Automatic casting production system
By designing an automated production system for castings and integrating post-processing equipment for the front cabin and rear floor, the problem of equipment redundancy was resolved, efficient production management was achieved, costs and vibration impacts were reduced, and inspection efficiency was improved.
Patent Information
- Application Number
- CN202422787898.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-15
- Publication Date
- 2025-09-23
- Estimated Expiration
- 2034-11-15
AI Technical Summary
The redundancy of post-processing equipment for die-cast parts leads to waste of production equipment and difficulty in management, especially in the production of automobile front cabins and rear floors, where there is a lack of effective integration solutions.
Design an automated production system for castings. By rationally arranging equipment such as a pick-up robot, a hydraulic breaking machine, a cooling water tank, a hydraulic press, a marking machine, X-ray inspection equipment, and a handling robot, a production line is formed to achieve post-processing of the front cabin and rear floor, reducing equipment redundancy.
It saves configuration and space costs, improves the utilization rate of X-ray detection, shortens the process adjustment response cycle, and reduces the generation of waste parts.
Smart Images
Figure CN223368167U_ABST
Abstract
Description
Technical Field
[0001] The utility model belongs to the technical field of die-casting equipment, and in particular relates to an automated production system for castings. Background Art
[0002] Pressure casting (hereinafter referred to as die casting) is a common metal casting process that involves injecting molten metal into a mold cavity under high pressure and then cooling it to form the final product. Compared to traditional casting methods, die castings offer advantages such as improved surface finish, better dimensional consistency, higher tensile strength, and the ability to manufacture complex parts.
[0003] In recent years, die-casting has been widely used in the manufacturing of new energy vehicles. Advances in die-casting processes and die-casting machine manufacturing have led to an increase in the size of parts that can be directly cast. For example, large new energy vehicle components such as the front engine compartment and rear floor can now be formed in a single die-cast process, significantly improving overall part strength and reducing assembly costs. However, this increase in die-cast part size also presents challenges for the overall design and management of die-casting units.
[0004] Since die-cast parts inevitably have redundant parts such as runners and slag bags that need to be removed, the post-processing of the front engine compartment and rear floor of the automobile is currently carried out on different production lines due to their differences in structure and die-casting process. However, different production lines actually have a lot of duplicate equipment, which causes redundancy in production equipment.
[0005] Therefore, it is necessary to effectively integrate its post-processing equipment and integrate the post-processing equipment of the front engine compartment and rear floor of the car into one production line to reduce equipment redundancy. As of now, there is no better processing solution. Utility Model Content
[0006] To solve the above problems, the present application provides an automated production system for castings, including a picking robot, a hydraulic breaking machine, a cooling water tank, a hydraulic press, a marking machine, an X-ray detection device, a handling robot, and a product return inlet and outlet.
[0007] The pickup robot is movably arranged on a first track, and the transport robot is movably arranged on a second track, and the second track is arranged parallel to the first track.
[0008] Among them, the die-casting machine's mold opening area, hydraulic breaking machine, product return inlet and outlet, cooling water tank, marking machine, and X-ray detection equipment are all located within the picking and placing range of the picking robot, and the hydraulic press, cooling water tank, marking machine, X-ray detection equipment and conveyor vehicle are all within the picking and placing range of the handling robot.
[0009] Optionally, the hydraulic breaking machine and the product return inlet and outlet are arranged on one side of the first track, the cooling water tank and the marking machine are arranged on the other side of the first track, and the X-ray detection equipment is arranged at a certain distance from its end.
[0010] Optionally, the cooling water tank and the marking machine are arranged on one side of the second track, the hydraulic press and the conveyor vehicle are arranged on the other side of the second track, and the X-ray detection equipment is arranged at a certain distance from the end thereof.
[0011] Optionally, the conveyor vehicle is used to convey the die-cast parts into the lifting range of the gantry crane.
[0012] Optionally, a vibration isolation groove is provided around the X-ray detection equipment.
[0013] Optionally, the X-ray detection equipment includes a C-arm, one end of the C-arm is a ray tube, and the other end is an imaging plate, the ray tube is used to emit X-rays, and the imaging plate is used to receive X-rays that penetrate the die casting to form a detection image.
[0014] Through the rational layout of post-processing equipment, this application can be used for the post-processing of various die-casting parts such as the front cabin and the rear floor, saving configuration costs and space costs.
[0015] This application utilizes X-ray inspection equipment. Existing technologies typically place X-ray inspections on machining or grinding lines, increasing transportation and storage costs and requiring longer response times for process adjustments. This application performs inspections directly on the die-casting unit, eliminating intermediate steps. When problems are detected, process parameters can be adjusted immediately to avoid significant scrap.
[0016] The present application also dug a vibration isolation trench around the X-ray detection equipment to ensure that the detection is not affected by the vibration of equipment such as the die-casting machine and the trimming machine.
[0017] This application can input products from the reflux port and complete the inspection when the die-casting machine is shut down, thereby improving the utilization rate of the X-Ray inspection device.
[0018] This application uses a conveyor truck to transport die-casting parts, and personnel can conduct appearance inspection and burr grinding on the products around the conveyor truck. BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The above features and technical advantages of the present invention will become clearer and easier to understand by describing the embodiments thereof in conjunction with the following drawings.
[0020] Figure 1 This is a schematic diagram of the layout of an automated production system for castings according to an embodiment of the present utility model.
[0021] Figure 2 This is a post-processing flow chart of the front cabin and rear floor according to an embodiment of the present utility model.
[0022] Figure 3 This is a cross-sectional view of a vibration isolation groove according to an embodiment of the present invention. DETAILED DESCRIPTION
[0023] The following describes embodiments of the present invention with reference to the accompanying drawings. Those skilled in the art will recognize that the described embodiments may be modified in various ways or combinations thereof without departing from the spirit and scope of the present invention. Therefore, the drawings and description are illustrative in nature and are not intended to limit the scope of the claims. Furthermore, throughout this specification, the drawings are not drawn to scale, and like reference numerals represent like parts.
[0024] After the die casting is formed through mold closing, molten metal feeding, injection molding, and molten metal solidification, the automated casting production system of this embodiment can be used for post-processing of the die casting. By utilizing a single set of post-processing equipment, it can be applied to die castings with diverse process characteristics. This embodiment uses the post-processing of automotive front engine compartment and rear floor die castings as an example. This embodiment adapts to various die casting flow processes and implements post-processing of two mainstream, ultra-large die castings, namely the front engine compartment and rear floor, significantly saving configuration and space costs.
[0025] The automated production system for castings includes a picking robot 1, a hydraulic breaking machine 2, a cooling water tank 3, an oil press 4, a marking machine 5, an X-ray detection device 6 (X-Ray), a handling robot 7, and a product return inlet and outlet 8.
[0026] The retrieval robot 1 is mounted on a first track 10 and is movable on the track. The range of the robot 1 from one end of the track 10 to the other is defined as the retrieval range of the robot 1. The hydraulic breakers 2 and product return inlet and outlet 8 are located on one side of the track 10, while the cooling water tank 3 and marking machine 5 are located on the other side. The X-ray inspection equipment 6 is located at a certain distance from the end of the track 10.
[0027] Among them, the hydraulic breaking machine 2, cooling water tank 3, marking machine 5, product return inlet and outlet 8, X-ray detection equipment 6 and the mold opening area of the die-casting machine 100 are all located within the picking and placing range of the picking robot 1. Figure 1The circular trajectory in the figure represents the rotational circumference of the retrieval robot at its current position. Therefore, the retrieval robot 1 can remove the finished die-cast parts from the die-casting machine 100 and then place them on the hydraulic breakers 2, cooling water tanks 3, marking machines 5, or X-ray inspection equipment 6, or retrieve and place parts from the product return inlet and outlet 8, depending on the process requirements.
[0028] More specifically, for example, the retrieval robot 1 moves on the first track 10. At one end of the first track 10, the retrieval robot 1 can retrieve components from the die-casting machine 100. On the other side, the retrieval robot 1 can pick up and place components on the hydraulic breaking machine 2 and the product return inlet and outlet 8. On the other side, the retrieval robot 1 can pick up and place components on the cooling water tank 3 and the marking machine 5. At the other end of the first track 10, the retrieval robot 1 can pick up and place components on the X-ray inspection equipment 6, the hydraulic breaking machine 2, and the marking machine 5.
[0029] The transport robot 7 is arranged on the second track 20 , which is arranged parallel to the first track 10 and is arranged on the other side of the first track 10 , that is, the side where the cooling water tank 3 and the marking machine 5 are located.
[0030] The range in which the handling robot 7 can pick up and place parts from one end to the other end of the second track 20 is referred to as the picking up and placing range of the handling robot 7. The cooling water tank 3, the hydraulic press 4, and the marking machine 5 are all within the picking up and placing range of the handling robot 7. For example, when the handling robot 7 is on one side of the second track, it can pick up and place parts on the cooling water tank 3 and the marking machine 5. When the handling robot 7 is on the other side of the second track, it can pick up and place parts on the hydraulic press 4, and can also pick up and place parts on the transport vehicle. The transport vehicle is used to transport the die-cast parts to the lifting range of the gantry crane 40. When the handling robot 7 is at the end of the second track, it can pick up and place parts on the X-ray detection equipment 6.
[0031] Existing technology uses X-rays to detect internal defects in die-castings. Usually, the inspection is completed by using a robot to clamp a C-arm to scan the product. One end of the C-arm is a X-ray tube and the other end is an imaging plate. The rays penetrate the die-casting and are received by the imaging plate to form an image, which can then be used to determine whether there are internal defects.
[0032] Since there are large vibrations around equipment such as die-casting machines, the existing technology takes vibrations and layout convenience into consideration, and generally places the X-ray detection equipment 6 on the machining or grinding process line. This increases the intermediate transportation, storage and other costs, and the response cycle of process adjustment is also longer. In this embodiment, a vibration isolation groove 61 is provided around the X-ray detection equipment 6 to ensure that the detection is not affected by the vibration of equipment such as die-casting machines and breaking machines. The internal defects of the die-casting parts can be detected directly in the die-casting unit, saving intermediate steps, and when a problem is detected, the process production parameters can be adjusted immediately to avoid generating a large number of scrap parts. The vibration isolation groove 61 is arranged in a whole circle around the X-ray detection equipment 6, such as Figure 3 As shown, the vibration isolation trench is designed to be 150mm wide and 600mm deep, which can effectively control vibration within 400μm / s, meeting the operating conditions of X-ray detection. Preferably, a steel cover plate 62 is laid above the vibration isolation trench to prevent people or objects from falling into the trench.
[0033] In addition, in this embodiment, a product return inlet and outlet 8 is provided on one side of the first track 10. Other products requiring X-ray inspection can be placed on the product return inlet and outlet 8. The product can then be retrieved by the pickup robot 1 and placed on the X-ray inspection device 6 for defect inspection, thereby improving the utilization rate of the X-ray inspection equipment.
[0034] Through the above arrangement, the automated casting production system of this embodiment can handle the post-processing of the front engine compartment and the rear floor.
[0035] 1. Post-processing process of rear base plate die castings
[0036] like Figure 2 As shown, the pick-up robot 1 takes the die-casting from the die-casting machine 100, firstly detects the external dimensions of the die-casting through an electric eye, and then places the die-casting into a cooling water tank 3 for cooling, and then places it into a marking machine 5 for marking.
[0037] A handling robot 7 retrieves the die-casting from the marking machine 5 and transfers it to the hydraulic press 4 for slag removal and runner processing. The handling robot then takes the die-casting to the X-ray inspection equipment 6 for defect inspection. After X-ray inspection, the die-casting is placed on a transport vehicle, which transports it to the area of the gantry crane 400. The gantry crane can then manually lift the die-casting for quality inspection. After inspection, the die-casting is stacked in a die-casting frame, facilitating operation and transportation.
[0038] 2. Post-processing process of front cabin die castings
[0039] like Figure 2As shown, the picking robot 1 takes the die-casting from the die-casting machine 100, firstly detects the external dimensions of the die-casting by an electric eye, and then places the die-casting on the hydraulic breaking machine 2 to remove the slag bag, and then places the die-casting on the cooling water tank 3 for cooling, and then moves it to the marking machine 5 for marking.
[0040] The handling robot 7 retrieves the die-casting from the marking machine 5 and places it in the hydraulic press 4 for runner removal. The handling robot then takes the die-casting to the X-ray inspection equipment 6 for internal defect inspection. The handling robot then transfers the die-casting to a transport vehicle, which transports it to the area of the gantry crane 400. The gantry crane allows manual lifting of the die-casting for quality inspection. After inspection, the die-casting is stacked in a die-casting frame, facilitating operation and transportation.
[0041] 3. X-ray reflux testing process
[0042] The product is placed on the product return entrance and exit 8, and the picking robot 1 picks up the product on the product return entrance and exit 8. The picking robot 1 moves along the first track 10 to the end, places the product on the X-ray detection equipment 6 for internal defect detection, and after the detection is completed, the picking robot picks up the product from the X-ray detection equipment 6, places it on the conveyor vehicle of the product return entrance and exit 8, and transports it out.
[0043] The above uses the front engine compartment and rear floor as examples to illustrate that the automated production system of the castings of this application can be applied to different process flows, but this application is not limited to the post-processing system used only for the front engine compartment, rear floor, and battery shell of the automobile. As long as the die-castings are consistent with the process flow of this application, the automated production system of the castings can be used.
[0044] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that the present invention is susceptible to various modifications and variations. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.
Claims
1. An automated production system for castings, characterized in that: Including picking robot, hydraulic breaking machine, cooling water tank, hydraulic press, marking machine, X-ray detection equipment, handling robot, product return inlet and outlet, The pickup robot is movably arranged on a first track, and the transport robot is movably arranged on a second track, and the second track is arranged parallel to the first track. Among them, the die-casting machine's mold opening area, hydraulic breaking machine, product return inlet and outlet, cooling water tank, marking machine, and X-ray detection equipment are all located within the picking and placing range of the picking robot, and the hydraulic press, cooling water tank, marking machine, X-ray detection equipment and conveyor vehicle are all within the picking and placing range of the handling robot.
2. The automated production system for castings according to claim 1, characterized in that: The hydraulic breaking machine and the product return inlet and outlet are arranged on one side of the first track, the cooling water tank and the marking machine are arranged on the other side of the first track, and the X-ray detection equipment is arranged at a certain distance from the end thereof.
3. The automated production system for castings according to claim 2, characterized in that: The cooling water tank and the marking machine are arranged on one side of the second track, the hydraulic press and the conveyor vehicle are arranged on the other side of the second track, and the X-ray detection equipment is arranged at a certain distance from the end thereof.
4. The automated production system for castings according to claim 3, characterized in that: The conveyor vehicle is used to convey the die castings into the hoisting range of the gantry crane.
5. The automated production system for castings according to claim 3, characterized in that: A vibration isolation groove is provided around the X-ray detection equipment.
6. The automated casting production system according to claim 3, characterized in that: The X-ray detection equipment includes a C-arm, one end of which is a ray tube and the other end is an imaging plate. The ray tube is used to emit X-rays, and the imaging plate is used to receive X-rays that penetrate the die casting to form a detection image.