Modular molding molded set and related mold

Abstract

The utility model relates to a modularized model suite for molding, the model suite for molding is constructed to manufacture a mold cavity of a mold corresponding to different expected parts to be cast, and the model suite for molding can be selectively assembled to be consistent with the expected parts in shape, structure and size. The model suite for molding comprises a suite main body and a suite sub-part, the suite main body is constructed to be capable of being detachably and fixedly connected and assembled with the suite sub-part to form an assembly part consistent with an expected part, and the suite main body is constructed to be the same main structural part commonly used for different expected parts to be cast. The mold cavities of corresponding molds for different desired parts can be manufactured by assembling the same kit body and different kit sub-parts. The utility model further relates to a mold with a mold cavity formed by the mold kit. By means of the method, the flexible manufacturing requirement for different parts can be met, and various model parts do not need to be manufactured independently.

Description

Technical Field

[0001] This application generally relates to a modular molding kit and related molds. Background Technology

[0002] As is well known, casting is widely used in various molding fields. For example, it involves introducing liquefied material into the cavity of a mold and subsequently solidifying it to obtain a part that conforms to the shape and structure of the cavity. Such casting processes include, for example, sand casting, lost foam casting, investment casting, and various other specialized casting methods.

[0003] In the wind power sector, components in wind turbine equipment, especially their gear mechanisms (such as gearboxes), can be manufactured using the aforementioned casting process. Currently, the design of these components widely adopts customized designs based on OEM (Original Equipment Manufacturer) requirements. In this case, the design of these components, especially the large-sized components, is also customized, which complicates the process by requiring individual design for each component. Furthermore, casting these large-sized components using the casting process additionally requires the pre-manufacturing or implementation of corresponding individual molds. These individual molds, for example, require the pre-manufacturing of corresponding model parts for these large-sized components to customize cavities consistent with these large-sized components within the mold, which are then used in the subsequent casting process.

[0004] Clearly, the process of prefabricating corresponding model parts and then separately creating molds for different large-sized components significantly increases the time and cost of the casting process.

[0005] Therefore, it is desirable to simplify the above casting process, especially to simplify the manufacturing process of model parts that are consistent with the parts to be manufactured (cast) and thus reduce the time and cost of mold (especially its cavity) manufacturing, while meeting the manufacturing requirements of different users for different parts. Utility Model Content

[0006] This invention generally relates to a modular molding kit, which is configured to manufacture mold cavities corresponding to different desired parts to be cast. The molding kit can be selectively assembled to conform to the desired parts in shape, construction, and size. The molding kit includes a kit body and kit sub-parts, wherein the kit body is configured to be detachably and fixedly connected to the kit sub-parts to form an assembly conforming to the desired parts. The kit body is configured to correspond to the same main structural parts common to the different desired parts to be cast, enabling the manufacture of mold cavities for corresponding molds of different desired parts by assembling the same kit body and different kit sub-parts.

[0007] Alternatively, the aforementioned different desired components can be components in a wind turbine gearbox.

[0008] Alternatively, the assembly is configured to be placed in a sand mold for manufacturing a mold cavity.

[0009] Optionally, the molding kit is configured to form an assembly consistent with a planetary carrier component, which includes a central column and end portions disposed at both ends of the central column. The kit body is configured to correspond to the end portions of the planetary carrier component, and the kit sub-parts are configured to correspond to multiple central column portions of the central column so that they can be assembled into planetary carrier components of different sizes.

[0010] Optionally, the molding kit is selected as a molding kit for forming an assembly consistent with a planetary carrier component, the planetary carrier component including a central column and end portions disposed at both ends of the central column. The kit body is configured as an end kit body corresponding to the end portions of the planetary carrier component, wherein at least one of the end kit bodies includes a column segment corresponding to at least a portion of the central column; and the kit sub-parts are configured to be selectively inserted into and connected between the end kit bodies, aligned with the column segments.

[0011] Optionally, the molding kit includes a molding kit selected for forming an assembly consistent with a flange component, the flange component including a flange body and additional components integral with the flange component, the kit body being configured to correspond to the flange body and the kit sub-parts being configured to correspond to the additional components so as to selectively connect to the kit body to form an assembly consistent with the flange component to be molded.

[0012] Alternatively, the additional component may be configured as an interface component for connecting or communicating the flange component to an additional system, or as a support arm component for supporting the flange component when the flange component is assembled to a desired structure.

[0013] Optionally, the additional components may differ in at least one of the following: size, position relative to the flange body, construction, and shape.

[0014] Optionally, the support arm components are respectively configured as support arm components with screw holes or support arm components without screw holes.

[0015] Alternatively, the interface components are configured as either a lubrication system interface component for connection to a lubrication system or a lifting interface component for connection to a lifting system.

[0016] This application also relates to a mold configured to have a cavity formed by an assembly of selected kit bodies and kit sub-parts from a self-molding model kit that conforms to an desired part to be cast, wherein the self-molding model kit is a self-molding model kit as described above.

[0017] This application simplifies the casting process, particularly the manufacturing process of model parts that are consistent with the desired part to be manufactured, thereby reducing the time and cost of manufacturing casting molds and thus enabling the flexible manufacturing requirements of different users for different parts without the need to manufacture various model parts separately. Attached Figure Description

[0018] Figure 1 A schematic diagram of a molding kit according to a first embodiment of this application is shown;

[0019] Figure 2 A schematic diagram of a molding kit according to a second embodiment of this application is shown;

[0020] Figure 3 A schematic diagram of a molding kit according to a third embodiment of this application is shown;

[0021] Figure 4 A schematic diagram of a molding model kit according to a fourth embodiment of this application is shown; and

[0022] Figure 5 A block diagram of a casting system according to an embodiment of this application is shown; Detailed Implementation

[0023] The details shown herein are merely examples for illustrative discussion of the disclosed embodiments and to provide an easily understood description of principles and concepts. No further detail is intended to be shown in this regard except for the purpose of providing a basic understanding and enabling those skilled in the art to clearly see how the disclosed molding kits can be implemented in practice.

[0024] Figure 1-4 Schematic diagrams of the molding kit 10 according to the first to fourth embodiments of this application are shown respectively. Although in Figure 1-4 The present application illustrates specific molding kits 10 corresponding to specific components. However, those skilled in the art should understand that these specific components are merely exemplary and not restrictive. The specific protection scope of the molding kits 10 of the present application should be determined by the protection scope defined in the claims and may be extended to the manufacturing field of any other possible components without departing from the scope of the present application.

[0025] Overall, see Figures 1 to 4 As exemplified, this utility model generally relates to a modular molding kit 10, which is configured to manufacture mold cavities (not shown) corresponding to molds (not shown) for different desired parts to be cast. In other words, in embodiments of this application, the model kit 10 described herein is used in the casting field to form the cavity of a mold used for casting. As those skilled in the art will understand, in the casting process, it is necessary to obtain a mold cavity consistent with the desired part to be cast in advance for subsequent casting processes. Specific implementation methods of the mold cavity in the casting process are known to those skilled in the art and will not be described further here.

[0026] These molding model kits 10 can be selectively assembled to form an assembly that conforms to the desired part in shape, construction, and size. Specifically, these molding model kits include a kit body 102 and kit sub-parts 104, such that the kit body 102 and kit sub-parts 104 can be detachably and fixedly connected to form an assembly conforming to the desired part. This assembly can also be referred to as a model for manufacturing the desired part. Because these kit bodies 102 and kit sub-parts 104 can be selectively assembled in different combinations, the resulting assembly can be adapted to different desired parts, thereby greatly expanding the range of desired parts that these model kits 10 can be used for. This allows for the creation of effective model parts for desired parts through simple assembly, without the need to separately manufacture model parts to prefabricate the mold cavity for casting.

[0027] To further reduce the number of parts in the model kit 10, this application preferably manufactures the same and different parts of similar components separately as kit bodies 102 and kit sub-parts 104 in the model kit 10, so that different components can be easily obtained by assembling the same kit body 102 with different kit sub-parts 104. It should be understood that, within the scope of this application, similar components refer to components that are substantially the same in shape, construction, and / or size, differing only locally. To more clearly represent the components of the different components, the corresponding and identical parts of the different desired components are referred to as primary structural parts, while the differing parts are referred to as secondary parts. Therefore, it is conceivable to include multiple different kit bodies 102 corresponding to various primary structural parts and various possible kit sub-parts 104 corresponding to various secondary parts in a set of model kits 10. Therefore, in various embodiments of this application, the kit body 102 is configured to correspond to the same main structural parts common to different desired parts to be cast, so that the mold cavities of the corresponding molds for different desired parts can be manufactured by assembling the same kit body 102 and different kit sub-parts 104.

[0028] Additionally, it may be envisioned that these different desired components could correspond to substantially the same structural components in different mechanisms or different models of the same mechanism. Therefore, these structural components can have significantly corresponding common main structural parts, and thus the kit body 102 common to these structural components is easily determined. Additionally, it may be envisioned that these different structural components or desired components to be cast could be components in a wind turbine gearbox (not shown), but this is merely exemplary and not limiting. However, using a wind turbine gearbox as an example, it will be understood why this model kit 10 is flexible and economical: it is understood that for different models of wind turbine gearboxes, certain components, such as flange components (which will be referred to...), are generally the same. Figure 2 and 3 (Detailed description) Minor adjustments will occur depending on the model, but these adjustments do not fundamentally change the overall design of the flange component. For example, flange components (including but not limited to flanges, flange rings, etc.) used in various models of wind turbine gearboxes include bodies of various shapes, such as circular or annular, and various additional components mounted on the body. Considering the design requirements of different models or designs of wind turbine gearboxes, the bodies of these flange components, such as circular bodies, have the same construction, differing only in the location, quantity, size, and interface construction of various additional components. In this case, for different flange components, traditional casting processes require separate integral mold parts for casting, which is obviously very time-consuming and costly. In contrast, by adopting the model kit technical solution of this application, the same-shaped bodies of various different flange components can be manufactured separately as the kit body, and various possible additional components can be manufactured as various kit sub-parts. Therefore, for different flange cover components, only the kit body and the different kit sub-parts need to be selectively assembled to realize the manufacturing of the mold cavity for casting the flange component of various types of wind turbine gearboxes, without the need to separately manufacture the entire flange component as a whole. Furthermore, after the mold used to manufacture the mold, the kit body can be separated from the various kit sub-parts for subsequent manufacturing of the mold cavity for other types or designs of desired components.

[0029] Optionally, or as an example, the assembly corresponding to the desired component, formed by connecting the main body 102 and the sub-parts 104 of the kit to each other, is placed in a sand mold, such as that used for sand casting, to define or create a cavity therein for subsequent casting of the desired component. Of course, this mold can be used for the manufacture of cavities in molds of other casting processes, such as lost foam casting, lost-wax casting, etc., and is not limited thereto. In other words, the model kit 10 of this application can be used in any process requiring cavity manufacturing.

[0030] As an example, the kit body 102 and kit sub-parts 104 can be fixed or assembled to each other by any possible means such as snap-fit ​​connection, bolt / thread connection, adhesive, or socket. It should be noted that these fixations or assemblies are preferably reversible to facilitate subsequent disassembly for casting other desired parts.

[0031] Now for reference Figure 1-4 A detailed description of the desired components and their composition that this model kit 10 may realize is provided to more clearly illustrate the principles and construction of this application. It should be noted that... Figures 1-4 The embodiments can be included in a set of model kits 10 in any possible combination without departing from the scope of this application. It should be noted that although the same reference numerals may be used to identify different parts in various figures, these parts all represent the same category, classification, or function in model kit 10, and are therefore represented by the same reference numerals. Therefore, it should be understood that the same reference numerals are not limiting, but can be extended to various possible alternatives that can implement the technical solutions of this application.

[0032] Figure 1 A schematic diagram of a molding kit 10 according to a first embodiment of this application is shown. Figure 1 In the first embodiment, the molding kit 10 is used to mold the planet carrier component, that is, to form an assembly consistent with the planet carrier component. Figure 1 In the embodiments described, the planet carrier component is shown as an example of a double-side plate planet carrier, but other types of planet carrier components are also possible without departing from the scope of this application.

[0033] like Figure 1 As shown, the planetary carrier component includes a central column (which serves as the end portion connecting the two ends) and end portions disposed at both ends of the central column (in the case of a double-side-plate planetary carrier, these end portions correspond to the side plate portions disposed on both sides of the column). For different models of planetary carriers (e.g., planetary carriers with different load requirements), the difference may only lie in the length of the central column to accommodate planetary gears of different gear widths, with no other differences. In this case, the kit body 102 is selected to correspond to the end portion of the planetary carrier component, and the kit sub-parts 104 are constructed with central columns of different lengths. When assembled into an assembly, the kit sub-parts 104 corresponding to central columns of different lengths can be connected and inserted between identical kit bodies 102 to form a planetary carrier component of the desired model capable of engaging gears of different sizes (tooth widths). That is, in Figure 1 In some embodiments, the same kit body 102 and different kit sub-parts 104 can be selectively assembled into assemblies corresponding to planetary carrier components of different sizes for use in subsequent cavity manufacturing processes.

[0034] Figure 2 A schematic diagram of a molding kit 10 according to a second embodiment of this application is shown. Figure 2 In the second embodiment, the molding model kit 10 is also used to mold the planetary carrier component, that is, to form an assembly consistent with the planetary carrier component. Compared with the first embodiment, the model kit of the second embodiment differs from that of the first embodiment in the construction of the kit body 102 and the kit sub-parts 104. These first and second embodiments also reflect that, in practice, those skilled in the art can flexibly design and manufacture the kit body 102 and kit sub-parts 104 that are universal in the model kit based on various similar components without departing from the scope of this application, as long as these kit bodies 102 are universal for their respective desired components.

[0035] Similar to the first embodiment, the planetary carrier component in this second embodiment also includes a central column and end portions disposed at both ends of the central column, and the kit body 102 is constructed as an end kit body including portions corresponding to the end portions of the planetary carrier component. However, unlike the first embodiment, at least one of the end kit bodies includes a column segment corresponding to at least a portion of the central column; that is, at least a portion of the central column is directly constructed together with the end portions as the kit body 102. In this case, the kit sub-part 104 can be constructed as a segmented kit sub-part that can be selectively inserted into and connected between the end kit bodies, aligning with the column segments. This segmented kit sub-part 104 corresponds, for example, to segment pieces of the same or different sizes, whose cross-section matches the cross-section of the central column. When it is necessary to cast planetary carrier components with central columns of different sizes, different numbers of segment pieces of the same size, or segment pieces of different sizes, or a combination of both, can be inserted and connected between the two end kit bodies to assemble assemblies with different central column lengths for molding different planetary carrier components. Although Figure 2 The image only shows the use of one set of segment pieces, but in practice, different numbers of sets of segment pieces could be used to mold intermediate columns of different sizes. Furthermore, for Figure 1 In a secondary embodiment, the kit sub-part 104 may also be constructed as stackable segments without departing from the scope of this application.

[0036] Figure 3 and Figure 4Schematic diagrams of a molding model kit 10 according to the third and fourth embodiments of this application are shown respectively. In the third and fourth embodiments, the molding model kit 10 is configured for molding flange components, i.e., for forming an assembly consistent with the flange component. The flange component includes a flange body and additional components that mate with other structures to enable the flange component to mate with other structures, such as interface components for transport, fixing, and functional connection of the flange component, and support arm components, etc., without limitation. These additional components may have different configurations and be integral with the flange component in different locations depending on their use and function. Optionally, the additional components in different flanges may differ in at least one of the following: the number of components, size, position relative to the flange body, configuration, and shape, which is exemplary and not limiting. These additional components may differ in other aspects not mentioned without departing from the scope of this application. In this case, the kit body 102 may be configured to correspond to the flange body and the kit sub-parts 104 may be configured to correspond to various additional components. With the help of this model kit 10, different assemblies consistent with the flange component to be molded can be formed by selectively connecting different kit sub-parts 104 to the kit body 102, so as to be used for subsequent casting of different models of flange components.

[0037] In such Figure 3 In the illustrated embodiment, the flange assembly includes a flange body and an interface component (e.g., a connection or communication component to the aforementioned additional system) for connecting or communicating with an additional system (e.g., a lifting system, a lubrication system, or various other possible systems). It should be noted that in... Figure 3 Only different types of lifting interface components to the lifting system are shown (where lifting holes for connecting to the lifting system can take different orientations, etc.), and other types of interface components (e.g., lubrication system interface components to the lubrication system) are not shown. However, it should be understood that various other interface components can be assembled with the flange body in a similar manner to those used for the lifting system without departing from the scope of this application. In this case, the kit body 102 can be constructed to correspond to the flange body and the kit sub-parts 104 can be constructed to correspond to the interface components. With the aid of this model kit 10, different assemblies consistent with the flange components to be molded can be formed by selectively connecting different kit sub-parts 104 to the kit body 102, thereby enabling the casting of different models of flange components. Figure 3In this embodiment, the flange component is selected as a flange ring component, and therefore the kit body is selected as a flange ring body. In this case, the interface component can be any of the following possible mechanisms without departing from the scope of this application: a lubrication system interface component (e.g., located in a flange component for connection to a lubrication system, which, as an example, includes a lubrication channel to the lubrication system), a lifting system interface component (e.g., located in a flange component for connection to a lifting system, which, as an example, includes a lifting hole (as described above) that mates with lifting fittings of the lifting system). It is understood that in embodiments of this application, the aforementioned interface components in the flange component may differ in at least one of the following: the number of components, their size, their position relative to the flange body, their construction, and their shape; this is merely exemplary and not limiting. Kit sub-parts 104, such as interface components, may differ in other aspects not mentioned without departing from the scope of this application.

[0038] Figure 4 A schematic diagram of a molding model kit 10 according to a fourth embodiment of this application is shown. Compared to the third embodiment, the model kit 10 of the fourth embodiment differs from the third embodiment in the specific construction of the kit body 102 and the kit sub-parts 104. Figure 4 In one embodiment, the flange component also includes a flange body and various torque components or support arm components for supporting the flange component when it is assembled to a desired structure, such as for securing it to a gearbox housing or another flange or other support structure, to achieve stable support for the flange component. Figure 4 In this embodiment, the flange component is selected as a flange plate component, and therefore the kit body is selected as a flange plate body. In this case, various support arm components can be of various possible different constructions or forms, such as support arm components with bolt holes or support arm components without bolt holes (depending on the construction or design of the support structure to which the flange component is connected), without departing from the scope of this application. It is understood that in Figure 4 In one embodiment, the kit body 102 is configured to correspond to a flange body (such as a flange plate body), and the kit sub-parts 104 are configured to correspond to various support arm components so as to selectively connect to the kit body 102 to form an assembly consistent with the flange component to be molded. With this model kit, different assemblies consistent with the flange component to be molded can be formed by selectively connecting different kit sub-parts 104 to the kit body 102, thereby enabling the manufacture of different types of flange components. It can be understood or envisioned that... Figure 4The various support arms in the flange components of the embodiments differ in at least one of the following: the number of arms, their size, their position relative to the flange body, their construction, and their shape, which are exemplary and not limiting. Sub-components such as support arm components may differ in other aspects not mentioned without departing from the scope of this application.

[0039] It needs to be clarified here, Figure 3 In this context, interface components refer to components that combine with additional systems or structures to achieve additional functions for the flange component, such as lubrication and transportation; while support arm components or torque arm components refer to those structural components that provide the final fixed support for the flange component. In other words, support arm components represent essential components indispensable for fixing the flange component; while interface components represent additional components that supplement or provide additional functions to the flange component.

[0040] Figure 5 A block diagram of a casting system 500 according to an embodiment of this application is shown. The casting system can be, for example, a production line system or a casting platform system. In the following description, sections represent a portion of the production line or casting platform system, having the meaning known to those skilled in the art. In an embodiment of this application, the casting system preferably includes:

[0041] - The kit selection section 502 is configured to select the kit body 102 and kit sub-part 104 in the self-molding model kit 10 that can be assembled into an assembly consistent with the desired part to be cast, wherein the molding model kit 10 is the molding model kit according to the foregoing; as those skilled in the art will understand, the kit selection section may additionally include a model kit providing device or a storage device that enables the selection of the desired kit body 102 and kit sub-part 104 from therein;

[0042] - A molding kit assembly section 504 is configured to assemble the selected kit body 102 and kit sub-parts 104 to form an assembly corresponding to the desired component; as those skilled in the art will understand, this section includes assembly fasteners to assemble the kit body 102 and kit sub-parts 104 to each other in a desired design to form an assembly corresponding to the desired component.

[0043] - A mold forming section 506, configured to form a mold with a cavity conforming to the assembly, as those skilled in the art will appreciate, includes, for example, a sand supply device for sand casting, a container supply device for providing a sand container to contain the sand, and a compaction device for pressing the assembly against the sand within the sand container to achieve the desired mold cavity within the sand; and

[0044] - Desired part casting section 508, which is configured to pour casting material into a mold and cool to form the desired part.

[0045] Based on the above, it can be determined that, Figure 5 Among the related examples, a mold manufactured based on the molding kit 10 of this application for casting operations is also involved. Specifically, this mold obviously has a cavity formed by an assembly of the kit body 102 and kit sub-parts 104 selected from the molding kit 10 of this application, which corresponds to the desired part to be cast, for casting purposes. It should be noted that since the kit body 102 and kit sub-parts 104 need to be assembled with each other, there may be assembly marks that require further finishing in later processing, and thus related finishing devices are involved, the details of which are omitted here, which is to be expected.

[0046] It should be understood that the structure and function of the various sections and devices within the aforementioned casting system are well known to those skilled in the art and will not be described in detail here. Furthermore, the functions of the aforementioned casting system can be achieved using technologies such as automatic control without departing from the scope of this application. For example, image recognition devices known to those skilled in the art can be used to automatically select the main body and sub-parts of the kit without departing from the scope of this application.

[0047] Although this application has been described with reference to the accompanying drawings and embodiments, those skilled in the art can conceive of various modifications based on the teachings of this application without departing from the scope of this application.

Claims

1. A modular molding kit, characterized in that, The molding kit is configured to manufacture mold cavities corresponding to different desired parts to be cast. The molding kit can be selectively assembled to conform to the desired parts in shape, construction, and size. The molding kit includes a kit body and kit sub-parts. The kit body is configured to be detachably assembled with the kit sub-parts to form an assembly conforming to the desired parts. The kit body is configured to correspond to the same main structural parts common to the different desired parts to be cast, so that mold cavities corresponding to the molds of the different desired parts can be manufactured by assembling the same kit body and different kit sub-parts.

2. The molding kit according to claim 1, characterized in that, The different desired components are components in the wind turbine gearbox.

3. The molding kit according to claim 1 or 2, characterized in that, The molding kit includes a molding kit selected for forming an assembly consistent with a planetary carrier component, the planetary carrier component including a central column and end portions disposed at both ends of the central column, wherein the kit body is configured to correspond to the end portions of the planetary carrier component and the kit sub-parts are configured to correspond to a plurality of central column portions of the central column so as to be assembled into planetary carrier components of different sizes.

4. The molding kit according to claim 1 or 2, characterized in that, The molding kit includes a molding kit selected for forming an assembly consistent with a planetary carrier component, the planetary carrier component including a central column and end portions disposed at both ends of the central column, wherein the kit body is configured to include end kit bodies including portions corresponding to the end portions of the planetary carrier component, wherein at least one of the end kit bodies includes a column segment corresponding to at least a portion of the central column; and the kit sub-parts are configured to be selectively inserted into and connected between the end kit bodies, aligned with the column segments.

5. The molding kit according to claim 1 or 2, characterized in that, The molding kit includes a molding kit selected for forming an assembly consistent with a flange component, the flange component including a flange body and additional components for integral bonding with the flange component, the kit body being configured to correspond to the flange body and the kit sub-parts being configured to correspond to the additional components so as to selectively connect to the kit body to form an assembly consistent with the flange component to be molded.

6. The molding kit according to claim 5, characterized in that, The additional component is configured as an interface component for connecting or communicating the flange component to an additional system, or as a support arm component for supporting the flange component when it is assembled into a desired structure.

7. The molding kit according to claim 5, characterized in that, The additional components differ in at least one of the following: size, position relative to the flange body, construction, and shape.

8. The molding kit according to claim 6, characterized in that, The support arm components are respectively configured as support arm components with screw holes or support arm components without screw holes.

9. The molding kit according to claim 6, characterized in that, The interface components are respectively configured as a lubrication system interface component for connecting to a lubrication system or a hoisting interface component for connecting to a hoisting system.

10. A mold, characterized in that, The mold has a cavity, which is formed by an assembly that is consistent with the desired part to be molded, assembled from a kit body and kit sub-parts selected in a self-molding model kit, wherein the molding model kit is a molding model kit according to any one of claims 1-9.

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