasonable guide structure, causes the floating slag to be intercepted for a long time, and is easy to erode and damage the prefabricated lining plate and the skimming core. The present application provides a molten metal skimming mechanism for intelligent casting sanding pouring process, which comprises a base, a channel is arranged at the top of the base, a groove is arranged in the middle of the channel, a blocking block is arranged above the groove, a slag outlet is arranged on one side of the front end face of the base in front of the blocking block, a guide plate is arranged on the inner side end of the slag outlet, the top end face of the guide plate gradually spirals upward from the inlet end to the outlet end, a filter gap is arranged between the guide plate and the front end face of the blocking block, and a positive discharge device is further arranged on the top of the base. The present application forcibly guides the floating slag through the spirally rising guide plate, cooperates with the positive discharge device to realize efficient slag removal, greatly shortens the floating slag residence time, reduces the erosion and damage to the equipment, prolongs the service life, and improves the casting quality.

Description

Technical Field

[0001] This invention relates to the field of slag and iron separation technology before casting, specifically to a molten metal skimming mechanism and method for intelligent casting sand casting process. Background Technology

[0002] In the sand casting process of intelligent casting, slag removal is not only a core step in ensuring casting quality, but also a key process for achieving intelligent and automated casting production. During the melting and pouring of molten metal, slag composed of oxides, non-metallic inclusions, and flux residues forms on the surface. If this slag is not removed in time, it will mix into the casting, forming defects such as inclusions and porosity, directly leading to product scrap and seriously affecting the mechanical properties and service life of the casting.

[0003] In traditional casting processes, slag removal mainly relies on manual slag skimming in a high-temperature environment. Operators use tools such as slag skimmers to remove the slag from the surface of the molten metal. This method is not only labor-intensive and inefficient, but also poses significant safety hazards, as the splashing and radiant heat from the high-temperature molten metal seriously threaten the health of the operators. With the continuous development of intelligent casting technology, more and more casting companies are beginning to adopt automated slag skimming equipment to replace manual operations.

[0004] Chinese patent CN202120851919.7 discloses a slag skimmer, comprising an iron trough with channels for molten iron flow, the channels being divided into a top channel and a bottom channel; a prefabricated liner inserted into the top channel and fitting against its two sides; a slag skimmer core penetrating the prefabricated liner vertically and sliding up and down on it, the two sides of the core being flush with the two sides of the bottom channel; a suspension ring fixed to the top of the core; and a crossbar penetrating the core horizontally and supporting it on the top of the liner. In this design, when the bottom of the core is eroded and rises in height, the core can simply be slid downwards, extending its service life and eliminating the need for frequent repairs, thus improving the slag removal efficiency of the molten iron.

[0005] However, the aforementioned existing technical solutions still have significant technical defects. The slag intercepted by the precast liner is simply discharged naturally through the slag outlet, relying on the combined force of the molten metal flow at the bottom and the slag at the top. Due to the lack of a proper guiding structure, the slag lacks effective directional guidance after interception, resulting in a prolonged residence time of the slag in the interception area. Prolonged high-temperature slag retention severely erodes and damages the structure of the precast liner and the skimming core, shortening the equipment's lifespan and affecting skimming efficiency, thus impacting the stability of casting quality. Furthermore, existing skimmers lack an active slag removal mechanism, relying entirely on the passive driving force of the molten metal flow. When the molten metal flow rate is low or the slag viscosity is high, the slag removal effect significantly decreases, making it difficult to meet the requirements of intelligent casting production lines for skimming efficiency and stability. Summary of the Invention

[0006] The present invention aims to solve the above-mentioned problems existing in the prior art and provides a molten metal skimming mechanism and method for intelligent casting sand casting process.

[0007] This invention is implemented as follows: A molten metal skimming mechanism for intelligent casting sand pouring process includes a base. The longitudinal profile of the top of the base is U-shaped. A concave area in the middle of the top of the base forms a linear channel facing forward and backward. A groove is provided in the middle of the channel along its length. Blocks are spaced above the groove. A slag outlet is provided on one side of the front end of the block on the base. A guide plate is provided on the inner end of the slag outlet. The front end of the guide plate is an inlet end near the input side of the channel, and the rear end of the guide plate is an outlet end near the slag outlet. The top end of the guide plate gradually spirals upward from the inlet end to the outlet end. The bottom of the guide plate is spaced apart from the bottom of the channel, and a filter material gap is provided between the guide plate and the front end of the block. An active discharge device is also provided on the top of the base. The active discharge device can drive the slag on the front side of the block and above the guide plate to be discharged through the slag outlet.

[0008] Based on the above technical solution, the guide plate is provided with an installation part on the side away from the slag outlet, and the installation part is detachably connected to the top edge of the base.

[0009] Based on the above technical solution, the inlet and outlet ends of the channel are respectively the inlet end and the outlet end. The bottom of the channel, from the inlet end to the guide plate, is provided with oscillation patterns, which are several inclined stripes distributed at intervals.

[0010] Based on the above technical solution, the oscillation pattern is a raised pattern and / or a groove structure.

[0011] Based on the above technical solution, the active discharge device includes a connecting block located at the bottom and connected to the base. A bracket is connected to the connecting block. The top of the bracket extends above the base and is connected to a flipping seat. The flipping seat has an adjustable mounting block. A pulse nozzle is detachably connected to the mounting block. The output end of the pulse nozzle faces the area in front of the blocking block and above the guide plate.

[0012] Based on the above technical solution, the bracket is a telescopic rod structure.

[0013] Based on the above technical solution, a vision inspection module is also included. The vision inspection module can detect the scum content in the area in front of the blocking block and above the guide plate. The vision inspection module is electrically connected to the control system of the active discharge device.

[0014] Based on the above technical solution, a position adjustment structure is provided between the mounting part and the base.

[0015] Based on the above technical solution, the blocking block has a detachable core block inside.

[0016] A slag skimming method employs a molten metal slag skimming mechanism for intelligent casting sand casting process as described in any of the above-mentioned embodiments.

[0017] Compared with the prior art, the present invention has at least the following advantages: 1. This invention utilizes a guide plate that spirals upwards from the top face of the inlet to the outlet, creating a forced spiral guiding effect on the scum. The scum is guided by an upward force on the surface of the spirally rising guide plate, continuously pushed towards the scum outlet, preventing prolonged scum retention in the interception area, effectively reducing high-temperature erosion of the blocking block and the guide plate itself, and extending the service life of the equipment.

[0018] 2. This invention utilizes an active discharge device, employing pulse nozzles to perform directional pulse blowing on the slag area, actively pushing the slag towards the discharge port. Compared to the passive method in existing technologies that relies entirely on the flow of molten metal to drive slag discharge, the active discharge device of this invention is unaffected by the flow rate of the molten metal, maintaining a high efficiency in slag discharge even under low flow rate conditions, significantly improving the stability and reliability of slag discharge.

[0019] 3. This invention, by setting up a visual detection module, can detect the scum content in the area in front of the blocking block and above the guide plate in real time, and transmit the detection signal to the control system of the active discharge device. The control system automatically adjusts the working parameters of the pulse nozzle (such as blowing frequency, blowing pressure, blowing angle, etc.) according to the scum content, realizing the full automation and intelligence of the scum skimming operation without manual intervention.

[0020] 4. By setting an oscillating texture structure at the bottom of the channel, the present invention generates a weak longitudinal oscillation effect when the molten metal flows through the oscillating texture area, which can help the scum "climb" to the top of the guide plate and effectively intercept some of the sedimentary impurities.

[0021] 5. The guide plate of the present invention is detachably connected to the base through the mounting part, and the blocking block is provided with a detachable core block. All major vulnerable parts adopt a modular design, which facilitates individual replacement and maintenance, thereby reducing the maintenance cost and downtime of the equipment.

[0022] 6. The bracket of the present invention is a telescopic rod structure, the flipping seat has an angle adjustment function, and a position adjustment structure is provided between the mounting part and the base, so that the position and angle of the pulse nozzle and the position of the guide plate can be flexibly adjusted according to the actual working conditions to meet the skimming requirements of different metal types and different scum characteristics. Attached Figure Description

[0023] To more clearly illustrate the technical solutions of the 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 of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of a molten metal skimming mechanism for an intelligent casting sand pouring process in one embodiment; Figure 2 for Figure 1 Top view; Figure 3 for Figure 1 Longitudinal sectional view; Figure 4 for Figure 1 Side view; Figure 5 for Figure 1 Schematic diagram of the active discharge device; Figure 6 This is a schematic diagram of the channel structure in another embodiment.

[0025] The diagram is labeled as follows: 100, base; 110, channel; 111, inlet end; 112, outlet end; 113, groove; 114, oscillation pattern; 120, slag outlet; 200, blocking block; 210, core block; 300, guide plate; 301, guide end; 302, outlet end; 303, filter media gap; 310, mounting part; 400, active discharge device; 410, connecting block; 420, bracket; 430, tilting seat; 431, adjusting knob; 432, cover plate; 440, pulse nozzle. Detailed Implementation

[0026] 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. Obviously, the described embodiments are only a part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention.

[0027] In the description of this invention, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0028] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0029] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0030] Please refer to the following: Figures 1 to 5 This embodiment provides a molten metal skimming mechanism for intelligent casting sand pouring process.

[0031] The base 100 is prefabricated entirely from high-strength refractory castable, with its top longitudinal profile exhibiting a U-shaped structure. A linear, front-to-back oriented groove 110 is formed in the recessed area at the top center of the base 100. The base 100 is cast using silicon nitride-bonded castable, a material with excellent thermal shock resistance, slag erosion resistance, and oxidation resistance, capable of withstanding long-term scouring by molten iron at temperatures exceeding 1400℃. The wall thickness of the base 100 is 150mm to 250mm, preferably 200mm, to ensure sufficient structural strength and service life.

[0032] The channel 110 extends along the length (i.e., the front-to-back direction) of the base 100, and its cross-section is U-shaped or trapezoidal. The width of the channel 110 is 300mm to 600mm, and its depth is 200mm to 400mm. The inlet end 111 and the outlet end 112 of the channel 110 are respectively the inlet end 111 and the outlet end 112. The inlet end 111 is connected to the tapping port of the upstream smelting furnace, and the outlet end 112 is connected to the downstream casting system. Molten metal flows into the channel 110 from the inlet end 111, and after slag skimming, it flows out from the outlet end 112.

[0033] A groove 113 is provided in the middle of the length direction of the channel 110. The groove 113 extends along the width direction of the channel 110, and the width of the groove 113 is 50mm to 150mm, and the depth is 30mm to 80mm. The groove 113 is provided to accommodate and position the bottom of the blocking block 200, and at the same time provides settling space for some heavy inclusions in the molten metal.

[0034] In another embodiment, such as Figure 6 As shown, the bottom of the channel 110 is provided with an extension groove, which is conducive to the flow of molten metal.

[0035] A slag outlet 120 is provided on one side of the base 100, located on the front face of the blocking block 200 (i.e., the end face facing the inlet end 111). The slag outlet 120 penetrates the side wall of the base 100 and is connected to the channel 110. The cross-section of the slag outlet 120 is rectangular or circular, with a width of 100mm to 200mm and a height of 80mm to 150mm. A slag discharge channel is connected to the outer end of the slag outlet 120 for discharging scum to a collection device.

[0036] The blocking blocks 200 are spaced apart above the grooves 113, with a gap between the bottom of the blocking blocks 200 and the grooves 113, which serves as a channel for the molten metal to pass through. The blocking blocks 200 are prefabricated from high-alumina or corundum refractory material and are rectangular or trapezoidal in shape. The length of the blocking blocks 200 (along the width of the channel 110) matches the width of the channel 110. A gap of 5mm to 15mm is left between the two ends of the blocking blocks 200 and the side walls of the channel 110 to prevent jamming due to thermal expansion. The height of the blocking blocks 200 is 150mm to 300mm, and the width (along the length of the channel 110) is 80mm to 150mm.

[0037] The function of the blocking block 200 is to intercept the scum floating on the surface of the molten metal. Since the density of the scum is less than that of the molten metal, the scum floats on the surface of the molten metal and moves forward with the liquid flow. When it encounters the blocking block 200, the surface scum is intercepted by the blocking block 200, while the pure molten metal at the bottom flows through the gap between the bottom of the blocking block 200 and the groove 113, thereby achieving scum-iron separation.

[0038] Preferably, the blocking block 200 has a removable core block 210 inside. The core block 210 can be configured with a suspension structure at the top, facilitating hoisting operations during maintenance of the blocking block 200. This split structure means that after the blocking block wears out, only the external structure needs to be replaced, and the core block can be reused multiple times, reducing maintenance costs. Additionally, the core block 210 can also be equipped with a cooling module, allowing the blocking block to appropriately cool the top area of ​​the molten metal according to actual operational needs, thus aiding in the agglomeration and removal of scum.

[0039] A guide plate 300 is provided on the inner end of the slag outlet 120. The guide plate 300 is one of the core innovative components of this invention. Its function is to strongly guide the slag intercepted by the blocking block 200 so that it can be discharged efficiently through the slag outlet 120.

[0040] The deflector 300 is made entirely of corundum or silicon carbide refractory material, which has excellent erosion resistance and thermal shock resistance. The thickness of the deflector 300 is 30mm to 60mm, and the width (along the width direction of the channel 110) is 150mm to 300mm.

[0041] The front end of the guide plate 300 is the inlet end 301, located near the input side of the channel 110 (i.e., the inlet end 111 side), and the rear end of the guide plate 300 is the outlet end 302, located near the slag outlet 120. The top end face of the guide plate 300 gradually spirals upward from the inlet end 301 to the outlet end 302. Specifically, the top end face of the guide plate 300 rises smoothly in a spiral curve from the inlet end 301 towards the outlet end 302. The angle of ascent (i.e., the angle between the spiral surface and the horizontal plane) is 5° to 25°, preferably 10° to 15°. An excessively large angle of ascent (more than 25°) will result in excessive resistance to slag climbing, affecting the guiding effect; an excessively small angle of ascent (less than 5°) will result in an insignificant guiding effect.

[0042] The bottom of the guide plate 300 is spaced apart from the bottom of the channel 110 by a distance of 50mm to 120mm. This space allows the bottom layer of pure molten metal to pass through, while the scum is guided above the top end face of the guide plate 300.

[0043] A filter media gap 303 is provided between the front end face of the guide plate 300 and the blocking block 200. The width of the filter media gap 303 is 20mm to 60mm. Its function is to allow some small slag particles in the area below the guide plate to rise and enter the guiding area of ​​the guide plate 300, while blocking larger slag particles. However, it allows some molten metal in the area above the guide plate to seep down into the area below, thus achieving the effect of both slag discharge and filter media. It should be noted that the filter media gap 303 in this embodiment is a through-hole single-groove structure. In other embodiments, it can also be set as a porous structure.

[0044] A mounting part 310 is provided on the side of the guide plate 300 away from the slag outlet 120. The mounting part 310 has a bent flange structure and is detachably connected to the top edge of the base 100. The mounting part 310 is integrally formed from the same material as the guide plate 300, and its shape is flat or L-shaped. The mounting part 310 has mounting holes and is fixedly connected to the top edge of the base 100 by high-temperature resistant bolts. The detachable connection method allows the guide plate 300 to be easily replaced after wear, reducing maintenance difficulty and cost.

[0045] Preferably, a position adjustment structure is provided between the mounting part 310 and the base 100. The position adjustment structure includes an elongated adjustment groove provided on the top edge of the base 100 and a positioning bolt provided on the mounting part 310. By moving the position of the mounting part 310 along the adjustment groove, the front and rear position of the guide plate 300 in the channel 110 can be adjusted, thereby adjusting the size of the filter media gap 303 between the guide plate 300 and the blocking block 200 to adapt to the skimming requirements under different working conditions.

[0046] The operation of the guide plate 300 is based on the forced guidance principle of the spiral curved surface. When the scum intercepted by the blocking block 200 accumulates in the area between the front end face of the blocking block 200 and the guide plate 300, the scum is subjected to forces in two directions: one is the forward thrust generated by the flow of molten metal; the other is the upward component force generated by the spiral rising curved surface of the guide plate 300.

[0047] Specifically, the top surface of the guide plate 300 is a spirally rising curved surface that gradually rises from the inlet end 301 to the outlet end 302. Driven by the molten metal, the scum moves along the curved surface of the guide plate 300. As the curved surface gradually rises, the scum is forced upwards while moving horizontally forward. When the scum reaches the outlet end 302, its height has reached the height of the slag outlet 120. Under the combined action of the continuous push of the molten metal and the tangential component of its own gravity along the curved surface, the scum is smoothly discharged through the slag outlet 120.

[0048] Compared with existing planar guide structures, the spiral rising guide plate 300 of the present invention has the following significant advantages: First, forced guidance. Planar guide structures rely solely on the flow of molten metal to move the scum, lacking an active guidance mechanism. The spiral rising curved surface provides a forced movement path for the scum, causing it to move along a predetermined spiral trajectory, avoiding scum accumulation and retention in the interception area. Second, reduced residence time. Due to the forced guidance effect of the spiral curved surface, the time from scum interception to discharge is significantly shortened, reducing the erosion time of high-temperature scum on the blocking block 200 and the guide plate 300. Third, self-cleaning effect. The spiral rising curved surface structure causes the scum to be continuously subjected to an upward component force during movement, making it less prone to adhesion and deposition on the curved surface, thus exhibiting a certain degree of self-cleaning effect.

[0049] Furthermore, the bottom of the channel 110 is provided with oscillation patterns 114 in the area between the inlet end 111 and the guide plate 300 inlet end 301. The oscillation patterns 114 are several inclined stripes distributed at intervals.

[0050] The oscillation pattern 114 has a raised and / or grooved structure. When a raised structure is used, the height of the raised pattern is 2 mm to 10 mm, preferably 3 mm to 6 mm; when a grooved structure is used, the depth of the groove is 2 mm to 10 mm, preferably 3 mm to 6 mm. The width of the oscillation pattern 114 is 5 mm to 20 mm, and the spacing between adjacent oscillation patterns 114 is 10 mm to 40 mm. The inclination direction of the oscillation pattern 114 forms an angle of 15° to 45° with the length direction of the channel 110, preferably 30°.

[0051] The working principle of the oscillation pattern 114 is as follows: When the molten metal flows through the area where the oscillation pattern 114 is set, the oscillation pattern 114 generates a slight disturbance to the molten metal, causing a slight up-and-down undulation effect during the flow. This up-and-down undulation effectively helps the scum on top of the molten metal to oscillate appropriately. This oscillation action helps the scum generate a "climbing force" at the front end of the guide plate, allowing the scum to enter the area above the guide plate more efficiently. In addition, the oscillation pattern can form tiny interception dams at the bottom of the molten metal, causing some of the heavier inclusion particles to deposit here, making the molten metal at the output end purer. At the same time, the oscillation pattern 114 can also increase the contact area between the molten metal and the bottom of the channel 110 to a certain extent, which is conducive to the uniform heat transfer at the bottom of the channel 110 and reduces local overheating.

[0052] The oscillation pattern 114 can be manufactured by directly forming it in the mold during the casting process of the base 100, or by machining it after the base 100 has cured. For the base 100 formed by refractory castable, it is preferable to directly form the oscillation pattern 114 during the casting process to ensure the integrity and bonding strength between the oscillation pattern 114 and the base 100 body.

[0053] The base 100 is also equipped with an active discharge device 400, which can drive the scum in front of the blocking block 200 and above the guide plate 300 to be discharged through the scum outlet 120.

[0054] like Figure 5 As shown, the active discharge device 400 includes a connecting block 410 located at the bottom and connected to the base 100. The connecting block 410 is cast from heat-resistant steel (such as ZG40Cr25Ni20), and its bottom is provided with a mounting base, which is fixedly connected to the top of the base 100 by high-temperature resistant bolts. The thickness of the connecting block 410 is 20mm to 40mm, and the width is 80mm to 150mm.

[0055] A bracket 420 is connected to the connecting block 410. The bracket 420 is a vertical rod structure. In other embodiments, the bracket 420 can be configured as a telescopic rod structure, consisting of two coaxially sleeved heat-resistant steel pipes, with the inner and outer pipes telescopically positioned by a locking sleeve. The telescopic range of the bracket 420 is 200mm to 600mm, and the height position of the pulse nozzle 440 can be changed by telescopic adjustment to adapt to the skimming requirements at different liquid levels.

[0056] The bottom of the bracket 420 is welded or bolted to the connecting block 410, and the top of the bracket 420 extends above the base 100. A flip seat 430 is connected to the top of the bracket 420. The flip seat 430 includes a fixed base and a mounting block. The fixed base is fixedly connected to the top of the bracket 420, and the mounting block is hinged to the fixed base via a pivot. The flip seat 430 also has an adjustment knob 431 and a cover plate 432. The adjustment knob 431 is used to lock or release the mounting block, allowing it to be adjusted and locked within a certain angle range (-30° to +30°). The cover plate 432 covers the exterior of the flip seat 430, providing dust protection.

[0057] Two pulse nozzles 440 are detachably connected to the mounting block, and the pulse nozzles are connected to external air compressor equipment via pipe fittings. The output end of the pulse nozzle 440 faces the area in front of the block 200 and above the guide plate 300. The pulse nozzle 440 is made of heat-resistant stainless steel (such as 310S stainless steel), and its nozzle diameter is 6mm to 20mm, preferably 10mm to 15mm. The working medium of the pulse nozzle 440 is compressed air or nitrogen, the working pressure is 0.4MPa to 1.0MPa, the pulse frequency is 1Hz to 10Hz, and the duration of a single pulse is 0.1 seconds to 0.5 seconds.

[0058] The pulse nozzle 440 can be a commercially available general-purpose pneumatic pulse nozzle, such as the P-type pneumatic nozzle series from Spraying Systems Co. (USA) or the 466 series pneumatic nozzles from Lechler GmbH (Germany). These nozzle models feature high temperature resistance (maximum operating temperature can reach over 800°C), corrosion resistance, and adjustable spray angle (30° to 120°), meeting the requirements of this invention. The preferred spray angle is 60° to 90° to ensure coverage of the entire scum area.

[0059] The working principle of the active discharge device 400 is as follows: When the pulse nozzle 440 is connected to a compressed air or nitrogen source, pulse-type blowing is performed at a set frequency and pressure under the action of the control system. The high-speed pulse airflow impacts the scum area in front of the blocking block 200 and above the guide plate 300, blowing away the scum and pushing it towards the scum outlet 120. Compared with continuous blowing, pulse-type blowing has the following advantages: First, the impact force is greater, which can effectively break and loosen the clumps of scum; second, it saves air source consumption; and third, it avoids continuous disturbance to the surface of the molten metal, reducing molten metal splashing and oxidation.

[0060] The telescopic function of the bracket 420 and the angle adjustment function of the tilting seat 430 allow the position and spray angle of the pulse nozzle 440 to be flexibly adjusted according to actual working conditions. For example, when the height of the molten metal changes, the nozzle height can be adjusted by adjusting the telescopic length of the bracket 420; when the viscosity and accumulation morphology of the scum change, the spray direction can be changed by adjusting the angle of the tilting seat 430 to obtain the best blowing effect.

[0061] In other embodiments, a vision inspection module (not shown) is also included. The vision inspection module is capable of detecting the scum content in the area in front of the blocking block 200 and above the guide plate 300, and is electrically connected to the control system of the active discharge device 400.

[0062] The vision inspection module includes an industrial camera, lens, light source, and image processing unit. The industrial camera uses a high-temperature resistant CCD or CMOS camera, such as the ace series high-temperature resistant cameras from Basler AG (Germany) or the Blackfly series cameras from FLIR Systems (USA), with a resolution of at least 1280×1024 pixels and a frame rate of at least 30fps. The camera front is equipped with a high-temperature resistant lens and a quartz glass protective window to prevent damage from high-temperature radiation and splashes. The light source uses a high-brightness LED ring light source or a fiber optic cold light source to provide uniform illumination.

[0063] The vision inspection module is installed above the base 100, facing the front of the block 200 and above the guide plate 300. During installation, ensure the camera's optical axis forms an angle of 30° to 60° with the surface of the scum area to achieve optimal imaging. The working distance between the camera and the scum area is 300mm to 800mm.

[0064] The image processing unit employs an embedded industrial computer or a high-performance PLC, incorporating a deep learning-based scum recognition algorithm. This algorithm, trained on a large number of scum image samples, accurately identifies the distribution area, accumulation thickness, and coverage area of ​​the scum, and calculates the scum content accordingly. When the scum content exceeds a preset threshold, the control system automatically activates the active discharge device 400 for scum removal via injection; when the scum content drops below the preset threshold, the control system automatically stops injection or reduces the injection frequency.

[0065] The vision inspection module communicates with the control system of the active feeding device 400 via industrial Ethernet (such as PROFINET, EtherNet / IP) or fieldbus (such as DeviceNet, CANopen) to achieve real-time data transmission and immediate response to control commands.

[0066] By introducing a visual inspection module, the slag skimming mechanism of this invention achieves an intelligent upgrade from "timed slag discharge" to "on-demand slag discharge," avoiding unnecessary energy consumption and equipment wear, while ensuring timely removal of floating slag and improving the stability of casting quality.

[0067] A slag skimming method employs the molten metal slag skimming mechanism for intelligent casting sand pouring process described in any of the above-mentioned embodiments. The method includes the following steps: Step 1: The molten metal flows into the channel 110 from the inlet 111 and flows forward along the channel 110. When the molten metal flows through the area provided with the oscillation pattern 114, the oscillation pattern 114 generates a slight disturbance to the bottom of the molten metal.

[0068] Step 2: When the molten metal flows to the blocking block 200, the scum floating on the surface is intercepted by the blocking block 200, and the pure molten metal at the bottom flows through the gap between the bottom of the blocking block 200 and the groove 113 and flows out through the outlet end 112.

[0069] Step 3: The intercepted scum, propelled by the molten metal, enters the filter media gap 303 area between the guide plate 300 and the front end face of the blocking block 200. Under the forced guidance of the spirally rising top end face of the guide plate 300, the scum moves along the spiral curved surface from the inlet end 301 to the outlet end 302 and is gradually lifted.

[0070] Step 4: The visual inspection module detects the scum content in the area in front of the blocking block 200 and above the guide plate 300 in real time, and transmits the detection signal to the control system.

[0071] Step 5: When the scum content exceeds the preset threshold, the control system activates the active discharge device 400. The pulse nozzle 440 performs pulse-type blowing at a set frequency and pressure, blowing the scum towards the scum outlet 120. The scum is discharged through the scum outlet 120 to the collection device.

[0072] Step 6: When the visual inspection module detects that the scum content has dropped below the preset threshold, the control system stops the blowing operation of the active discharge device 400 or switches it to a low-frequency standby mode.

[0073] Step 7: Repeat steps 1 to 6 to achieve continuous and automated skimming operation.

[0074] In another embodiment, the active discharge device 400 employs a multi-nozzle array structure. Specifically, a crossbeam is connected to the top of the support 420, and 3 to 5 pulse nozzles 440 are spaced apart along the width of the channel 110 on the crossbeam. Each pulse nozzle 440 is independently controlled, and the nozzles at corresponding positions can be selectively activated according to the distribution of scum at different width positions, achieving precise blowing, further improving scum discharge efficiency and saving air source consumption. The control method of the multi-nozzle array is as follows: a vision detection module performs zone detection of the scum area and identifies the scum content in each zone. The control system independently controls the working state of the corresponding pulse nozzles 440 according to the scum content of each zone, achieving precise scum discharge by zone.

[0075] In another embodiment, the active discharge device 400 uses a mechanical actuation structure instead of the pulse nozzle 440. Specifically, the active discharge device 400 includes a drive motor, a transmission mechanism, and a scum-discharging plate mounted on the top of the base 100. The drive motor drives the scum-discharging plate to reciprocate or rotate in the area in front of the blocking block 200 and above the guide plate 300 via the transmission mechanism, pushing the scum towards the scum outlet 120. The mechanical actuation structure is suitable for working conditions where the scum has high viscosity and poor fluidity, achieving forced discharge of the scum through the direct action of mechanical force. However, compared to the pneumatic method of the pulse nozzle 440, the mechanical actuation structure has more moving parts, and its reliability and maintenance convenience in high-temperature environments are slightly inferior to the pneumatic method.

[0076] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A molten metal skimming mechanism for intelligent casting sand pouring process, characterized in that, Includes a base (100), the longitudinal section of the top of the base (100) has a U-shaped outer contour, the middle concave area of ​​the top of the base (100) forms a linear front-to-back channel (110), the middle of the channel (110) has a groove (113) in the length direction, and the groove (113) is provided with blocking blocks (200) at intervals above the groove (113), the base (100) has a slag outlet (120) on one side of the front end face of the blocking block (200), the inner end of the slag outlet (120) is provided with a guide plate (300), the front end of the guide plate (300) is the inlet end near the input side of the channel (110), and so on. The rear end of the guide plate (300) is the outlet end (302) near the slag outlet (120). The guide plate (300) gradually spirals upward from the top end face of the inlet end to the outlet end (302). The bottom of the guide plate (300) is spaced apart from the bottom of the channel (110). A filter material gap (303) is provided between the guide plate (300) and the front end face of the blocking block (200). The top of the base (100) is also provided with an active discharge device (400). The active discharge device (400) can drive the slag on the front side of the blocking block (200) and above the guide plate (300) to be discharged out through the slag outlet (120).

2. The molten metal skimming mechanism for intelligent casting sand pouring process according to claim 1, characterized in that, The guide plate (300) has an installation part (310) on the side away from the slag outlet (120), and the installation part (310) is detachably connected to the top edge of the base (100).

3. The molten metal skimming mechanism for intelligent casting sand casting process according to claim 1, characterized in that, The inlet end (111) and outlet end (112) of the channel (110) are respectively. The bottom of the channel (110) is provided with an oscillation pattern (114) in the area between the inlet end (111) and the guide plate (300). The oscillation pattern (114) is a number of inclined stripes distributed at intervals.

4. The molten metal skimming mechanism for intelligent casting sand pouring process according to claim 3, characterized in that, The oscillation pattern (114) is a raised pattern and / or a groove (113) structure.

5. The molten metal skimming mechanism for intelligent casting sand pouring process according to claim 1, characterized in that... The active discharge device (400) includes a connecting block (410) located at the bottom and connected to the base (100). A bracket (420) is connected to the connecting block (410). The top of the bracket (420) extends above the base (100) and is connected to a flip seat (430). The flip seat (430) has an adjustable mounting block. A pulse nozzle (440) is detachably connected to the mounting block. The output end of the pulse nozzle (440) faces the area in front of the blocking block (200) and above the guide plate (300).

6. The molten metal skimming mechanism for intelligent casting sand pouring process according to claim 5, characterized in that... The bracket (420) is a telescopic rod structure.

7. A molten metal skimming mechanism for intelligent casting sand pouring process according to claim 1, characterized in that... It also includes a vision detection module, which can detect the scum content in the area in front of the blocking block (200) and above the guide plate (300). The vision detection module is electrically connected to the control system of the active discharge device (400).

8. A molten metal skimming mechanism for intelligent casting sand pouring process according to claim 2, characterized in that... A position adjustment structure is provided between the mounting part (310) and the base (100).

9. A molten metal skimming mechanism for intelligent casting sand pouring process according to claim 1, characterized in that... The blocking block (200) has a removable core block (210) inside.

10. A method for skimming slag, characterized in that, The molten metal skimming mechanism for intelligent casting sand casting process as described in any one of claims 1-9 is adopted.

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