Full-automatic intelligent device for sand casting of large magnesium alloy products

Abstract

The utility model belongs to alloy casting processing field, provide a kind of magnesium alloy bulky product sand mould gravity casting full-automatic intelligent device including workstation, mould whole set component, trackless trolley and environmental protection air draft component;Mould whole set component contains movable mould trolley, lifting assembly, sand mould and the sprue cup of multiple sprue;Trackless trolley integration overturns casting component (including the crucible overturning structure of servo motor drive) and manipulator detection component (including quick detach detection plate, plugging plate, downhole detection head and flame-retardant powder injection head).The utility model replaces manual casting by full-automatic operation, solves the problems of poor safety, low detection accuracy, complicated operation and insufficient environmental protection of existing process, simultaneously improves casting efficiency and product qualification rate, adapts multiple-specification magnesium alloy bulky casting demand.

Description

Technical Field

[0001] This utility model relates to a fully automated intelligent device for sand-casting gravity casting of large magnesium alloy products. It belongs to the field of alloy casting processing technology. Background Technology

[0002] Magnesium alloys, due to their low density and high specific strength, are increasingly widely used in large components (typically weighing ≥50kg) in aerospace, automotive manufacturing, and other fields. However, magnesium alloys are highly chemically reactive and readily oxidize and burn upon contact with air at high temperatures (casting temperatures are typically 650-750℃). Furthermore, the molten alloy solution has high fluidity, requiring extremely high stability during the casting process. Existing sand-casting gravity casting processes for large magnesium alloy components suffer from the following core problems: 1. Poor safety: Relying on manual hand tools to control the casting process requires workers to be in close contact with high-temperature alloy molten metal, which easily leads to burns and molten metal splashes. Furthermore, when magnesium alloys oxidize and burn, it is difficult to manually and accurately extinguish the flame in real time, which easily causes fire risks. Statistics show that the accident rate of the existing manual casting process is as high as about 5%.

[0003] 2. Low inspection accuracy: The height of the solution in the sand mold is measured manually by visual inspection or simple tools. The error is usually ≥5mm, which can easily lead to molding defects such as missing material, shrinkage cavities, and excess material in the product. The product qualification rate is less than 85%.

[0004] 3. Cumbersome and inefficient operation: When changing molds, manual disassembly and positioning of the mold and gate structure are required, and a single mold change takes ≥2 hours; during the casting process, manual switching of the gate and cleaning of residual solution are required, and the processing cycle of a single product is as long as 4-6 hours, which is difficult to adapt to the needs of mass production.

[0005] 4. Insufficient environmental protection: The high-temperature fumes (including magnesium oxide dust and volatile organic compounds) generated during casting are not effectively collected and are directly discharged into the workshop environment, which not only pollutes the air but also endangers the health of workers. The dust concentration in the workshop often exceeds 10mg / m³, which does not meet environmental protection standards.

[0006] To address the aforementioned issues, there is an urgent need to design a fully automated, high-precision, and highly safe intelligent casting device and method to meet the industrial production needs of large magnesium alloy components. Utility Model Content

[0007] The purpose of this invention is to overcome the shortcomings of existing sand-casting gravity casting processes for large magnesium alloy parts, such as "poor safety, low detection accuracy, cumbersome operation, and insufficient environmental protection," and to provide a fully automatic intelligent device for sand-casting gravity casting of large magnesium alloy parts. This device enables unmanned operation, real-time accurate detection, efficient mold changing, and dust collection during the casting process, while also being adaptable to the general needs of various mold specifications.

[0008] To achieve the above objectives, the technical solution of this utility model is as follows: A fully automated intelligent device for sand gravity casting of large magnesium alloy products includes: The workstation is quick-connected to multiple mold assembly components. As a fixed platform for casting operations, the workstation is equipped with multiple quick-connect sockets that can be quickly plugged into and unplugged to connect with the mold assembly components, achieving precise positioning and fixing of the mold with a positioning accuracy of ≤±2mm. The mold assembly includes a movable mold carriage, a lifting assembly mounted on the mold carriage for adjusting the height of the sand mold, a sand mold mounted on the lifting assembly, and a sprue cup mounted on the sand mold; the sprue cup has a sprue cup collection groove, a small sprue, and a large sprue; Specifically, Mold trolley: Equipped with casters and locking mechanism at the bottom, it can move along the workshop track and be fixed to the workstation via quick-connect sockets. The time for a single movement and positioning is ≤5 minutes. Lifting assembly: Installed on the mold trolley, it adopts a screw or hydraulic drive structure, which can drive the sand mold to rise and fall in the vertical direction. The adjustment range is 0-500mm to meet the casting requirements of different heights. Sand mold: It has a multi-layer splicing structure (2-4 layers, depending on the product size), and the outer wall is equipped with a mold limiting frame; Sprue cup: Installed on the top of the sand mold, it is fixed by "connecting shaft and mold limiting frame"; the sprue cup has a sprue cup collection groove (for collecting residual solution), a small sprue (diameter 10-15mm, for precise material replenishment) and a large sprue (diameter 30-40mm, for rapid casting), and a handle at the rear end.

[0009] The trackless trolley includes a tilting and casting component and a robotic arm detection component; the trackless trolley is a functional carrier that can move autonomously (equipped with a laser navigation system, with a movement accuracy of ≤±1mm), integrating the tilting and casting component and the robotic arm detection component; The flipping casting assembly includes a crucible fixing frame fixedly installed on the trackless trolley and a flipping component installed on the crucible fixing frame and capable of driving the crucible to flip for casting. One end of the flipping component is connected to a servo motor, and the other end is connected to a crucible for holding alloy solution through a flipping side plate. The crucible has a crucible casting port corresponding to the pouring cup collection groove. Crucible fixing frame: fixed to the top of the trackless trolley, used to support the flipping assembly and the crucible; Flipping assembly: adopts a dual-axis flipping structure, one end is connected to a servo motor (speed adjustable, range 5-10r / min) via a coupling, and the other end is connected to the crucible via a flipping side plate; Crucible: with a capacity of 50-200L, used to hold alloy solution, and its side wall has a crucible casting port (the diameter of which matches the large gate) corresponding to the collection groove of the pouring cup. Counterweight: Installed on one side of the tilting assembly to balance the weight of the crucible and the solution and prevent shaking during tilting; The robotic arm detection assembly includes a robotic arm base, a robotic arm that can rotate relative to the robotic arm base, and a quick-release detection plate connected to the robotic arm. The quick-release detection plate is equipped with a sealing plate corresponding to the large gate, a downward probe detection head for measuring the height of the solution in the sand mold, and a flame retardant powder spraying head.

[0010] Robotic arm base: fixed on a trackless trolley, with a built-in drive motor that can drive the robotic arm to rotate 360°; Robotic arm: It has a multi-joint structure (usually 2-3 sections) and its range of motion covers an area within 1m above the pouring cup; Quick-release inspection plate: It can be detachably connected to the robotic arm by bolts or clips and can be quickly replaced according to the specifications of the sand mold; it integrates a sealing plate (matching the size of the large gate, used to seal the large gate), a downward probe inspection head (using a contact sensor to provide real-time feedback on the solution level), a flame retardant powder spraying head (intermittently spraying flame retardant powder, with a spraying frequency of 5-10 seconds / time) and a pull hook (matching the handle of the pouring cup, used to pull up the pouring cup).

[0011] It also includes an environmentally friendly ventilation system, which includes a shielding canopy located on the workstation and a suction pipe installed in the shielding canopy. The shielding canopy has a telescopic opening for a crane to lift the pouring cup.

[0012] Canopy: Covers the work platform and is made of high-temperature resistant flexible material. One side of the canopy is retractable (0-1.5m in length) to facilitate the hoisting of the pouring cup by a crane. Suction pipes: evenly distributed on the inner wall of the shielding canopy, connected to the workshop dust removal system through pipes, with a dust collection efficiency of ≥90%.

[0013] The device also includes a safety monitoring system (such as temperature sensors and flame detectors) and an emergency stop device to further ensure operational safety.

[0014] The mold trolley is fixedly connected to the workstation via a quick-connect socket.

[0015] A handle is installed at the rear end of the pouring cup, and the quick-release detection plate is also equipped with a hook that matches the handle and pulls up the pouring cup after casting is completed.

[0016] A counterweight is also provided on one side of the flipping component.

[0017] The sand mold has a multi-layer structure and is equipped with a mold limiting frame. The pouring cup is equipped with a connecting shaft that matches the mold limiting frame.

[0018] Compared with the prior art, the beneficial effects of this utility model are as follows: This utility model relates to a fully automatic intelligent device for sand gravity casting of large magnesium alloy products. Through the coordinated operation of various components such as the workstation, mold assembly assembly, trackless trolley and environmentally friendly exhaust assembly, it achieves fully automatic casting and realizes intelligent and automated operation. Safety is greatly improved: no human contact with high-temperature alloy solution and flammable materials is required throughout the process. The flame-retardant powder spray head blocks oxidation and combustion in real time. At the same time, the shield canopy can prevent solution splashing and spreading. The accident rate in the casting process is reduced to less than 0.1% (the accident rate of the existing manual process is about 5%).

[0019] Improved inspection and casting accuracy: The error of the probe inspection head is ≤±1mm, the sealing plate precisely controls the switching of the gate, the product molding defect rate is reduced from ≥15% to ≤3%, and the pass rate is increased to over 97%.

[0020] Operational efficiency is significantly optimized: quick-connect connection and trackless trolley navigation enable rapid mold change, reducing the time for a single mold change from ≥2 hours to ≤30 minutes; the processing cycle for a single product is reduced from 4-6 hours to 2-3 hours, increasing production efficiency by more than 50%.

[0021] Environmental compliance: The dust collection efficiency of the environmentally friendly exhaust components is ≥90%, meeting the national "Emission Standard of Air Pollutants for Industrial Furnaces and Kilns". The dust concentration in the workshop is reduced to ≤5mg / m³, improving the working environment.

[0022] High versatility: The quick-release testing plate can be adapted to sand molds of different specifications (product weight covers 50-200kg), eliminating the need to customize a complete set of equipment for a single product, increasing the equipment reuse rate to over 80%, and reducing production costs.

[0023] High level of intelligence: Fully automated coordinated control is achieved through a central control system, reducing human intervention and improving production stability and consistency. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0025] Figure 1This is a schematic diagram of the structure of a fully automatic intelligent device for sand gravity casting of large magnesium alloy products according to the present invention (1).

[0026] Figure 2 (2) is a schematic diagram of the structure of a fully automatic intelligent device for sand gravity casting of large magnesium alloy products according to this utility model.

[0027] Figure 3 This is a schematic diagram (3) of the structure of a fully automatic intelligent device for sand gravity casting of large magnesium alloy products according to the present invention.

[0028] Figure 4 This is a schematic diagram of the mold assembly component in a fully automatic intelligent device for sand gravity casting of large magnesium alloy products according to this utility model.

[0029] Figure 5 This is a schematic diagram of the trackless trolley in a fully automatic intelligent device for sand gravity casting of large magnesium alloy products according to this utility model (1).

[0030] Figure 6 (2) is a schematic diagram of the trackless trolley in the fully automatic intelligent device for sand gravity casting of large magnesium alloy products according to this utility model.

[0031] In the diagram: 1-Environmental protection ventilation assembly; 2-Workstation; 3-Sand mold; 4-Mold assembly assembly; 5-Robot inspection assembly; 6-Trackless trolley; 7-Tilting casting assembly; 8-Telescopic canopy; 9-Suction pipe; 10-Lifting assembly; 11-Mold trolley; 12-Pour cup; 13-Connecting shaft; 14-Mold limiting frame; 15-Electrical cabinet; 16-Crucible fixing frame; 17-Crucible; 18-Tilting assembly; 19-Crucible casting port; 20-Servo motor; 21-Sealing plate; 22-Hook; 23-Detection probe; 24-Quick-release detection plate; 25-Robot arm base; 26-Quick socket; 27-Summoning cup collection tank; 28-Small gate; 29-Large gate; 30-First arm; 31-Second arm; 32-Handle; 33-Flame retardant powder spray head; 34-Downward detection head; 35-Flipping side plate; 36-Counterweight. Detailed Implementation

[0032] The specific embodiments of this utility model will be further described below with reference to the accompanying drawings. It should be noted that these descriptions are for the purpose of aiding understanding of this utility model, but do not constitute a limitation thereof. Furthermore, the technical features involved in the various embodiments of this utility model described below can be combined with each other as long as they do not conflict with each other.

[0033] This embodiment provides a fully automated intelligent device for sand gravity casting of large magnesium alloy products, such as... Figure 1-2As shown, it includes: a workstation 2, which is quickly connected to multiple mold assembly components 4; the workstation 2 serves as a fixed platform for casting operations, and is equipped with multiple quick-connect sockets 26, which can be quickly plugged into and unplugged from the mold assembly components 4 to achieve precise positioning and fixing of the mold, with a positioning accuracy of ≤±2mm. The mold assembly 4 includes a mold trolley 11: the bottom is equipped with casters and a locking structure, which can move along the workshop track and is fixed to the workstation 2 via a quick socket 26. The time for a single movement and positioning is ≤5 minutes. Lifting component 10: Installed on mold trolley 11, it adopts a screw or hydraulic drive structure and can drive the sand mold 3 to rise and fall in the vertical direction. The adjustment range is 0-500mm to meet the casting requirements of different heights. Sand mold 3: It has a multi-layer splicing structure (2-4 layers, depending on the product size), and the outer wall is equipped with a mold limiting frame 14; Sprue cup 12: Installed on the top of sand mold 3, and fixed by "connecting shaft 13 and mold limiting frame 14"; Sprue cup 12 has a sprue cup collection groove 27 (for collecting residual solution), a small sprue 28 (diameter 10-15mm, for precise material replenishment) and a large sprue 29 (diameter 30-40mm, for rapid casting), and a handle 32 at the rear end.

[0034] The trackless trolley 6 includes a flipping casting component 6, a robotic arm detection component 5, and an electrical cabinet 15 for power supply; the trackless trolley 6 is a functional carrier that can move autonomously (equipped with a laser navigation system, with a movement accuracy of ≤±1mm), integrating the flipping casting component 6 and the robotic arm detection component 5; The flipping casting assembly 6 includes: Crucible fixing frame 16: fixed to the top of trackless trolley 6, used to support the flipping assembly 18 and crucible 17; Flipping assembly 18: adopts a dual-axis flipping structure, one end is connected to servo motor 20 (speed adjustable, range 5-10r / min) through a coupling, and the other end is connected to crucible 17 through flipping side plate 35; Crucible 17: with a capacity of 50-200L, used to hold alloy solution, and its side wall has a crucible casting port 19 (the diameter of which matches the large gate 29) corresponding to the casting cup collection groove 27. Counterweight 36: Installed on one side of the flipping assembly 18 to balance the weight of the crucible 17 and the solution, preventing it from shaking during flipping; The robotic arm detection component 5 includes a robotic arm base 25: fixed on the trackless trolley 6, with a built-in drive motor that can drive the robotic arm to rotate 360°. The robotic arm is a multi-joint structure (usually 2-3 segments), with an operating range covering an area within 1m above the pouring cup 12; it includes a first arm 30 and a second arm 31. Quick-release detection plate 24: Detachably connected to the robotic arm via bolts or clips, allowing for rapid replacement according to the specifications of the sand mold 3; it integrates a sealing plate 21 (matching the size of the large gate 29 for sealing the large gate 29), a downward detection head 34 (using a contact sensor to provide real-time feedback on the solution level), a flame retardant powder spraying head 33 (intermittently spraying flame retardant powder at a frequency of 5-10 seconds / time), and a pull hook 22 (matching the handle 32 of the pouring cup 12 for lifting the pouring cup 12). It also includes a detection probe 23 for detecting the solution volume and temperature within the pouring cup collection tank 27.

[0035] It also includes an environmentally friendly ventilation component 1, which includes a shielding canopy located on the workstation 2 and a suction pipe 9 installed in the shielding canopy. The shielding canopy has a telescopic canopy 8 for inserting a crane to lift the pouring cup 12.

[0036] Canopy: Covers the work platform 2, made of high temperature resistant flexible material, with a telescopic canopy 8 (0-1.5m telescopic length) on one side to facilitate the hoisting of the pouring cup 12 by a crane; Suction pipe 9: Evenly distributed on the inner wall of the shielding canopy, connected to the workshop dust removal system through pipes, with a smoke and dust collection efficiency of ≥90%.

[0037] The mold trolley 11 is fixedly connected to the workstation 2 via a quick-connect socket 26. A handle 32 is installed at the rear end of the pouring cup 12, and the quick-release detection plate 24 is also equipped with a hook 22 that matches the handle 32 and pulls up the pouring cup 12 after casting. A counterweight 36 is also provided on one side of the flipping assembly 18. The sand mold 3 has a multi-layer structure and is equipped with a mold limiting frame 14. The pouring cup 12 is equipped with a connecting shaft 13 that matches the mold limiting frame 14.

[0038] This utility model is not limited to the described embodiments. For those skilled in the art, various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of this utility model, and these variations will still fall within the protection scope of this utility model.

Claims

1. A fully automatic intelligent device for sand gravity casting of large magnesium alloy products, characterized in that: include: The workstation allows for quick-connect connections to multiple mold assembly components. The mold assembly includes a movable mold carriage, a lifting assembly mounted on the mold carriage for adjusting the height of the sand mold, a sand mold mounted on the lifting assembly, and a sprue cup mounted on the sand mold; the sprue cup has a sprue cup collection groove, a small sprue, and a large sprue; A movable trackless vehicle, including a tilting casting assembly and a robotic arm inspection assembly; The flipping casting assembly includes a crucible fixing frame fixedly installed on the trackless trolley and a flipping component installed on the crucible fixing frame and capable of driving the crucible to flip for casting. One end of the flipping component is connected to a servo motor, and the other end is connected to a crucible for holding alloy solution through a flipping side plate. The crucible has a crucible casting port corresponding to the pouring cup collection groove. The robotic arm detection assembly includes a robotic arm base, a robotic arm that can rotate relative to the robotic arm base, and a quick-release detection plate connected to the robotic arm. The quick-release detection plate is equipped with a sealing plate corresponding to the large gate, a downward probe detection head for measuring the height of the solution in the sand mold, and a flame retardant powder spraying head.

2. The fully automatic intelligent device for sand gravity casting of large magnesium alloy products according to claim 1, characterized in that: It also includes an environmentally friendly ventilation system, which includes a shielding canopy located on the workstation and a suction pipe installed in the shielding canopy. The shielding canopy has a telescopic opening for a crane to lift the pouring cup.

3. The fully automatic intelligent device for sand gravity casting of large magnesium alloy products according to claim 1, characterized in that: The mold trolley is fixedly connected to the workstation via a quick-connect socket.

4. The fully automatic intelligent device for sand gravity casting of large magnesium alloy products according to claim 1, characterized in that: A handle is installed at the rear end of the pouring cup, and the quick-release detection plate is also equipped with a hook that matches the handle and pulls up the pouring cup after casting is completed.

5. The fully automatic intelligent device for sand gravity casting of large magnesium alloy products according to claim 1, characterized in that: A counterweight is also provided on one side of the flipping component.

6. The fully automatic intelligent device for sand gravity casting of large magnesium alloy products according to claim 1, characterized in that: The sand mold has a multi-layer structure and is equipped with a mold limiting frame. The pouring cup is equipped with a connecting shaft that matches the mold limiting frame.

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