Single-model ring type automatic V-method production line
By designing a single-molding ring automatic V-method production line, we can achieve automatic online replacement of multiple pairs of models and alternating molding of upper and lower boxes, solving the problem of low automation level of the V-method molding production line, improving production efficiency and environmental quality, and meeting the requirements of modern digital factories.
Patent Information
- Application Number
- CN202422515723.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-17
- Publication Date
- 2025-09-30
- Estimated Expiration
- 2034-10-17
AI Technical Summary
The existing V-method molding production line has a low level of automation, resulting in low production efficiency, high labor intensity and poor environment.
A single molding ring automatic V-method production line is designed, which uses components such as a molding ring, a lower box and core wire, an upper box line, an end transfer vehicle, and a box closing robot to achieve automatic online replacement of multiple pairs of molds and alternating molding of upper and lower boxes. Combined with a vacuum system, dust removal system and digital management, the production line layout is optimized.
It improves production efficiency, improves the working environment, reduces noise pollution, improves resource utilization, and meets the needs of modern digital factories.
Smart Images
Figure CN223394320U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of casting, in particular to a single molding ring type automatic V-method production line. Background Art
[0002] V-method molding uses dry sand as molding material, uses plastic film to cover the molding and seal the sand box, relies on a vacuum pump to extract the air in the mold, creates a pressure difference between the inside and outside of the mold box, and makes the dry sand compact to form the required cavity.
[0003] For a long time, most of the V-method production lines in domestic foundries have adopted double-shuttle vibrating trolley or turntable molding equipment. The turning, closing and unpacking of boxes after molding are mostly done manually, and the pouring is also done manually on the ground. The production line has a low level of automation, relatively backward equipment, low efficiency, poor working environment for workers, and high labor intensity.
[0004] Therefore, the technical problem of low automation level of V-method molding production line in the related art has not yet been effectively solved. Utility Model Content
[0005] The purpose of the utility model is to provide a single molding ring type automatic V-method production line to solve the problem of low automation level of the V-method molding production line in the related art.
[0006] In order to achieve the above purpose, the present invention adopts the following technical solutions:
[0007] A single molding ring automatic V-method production line includes a molding ring, a lower box and lower core wire, an upper box line, an end transfer vehicle, a box closing robot, a pouring line, an intermediate transfer vehicle, a cooling line, a box unpacking transfer vehicle, an empty box return roller, a box unpacking and casting removal robot, a sand processing system, a vacuum system, and a dust removal system; the molding ring includes a lower line model roller, an upper line model roller, a second model transfer vehicle, an empty box robot, a rain sand adding device, a vibrating table, a back film covering device, and a mold removal robot; the lower line model roller includes a sand adding section and a vacuum switching device and a molding sand hopper; the upper line model roller includes a first model transfer vehicle, a film covering mechanism, a film covering section and a vacuum switching device, a spraying device, and a paint drying device.
[0008] It is further configured as follows: the pouring line, cooling line, upper box line, lower box lower core line, lower line model roller, upper line model roller and empty box return roller are arranged in parallel.
[0009] It is further configured as follows: an end transfer vehicle is provided at the head ends of the pouring line, the lower box lower core line and the upper box line, and the running direction of the end transfer vehicle is perpendicular to the pouring line.
[0010] It is further configured as follows: an intermediate transfer vehicle is provided between the tail end of the pouring line and the head end of the cooling line, and the running direction of the intermediate transfer vehicle is perpendicular to the pouring line.
[0011] It is further configured as follows: a box unpacking transfer vehicle is provided at the tail end of the cooling line, the empty box return roller and the lower box lower core line, and the running direction of the box unpacking transfer vehicle is perpendicular to the cooling line.
[0012] It is further configured as follows: the box closing robot is set at the head end of the upper box line; the mold removing robot is perpendicular to the lower core line of the lower box, the upper box line and above the lower line model roller; the empty box robot is perpendicular to the lower core line of the lower box, the upper box line and above the empty box return roller.
[0013] It is further configured as follows: the first model transfer vehicle is arranged at the head end of the offline model roller conveyor and the upstream model roller conveyor; the second model transfer vehicle is connected to the tail end of the offline model roller conveyor and the upstream model roller conveyor.
[0014] It is further configured as follows: the unpacking and casting removal robots are completely enclosed in the unpacking room, and the unpacking and casting removal robots share a walking track on the top of the truss.
[0015] It is further configured as follows: the unpacking and casting removal robot includes a unpacking robot and a casting removal robot.
[0016] It is further configured as follows: the vacuum system is a water ring vacuum pump; the vacuum system is arranged in a vacuum pump room.
[0017] Compared with the prior art, the beneficial technical effects of the present invention are:
[0018] 1. The production line uses a working mode in which multiple sets of molds are simultaneously online within a molding circle, with upper and lower boxes molding alternately. The molds can be automatically changed online, greatly improving work efficiency. The manual operation station and mold change of this production line are all in an open environment, and the transportation of sand cores for the production line and the passage of personnel are well guaranteed.
[0019] 2. The pouring area of the production line is located close to the melting area of the electric furnace, which is convenient for the transfer of molten iron from the electric furnace to the pouring machine; the unpacking area is close to the casting cooling and cleaning department, which is convenient for the automatic transfer of castings to the cooling department.
[0020] 3. The casting area, unpacking area and model spraying area of the production line are completely closed and dust-removed to ensure that smoke does not leak out; dust removal interfaces are set at the sand adding and compacting areas and all sand processing transfer points, and a scattered sand recovery belt is set under the sand adding section of the molding circle to improve the working environment.
[0021] 4. Production line equipment is equipped with relevant data acquisition interfaces. Equipment status data, process setting parameters, operating process data, product information, energy consumption information, etc. can be exchanged with the factory information system to meet the requirements of modern digital factories. Product information of each mold on the production line can be tracked. The production line is interlocked with the pouring machine, which automatically receives product information and pouring quality for each mold. If a mold is rejected, it will be skipped and not poured.
[0022] 5. All vacuum pumps on the production line are placed in a dedicated vacuum pump room to reduce noise pollution. The vacuum system uses water ring vacuum pumps, all of which are frequency-controlled.
[0023] In summary, the simultaneous operation of multiple molds within the molding line, with alternating molding of upper and lower molds and automatic mold changeover, significantly reduces waiting time and mold changeover time, thereby improving overall production efficiency. The entire production line is highly automated, with automated operations in every step, from mold change and core transfer to pouring, cooling, unpacking, and part removal. This reduces manual intervention and increases production speed. The pouring area is located near the furnace melting zone, and the unpacking area is located near the cooling and cleaning section. This layout reduces the distance required to transfer molten iron and castings, improving transfer efficiency. The well-designed channels for transferring sand cores and personnel flow ensure smooth logistics, avoiding congestion and waiting. The pouring, unpacking, and mold spraying areas are fully enclosed and dust-collected, effectively preventing smoke leakage and improving the working environment. Dust collection ports are installed at the sand filling and compaction area and all sand handling transfer points. A loose sand recovery belt is installed under the sand filling section of the molding line, reducing dust pollution and improving resource utilization. The production line equipment is equipped with a data acquisition interface that collects real-time information such as equipment status, process parameters, operational data, product information, and energy consumption. This data is then exchanged with the factory information system, meeting the requirements of a modern digital factory. The production line is interlocked with the pouring machine, which automatically receives product information and pouring quality for each mold. It skips pouring if a mold is rejected, improving pouring accuracy and efficiency. The vacuum pump is housed in a dedicated pump room, reducing noise pollution. The use of a water-ring vacuum pump and variable frequency control improves energy efficiency and reduces consumption.
[0024] This utility model achieves a significant increase in production efficiency, an improvement in the working environment, an increase in resource utilization, and a reduction in noise pollution through technical means such as high automation, optimized layout, environmental protection measures, digital intelligence, and energy conservation and emission reduction, and has significant technical and economic benefits. BRIEF DESCRIPTION OF THE DRAWINGS
[0025] In order to more clearly illustrate the specific implementation methods of the utility model or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.
[0026] Figure 1 This is the layout diagram of the single molding circle automatic V-method production line;
[0027] Figure 2 This is a layout diagram of the modeling circle of the present utility model.
[0028] Figure numerals: 1. Molding ring; 2. Lower box and lower core line; 3. Upper box line; 4. End transfer vehicle; 5. Box closing robot; 6. Pouring line; 7. Intermediate transfer vehicle; 8. Cooling line; 9. Vacuum system; 10. Empty box return roller; 11. Box unpacking transfer vehicle; 12. Box unpacking and casting removal robot; 13. Sand processing system; 14. Lower line model roller; 15. Upper line model roller; 16. First model transfer vehicle; 17. Laminating mechanism; 18. Laminating section and vacuum transfer device; 19. Spraying device; 20. Paint drying device; 21. Second model transfer vehicle; 22. Empty box robot; 23. Sand adding section and vacuum transfer device; 24. Molding sand hopper; 25. De-molding robot. DETAILED DESCRIPTION
[0029] The following is a clear and complete description of the technical solution of the present invention in conjunction with the accompanying drawings. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of the present invention.
[0030] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating positions or relationships, are based on the positions or relationships shown in the accompanying drawings and are intended solely to facilitate the description of this utility model and simplify the description. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this utility model. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.
[0031] In the description of this utility model, it should be noted that, unless otherwise expressly specified or limited, the terms "installed," "connected," and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; mechanical connections, electrical connections; direct connections, indirect connections through an intermediate medium, and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in this utility model based on specific circumstances.
[0032] Example 1
[0033] Reference Figure 1 , which is a single molding ring 1 type automatic V-method production line disclosed by the utility model, and the utility model includes: a molding ring 1, a lower box and lower core line 2, an upper box line 3, an end transfer car 4, a box closing robot 5, a pouring line 6, an intermediate transfer car 7, a cooling line 8, a box unpacking transfer car 11, an empty box return roller 10, a box unpacking and casting removal robot 12, a sand processing system 13, a vacuum system 9, and a dust removal system; the molding ring 1 includes a lower line model roller 14, an upper line model roller 15, a second model transfer car 21, an empty box robot 22, a rain sand adding device, a vibration table, a back film covering device, and a mold removal robot 25; the lower line model roller 14 includes a sand adding section and a vacuum switching device 23 and a molding sand hopper 24; the upper line model roller 15 includes a first model transfer car 16, a coating mechanism 17, a coating section and a vacuum switching device 18, a spraying device 19, and a paint drying device 20.
[0034] Specifically, the production line utilizes a modeling cycle (1) where multiple molds are simultaneously produced online, with upper and lower mold boxes alternately molding. This allows for automatic mold replacement, significantly improving work efficiency. The production line's manual operation stations and mold replacement are both located in an open environment, ensuring smooth transportation of sand cores and personnel flow. The production line's pouring area is located near the furnace melting zone, facilitating the transfer of molten iron from the furnace to the pouring machine. The unpacking area is located near the casting cooling and cleaning section, facilitating the automatic transfer of castings to the cooling section.
[0035] It is further configured as follows: the pouring line 6, the cooling line 8, the upper box line 3, the lower box lower core line 2, the lower line model roller 14, the upper line model roller 15 and the empty box return roller 10 are arranged in parallel.
[0036] Specifically, the parallel arrangement makes the production lines and roller conveyors more compact, reducing floor space and improving workshop space utilization. The parallel arrangement of the production lines and roller conveyors facilitates a continuous and smooth production process, reduces material transfer and waiting time, and improves production efficiency. The independence of each production line and roller conveyor prevents cross-interference between materials and equipment, improving the stability and safety of the production line. The parallel arrangement provides greater clarity and clarity for each production line step, facilitating real-time monitoring and scheduling by management personnel.
[0037] Further configurations include: an end transfer vehicle 4 is installed at the beginning of the pouring line 6, the lower box lower core line 2, and the upper box line 3. The end transfer vehicle 4 runs perpendicular to the pouring line 6. An intermediate transfer vehicle 7 is installed between the end of the pouring line 6 and the beginning of the cooling line 8. The intermediate transfer vehicle 7 runs perpendicular to the pouring line 6. An unpacking transfer vehicle 11 is installed at the end of the cooling line 8, the empty box return roller 10, and the lower box lower core line 2. The unpacking transfer vehicle 11 runs perpendicular to the cooling line 8.
[0038] Specifically, the end transfer vehicle 4 is used to transport the combined upper and lower boxes to the pouring line 6. The intermediate transfer vehicle 7 is used to transport the poured mold from the pouring line 6 to the cooling line 8. The unpacking transfer vehicle 11 transports the cooled mold from the cooling line 8 to the unpacking robot.
[0039] It is further configured as follows: the box closing robot 5 is arranged at the head end of the upper box line 3; the mold removing robot 25 is perpendicular to the lower core line 2 of the lower box, the upper box line 3 and the top of the lower line model roller 14; the empty box robot 22 is perpendicular to the lower core line 2 of the lower box, the upper box line 3 and the top of the empty box return roller 10.
[0040] Specifically, the box closing robot 5 is used to lift the upper box from the pallet of the upper box line 3 and move it to the box closing position of the end transfer vehicle 4 to close it with the lower box. The mold demolding robot 25 is used to demold the upper box or lower box after molding. The empty box robot 22 is used to grab the upper box or lower box from the empty box return roller 10.
[0041] It is further configured as follows: the first model transfer vehicle 16 is arranged at the head end of the offline model roller conveyor 14 and the online model roller conveyor 15 ; the second model transfer vehicle 21 is connected to the tail end of the offline model roller conveyor 14 and the online model roller conveyor 15 .
[0042] Specifically, the first model transfer vehicle 16 is used to transfer the model after demoulding to the coating section to start the next working cycle, and the second model transfer vehicle 21 is used to transfer the model after spraying and drying to the emptying sand box station.
[0043] It is further configured as follows: the unpacking and casting removal robot 12 is completely enclosed in the unpacking room, and the unpacking and casting removal robot 12 share a walking track on the top of the truss.
[0044] It is further configured as follows: the unpacking and casting removal robot 12 includes a unpacking robot and a casting removal robot.
[0045] It is further configured as follows: the vacuum system 9 is a water ring vacuum pump; and the vacuum system 9 is arranged in a vacuum pump room.
[0046] Modeling circle 1 workflow:
[0047] In the modeling circle 1, the lower box model and the upper box model are arranged alternately, and the lower box starts modeling first. The working process of the lower box model is as follows:
[0048] The lower box model is automatically coated (the model is vacuumed), and then the paint is sprayed and dried. The second model transfer car 21 transfers the model to the empty sand box station, and the empty box manipulator 22 takes the box from the empty box roller 10, flips it 180° and places it on the model, transports it to the sand adding station to add sand and vibrate it, transports it to the back film covering station to automatically scrape the back sand and cover the back film, and transports it to the demolding station. The demolding manipulator 25 automatically demolds, and the sand box is flipped 180° and placed on the upper and lower cores of the bottom plate trolley of the lower core line 2 of the lower box. Then the demolded model is transferred to the first model transfer car 16 and then transferred to the film covering section to start the next working cycle.
[0049] The workflow of the upper box model is:
[0050] The upper box model is automatically coated (the model is vacuumed), and then the coated upper box model is placed on the pouring mouth. After checking and repairing the coating, the paint is sprayed and the paint is dried. The second model transfer vehicle 21 transfers the model to the empty sand box station. The empty box manipulator 22 takes the upper box from the empty box roller 10 and places it on the model, and then transports it to the sand adding station for sand adding and vibration compaction. It is then transported to the back film covering station for scraping the back sand, covering the back film and taking the pouring mouth, and then sent to the demolding station. The demolding manipulator 25 automatically demolds, and the shape is repaired or the core is lowered through manual inspection. The demolding manipulator 25 travels to the box placement position of the upper box line 3, and the manipulator descends and places the upper box on the pallet of the upper box line 3. The demolded model is transferred to the coating section by the first model transfer vehicle 16 to start the next working cycle.
[0051] The lower box is pushed to the end transfer vehicle 4 after the lower box core line 2 unloads the core, and the end transfer vehicle 4 moves to the box closing station. The box closing robot 5 lifts the upper box from the upper box line 3 and closes it at the box closing station. The upper and lower boxes after closing are transferred by the end transfer vehicle 4 to the pouring line 6 to wait for pouring by the pouring machine. The two sides of the pouring line 6 work alternately. The mold after pouring is transferred by the intermediate transfer vehicle 7 to the cooling line 8, and then transferred to the unpacking robot by the unpacking transfer vehicle 11. The unpacking robot lifts the upper box from the unpacking transfer vehicle 11 and The whole set of castings is taken to the sand-falling station for sand-falling (after the unpacking robot lifts the whole set of castings, the unpacking transfer car 11 transfers the sand box bottom plate trolley to the lower core section of the lower box), and the casting falls on the grid. The casting robot takes the casting from the grid and puts it on the casting tray on the casting transfer car, and then automatically transfers it to the casting cooling area for cooling. After sand falling, the empty sand box is placed by the unpacking robot with the lower box and the upper box respectively on the empty box return line and automatically transported to the molding circle 1 empty box robot 22 to start the next cycle.
[0052] After unpacking, the sand is collected by the sand collecting hopper and fed into the screw feeder for magnetic separation through the vibrating conveying screen and the sand temperature regulator, and then passes through the boiling cooling bed, elevator, belt conveyor, intermediate sand hopper, elevator, belt feeder to the molding sand hopper 24 in sequence.
[0053] The scattered sand from the molding circle 1, the box loading line 3 and the empty box return line is transported by the scattered sand belt to the screw feeder at the box unpacking location, passes through the vibrating screen, and then enters the vacuum transfer device.
[0054] The working principle and beneficial effects of the present invention are as follows: multiple pairs of models are online at the same time in the molding circle 1, the upper and lower boxes are alternately molded, and the models are automatically replaced online, which significantly reduces waiting time and mold change time, thereby improving overall production efficiency. The entire production line is highly automated, and all links from model replacement and sand core transfer to pouring, cooling, unpacking and picking up are automated, reducing manual intervention and increasing production speed. The pouring area is close to the electric furnace melting area, and the unpacking area is close to the cooling and cleaning department. This layout reduces the transfer distance of molten iron and castings and improves transfer efficiency. The transportation of sand cores for the production line and the flow of people are reasonably designed to ensure smooth logistics and avoid congestion and waiting. The pouring area, unpacking area, and model spray coating area adopt an overall closed and dust removal method to effectively prevent the leakage of smoke and improve the working environment. Dust removal interfaces are set at the sand adding and compacting points and all sand processing transfer points, and a scattered sand recovery belt is set under the sand adding section of the molding circle 1 to reduce dust pollution and improve resource utilization. The production line equipment is equipped with a data acquisition interface that collects real-time information such as equipment status, process parameters, operational data, product information, and energy consumption. This data is then exchanged with the factory information system, meeting the requirements of a modern digital factory. The production line is interlocked with the pouring machine, which automatically receives product information and pouring quality for each mold. It skips pouring if a mold is rejected, improving pouring accuracy and efficiency. The vacuum pump is housed in a dedicated pump room, reducing noise pollution. The use of a water-ring vacuum pump and variable frequency control improves energy efficiency and reduces consumption.
[0055] This utility model achieves a significant increase in production efficiency, an improvement in the working environment, an increase in resource utilization, and a reduction in noise pollution through technical means such as high automation, optimized layout, environmental protection measures, digital intelligence, and energy conservation and emission reduction, and has significant technical and economic benefits.
[0056] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present invention.
Claims
1. A single molding ring type automatic V-method production line, characterized in that: include: Molding ring (1), lower box lower core line (2), upper box line (3), end transfer vehicle (4), box closing manipulator (5), pouring line (6), intermediate transfer vehicle (7), cooling line (8), box unpacking transfer vehicle (11), empty box return roller (10), box unpacking and casting removal manipulator (12), sand processing system (13), vacuum system (9), dust removal system; The molding circle (1) includes an offline mold roller (14), an online mold roller (15), a second mold transfer vehicle (21), an empty box manipulator (22), a rain shower and sand adding device, a vibration table, a back film covering device, and a mold removal manipulator (25); The offline model roller (14) includes a sand adding section and a vacuum switching device (23) and a molding sand hopper (24); The on-line model roller conveyor (15) comprises a first model transfer vehicle (16), a coating mechanism (17), a coating section and a vacuum transfer device (18), a spraying device (19), and a paint drying device (20).
2. A single molding ring type automatic V-method production line according to claim 1, characterized in that: include: The pouring line (6), the cooling line (8), the upper box line (3), the lower box lower core line (2), the lower line model roller (14), the upper line model roller (15) and the empty box return roller (10) are arranged in parallel.
3. A single molding coil type automatic V-method production line according to claim 2, characterized in that: include: An end transfer vehicle (4) is provided at the head ends of the pouring line (6), the lower box lower core line (2) and the upper box line (3), and the running direction of the end transfer vehicle (4) is perpendicular to the pouring line (6).
4. The single molding coil automatic V-method production line according to claim 2, characterized in that: include: An intermediate transfer vehicle (7) is provided between the tail end of the pouring line (6) and the head end of the cooling line (8), and the running direction of the intermediate transfer vehicle (7) is perpendicular to the pouring line (6).
5. The single molding coil automatic V-method production line according to claim 2, characterized in that: include: The cooling line (8), the empty box return roller (10) and the tail end of the lower box lower core line (2) are provided with a box unpacking transfer vehicle (11), and the running direction of the box unpacking transfer vehicle (11) is perpendicular to the cooling line (8).
6. The single molding coil automatic V-method production line according to claim 2, characterized in that: include: The box closing manipulator (5) is arranged at the head end of the box loading line (3); The demoulding manipulator (25) is perpendicular to the lower core line (2) of the lower box, the upper box line (3) and the upper part of the lower line model roller (14); The empty box manipulator (22) is perpendicular to the lower box lower core line (2), the upper box line (3) and above the empty box return roller (10).
7. The single molding coil automatic V-method production line according to claim 2, characterized in that: include: The first model transfer vehicle (16) is arranged at the head end of the lower line model roller conveyor (14) and the upper line model roller conveyor (15); The second model transfer vehicle (21) is connected to the tail ends of the lower-line model roller conveyor (14) and the upper-line model roller conveyor (15).
8. The single molding coil automatic V-method production line according to claim 2, characterized in that: include: The unpacking and casting taking manipulator (12) is entirely enclosed in the unpacking room, and the unpacking and casting taking manipulator (12) shares a walking track on the top of a truss.
9. The single molding coil automatic V-method production line according to claim 8, characterized in that: include: The box opening and casting removal manipulator (12) comprises a box opening manipulator and a casting removal manipulator.
10. The single molding coil automatic V-method production line according to claim 2, characterized in that: include: The vacuum system (9) is a water ring vacuum pump; The vacuum system (9) is arranged in a vacuum pump room.