Continuous alloy feeder

Abstract

The utility model discloses a continuous alloy feeding machine, include: hopper, support, first motor, blanking pipe and blanking assembly, hopper fixed setting at the top of support, blanking assembly includes shell and gear, and the upper end of shell is communicated with the lower end of hopper, and the lower end of shell is communicated with blanking pipe, and the inside of shell is provided with gear, and first motor drives the rotation of gear in the inside of shell, solved the artificial addition difficult guaranteeing continuous, steady adding rhythm, easily influenced by operator experience, fatigue, and the problem of low, poor repeatability of addition precision, reduce manual intervention, avoid operator close contact high temperature pouring area, improve security.

Description

Technical Field

[0001] This utility model belongs to the field of automatic casting machines, and in particular relates to a continuous alloy feeding machine. Background Technology

[0002] In the automotive parts manufacturing industry, cast iron parts are widely used in key components such as engine blocks, brake discs, and chassis brackets due to their excellent strength, toughness, and cost advantages. To meet the specific performance requirements of different parts (such as improving wear resistance, fatigue resistance, or reducing brittleness), cast iron materials need to undergo alloying treatment. This involves introducing alloying elements such as silicon, manganese, chromium, and molybdenum into the molten iron to control the metallographic structure and mechanical properties of the cast iron. This is a core process step to ensure the reliability of automotive parts.

[0003] The current mainstream alloy addition method in the industry is the "pre-addition method in the melting furnace". The operation process is usually as follows: after the raw materials such as pig iron and scrap steel are melted and heated in melting equipment such as cupola furnace and medium frequency electric furnace, alloy blocks or alloy particles are directly put into the melting furnace. The alloy and molten iron are mixed by means of the natural convection of the molten iron in the furnace or by the stirring device. After the alloy is completely melted and evenly distributed, the molten iron that meets the composition requirements is then transferred to the casting process.

[0004] However, this traditional process has the following significant technical defects, making it difficult to meet the needs of efficient and high-precision production of automotive parts: severe alloy oxidation and burning loss, low element melting and utilization rate, poor alloy mixing uniformity, low consistency of parts performance, poor process connection, and difficulty in adapting to automated casting processes.

[0005] To address these issues, some companies have attempted an improved method of "manual addition before casting," where alloy particles are manually added to the trough of the casting machine after the molten iron is transferred from the furnace. However, this method still has significant shortcomings: manual addition cannot achieve precise control "proportionally to the molten iron flow rate," easily resulting in insufficient addition at high flow rates and excessive addition at low flow rates; furthermore, manual operation makes it difficult to maintain a continuous and stable addition rhythm, easily affected by the operator's experience and fatigue, leading to low addition accuracy and poor repeatability, failing to meet the process stability requirements of automated and large-scale production of automotive parts.

[0006] In summary, existing alloy addition processes, due to severe oxidation loss, poor mixing uniformity, and low compatibility with automated casting processes, have become key bottlenecks restricting the improvement of performance, cost control, and production efficiency optimization of automotive cast iron parts. Therefore, developing a continuous alloy feeder to reduce alloy oxidation loss, improve element recovery rate and mixing uniformity, and adapt to the needs of automated production lines has become an urgent technical problem to be solved in the field of automotive cast iron processing. Utility Model Content

[0007] The purpose of this invention is to provide a continuous alloy feeder that solves the problems of difficulty in ensuring a continuous and stable feeding rhythm when manually adding alloys, susceptibility to the influence of operator experience and fatigue, low feeding accuracy and poor repeatability. It reduces manual intervention, avoids close contact between operators and the high-temperature casting area, and improves safety.

[0008] To achieve the above objectives, the specific technical solution of this utility model for a continuous alloy feeding machine is as follows: A continuous alloy feeder includes: a hopper, a support frame, a first motor, a feeding pipe, and a feeding assembly; The hopper is fixedly mounted on the top of the support. The feeding assembly includes a housing and a gear. The upper end of the housing is connected to the lower end of the hopper, and the lower end of the housing is connected to the feeding pipe. The gear is disposed inside the housing, and the first motor drives the gear to rotate inside the housing.

[0009] Furthermore, the continuous alloy feeder also includes an air blowing assembly, which is disposed at the lower end of the feed pipe and communicates with the feed pipe.

[0010] Furthermore, the side of the air blowing assembly is provided with a compressed air inlet, and the compressed air inlet is connected to the feed pipe.

[0011] Furthermore, the air blowing assembly also includes a discharge pipe, which is connected to the compressed air inlet.

[0012] Furthermore, the continuous alloy feeder also includes a controller and a pressure sensor, the pressure sensor being disposed inside the feed pipe and electrically connected to the input terminal of the controller.

[0013] Furthermore, the continuous alloy feeder also includes an alarm, which is electrically connected to the output of the controller.

[0014] Furthermore, the continuous alloy feeder also includes a level gauge, which is located near the bottom of the hopper and is electrically connected to the input terminal of the controller.

[0015] Furthermore, the continuous alloy feeder also includes a frequency converter, which is electrically connected to the output of the controller and the first motor respectively.

[0016] Furthermore, the continuous alloy feeder also includes a detection switch, which is disposed between the housing and the feed pipe.

[0017] Furthermore, the continuous alloy feeder also includes a verification component and a display screen. The verification component is electrically connected to the input terminal of the controller, and the display screen is electrically connected to the output terminal of the controller.

[0018] The continuous alloy feeding machine of this invention has the following advantages: 1. Reduce oxidation loss and improve alloy utilization: Alloy particles are added directly to molten iron during the casting process, reducing the contact time with air. Compared with the pre-addition method in the smelting furnace, the oxidation loss rate is reduced by more than 30%, and the alloy element melting utilization rate is increased to more than 95%. 2. High addition accuracy and strong performance stability: Through the combination of frequency converter, gear transmission and linearity verification, the feeding speed can be adjusted from 1.00 to 6.99 g / s with an error of <3%. It can also adapt to alloys of different particle sizes without changing parts for adjustment, avoiding inconsistencies in the performance of castings due to composition fluctuations. 3. Automatic fault detection reduces quality risks: Pressure sensors, level gauges, and photoelectric detection switches form a triple detection system, providing real-time warnings for pipeline blockages, low material levels, and material shortages, thus preventing defective castings caused by malfunctions. 4. High degree of automation and improved safety: Automatic start / stop in conjunction with the casting machine, eliminating the need for close-range manual operation and avoiding injury from molten iron heat radiation and splashing; at the same time, remote operation via display screen reduces manual labor intensity and increases production efficiency by more than 20%; 5. Adaptable to flexible production: Supports adjustment of the amount added in the last three molds (optimized for the drop in molten iron temperature in the later stage of casting), and can quickly switch alloy types and addition parameters to adapt to the casting process requirements of different automotive parts. Attached Figure Description

[0019] Figure 1 This is a front view of the continuous alloy feeder of this utility model; Figure 2 This is a schematic diagram of the continuous alloy feeder of this utility model; Figure 3 This is a side view of the continuous alloy feeder of this utility model; Figure 4 This is a schematic diagram of the electrical connection structure of the continuous alloy feeder of this utility model.

[0020] Explanation of markings in the diagram: 1. Hopper; 2. Support frame; 3. First motor; 4. Feed pipe; 5. Feed assembly; 51. Housing; 52. Gear; 6. Air blowing assembly; 61. Compressed air inlet; 62. Discharge pipe; 63. Ceramic protective sleeve; 7. Controller; 8. Pressure sensor; 9. Alarm; 10. Level gauge; 11. Frequency converter; 12. Detection switch; 13. Calibration assembly; 14. Display screen; 15. Filter screen; 16. Switch valve; 17. Quick-connect clamp connector; 18. Casting machine; 19. Mounting base; 20. Air blowing port. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0022] Those skilled in the art will understand that although some embodiments herein include certain features included in other embodiments but not others, combinations of features from different embodiments are intended to be within the scope of this invention and form different embodiments. For example, in the claims, any of the claimed embodiments can be used in any combination.

[0023] The following reference Figures 1 to 4 This invention describes a continuous alloy feeder.

[0024] like Figures 1 to 3 As shown, a continuous alloy feeder includes: a hopper 1, a support 2, a first motor 3, a feeding pipe 4, and a feeding assembly 5; The hopper 1 is fixedly mounted on the top of the support 2; The feeding assembly 5 includes a housing 51 and a gear 52. The upper end of the housing 51 is connected to the lower end of the hopper 1, and the lower end of the housing 51 is connected to the feeding pipe 4. The gear 52 is disposed inside the housing 51, and the first motor 3 drives the gear 52 to rotate inside the housing 51.

[0025] Specifically, the hopper 1 is fixedly installed at the top of the support 2 for storing alloy particles. Its upper part is square, tapering to an inverted trapezoid at the bottom, and it is made of 2mm steel plate welded together to ensure structural strength and storage capacity. The feeding assembly 5 includes a housing 51 and a gear 52. The housing 51 is machined from metal, with its upper end connected to the lower end of the hopper 1 via a switch valve 16, and its lower end connected to the feeding pipe 4 via a quick-connect clamp connector 17. The gear 52 is located inside the housing 51, and baffles are provided on both sides of the gear 52 to prevent alloy particles from spilling. The first motor 3 is a geared motor, fixedly installed on the support 2, with its output shaft connected to the gear 52. The gear 52 is driven to rotate, achieving quantitative feeding of alloy particles. The rotation speed of the gear 52 is linearly positively correlated with the alloy feeding speed, providing a basis for flow rate control.

[0026] Preferably, a bracket 2 is made of 10mm steel plate welded together, and a hopper 1 made of 2mm steel plate welded together is fixed to the top of the bracket 2. A 30-mesh filter screen 15 is embedded inside the hopper 1 to prevent oversized alloys or impurities from entering. A mounting hole for a level gauge 10 is opened at the bottom of the hopper 1, and a proximity switch is installed as the level gauge 10. A 1 / 2-inch stainless steel ball valve is installed at the lower end of the hopper 1 as a switch valve 16, and the lower end of the switch valve 16 is connected to the housing 51. A gear 52 is installed inside the housing 51, and baffles are fixed on both sides of the gear 52 with bolts. A geared motor is fixed to the bracket 2, and the motor output shaft is connected to the gear 52 through a coupling. A short pipe is welded to the lower end of the housing 51 and connected to the discharge pipe 4 through a quick-connect clamp connector 17. The discharge pipe 4 is an iron pipe with an outer diameter of Φ16mm and a wall thickness of 1.5mm.

[0027] Furthermore, such as Figure 1 As shown, the continuous alloy feeder also includes an air blowing assembly 6, which is located at the lower end of the feed pipe 4 and is connected to the feed pipe 4.

[0028] Furthermore, the side of the air blowing assembly 6 is provided with a compressed air inlet 61, and the compressed air inlet 61 is connected to the feed pipe 4.

[0029] Furthermore, the air blowing assembly 6 also includes a discharge pipe 62, which is connected to the compressed air inlet 61.

[0030] Specifically, the blowing assembly 6 has a compressed air inlet 61 on its side, which is connected to an external compressed air source through an air pipe. The compressed air enters the feeding pipe 4 through the inlet, which accelerates the flow of alloy particles and prevents particles from accumulating. It can also assist in pressure detection. The blowing assembly 6 also includes a discharge pipe 62. One end of the discharge pipe 62 is connected to the compressed air inlet 61, and the other end extends to the top of the pouring ladle nozzle. The section of the discharge pipe 62 that contacts the molten iron is fitted with a ceramic protective sleeve 63 (inner diameter Φ16.2mm, wall thickness 5mm) to prevent the high-temperature molten iron from scalding the discharge pipe 62. After the alloy particles flow out through the discharge pipe 62, they directly contact the high-temperature molten iron during the pouring process, reducing the contact time with air and reducing oxidation and burning loss.

[0031] Preferably, an air blowing assembly 6 is welded to the lower end of the feeding pipe 4. A compressed air inlet 61 is opened on the side of the air blowing assembly 6. The upper end of the compressed air inlet 61 is connected to a 0.4MPa compressed air source, and the lower end is connected to the discharge pipe 62. A ceramic protective sleeve 63 is fitted at the end of the discharge pipe 62.

[0032] Furthermore, such as Figure 4 As shown, the continuous alloy feeder also includes a controller 7 and a pressure sensor 8. The pressure sensor 8 is disposed inside the feed pipe 4 and is electrically connected to the input terminal of the controller 7.

[0033] Specifically, the feeder also includes a controller 7, preferably a PLC programmable controller 7, and a pressure sensor 8, preferably a pressure transmitter. The pressure sensor 8 is installed inside the feed pipe 4 via a mounting base 19, and its signal output terminal is electrically connected to the input terminal of the controller 7. It is used to detect the compressed air pressure inside the feed pipe 4. When the pipe is blocked, the pressure will rise abnormally, and the pressure sensor 8 will transmit the signal to the controller 7 to trigger a fault warning.

[0034] Preferably, a pressure sensor 8 is installed in the middle of the feed pipe 4, with its detection end extending into the feed pipe 4.

[0035] Furthermore, such as Figure 4 As shown, the continuous alloy feeder also includes an alarm 9, which is electrically connected to the output terminal of the controller 7.

[0036] Specifically, the alarm 9 is preferably an alarm horn. The alarm 9 is electrically connected to the output terminal of the controller 7. When a pipeline blockage, low material level, or material interruption is detected, the controller 7 drives the alarm 9 to emit an audible and visual alarm to remind the operator to handle the situation.

[0037] Furthermore, such as Figure 4As shown, the continuous alloy feeder also includes a level gauge 10, which is located near the bottom of the hopper 1 and is electrically connected to the input terminal of the controller 7.

[0038] Specifically, the level gauge 10 is installed at the mounting hole near the bottom of the hopper 1, and its signal output terminal is electrically connected to the input terminal of the controller 7. It is used to detect the remaining amount of alloy particles in the hopper 1 in real time. When the remaining amount is lower than the set threshold, the level gauge 10 sends a signal to the controller 7 to trigger a low level alarm to avoid material shortage.

[0039] Specifically, the continuous alloy feeder also includes a casting machine 18, which is electrically connected to the input terminal of the controller 7 to send casting start and casting stop signals.

[0040] Furthermore, such as Figure 4 As shown, the continuous alloy feeder also includes a frequency converter 11, which is electrically connected to the output terminal of the controller 7 and the first motor 3.

[0041] Specifically, the frequency converter 11 is electrically connected to the output terminal of the controller 7 and the first motor 3 respectively. The controller 7 adjusts the output frequency of the first motor 3 through the frequency converter 11, thereby controlling the speed of the gear 52 to achieve precise fine adjustment of the alloy feeding speed. The speed adjustment range corresponds to the motor frequency of 5Hz~120Hz. The motor frequency is linearly related to the flow rate.

[0042] Furthermore, such as Figure 4 As shown, the continuous alloy feeder also includes a detection switch 12, which is disposed between the housing 51 and the feed pipe 4.

[0043] Specifically, a through-beam high-temperature resistant photoelectric detection switch is installed on the mounting base 19 between the outer shell 51 and the feed tube 4. The positions of the transmitting / receiving optical fibers are adjusted to ensure that the light is collinear with the alloy outflow hole. Preferably, an air blowing hole 20 is provided between the transmitting optical fiber position and the receiving optical fiber position of the through-beam high-temperature resistant photoelectric detection switch. The air blowing hole 20 is connected to a compressed air source. The air in the compressed air source is throttled by a flow meter and blown in to prevent the receiving optical fiber position from being contaminated by dust, which would affect the detection accuracy.

[0044] Preferably, the detection switch 12 is a through-beam high-temperature resistant photoelectric detection switch 12. The detection switch 12 is mounted on the mounting base 19 between the housing 51 and the feed tube 4. The mounting base 19 has two facing Φ4mm mounting holes, which are respectively used to install the transmitting optical fiber and the receiving optical fiber. The two are collinear with the alloy outflow hole. When the alloy particles flow out normally, they will block the light, and the detection switch 12 will output a "normal" signal to the controller 7. If the material is cut off, the light is not blocked, and the detection switch 12 will output an "abnormal" signal, triggering a material cut-off alarm.

[0045] Furthermore, such as Figure 4 As shown, the continuous alloy feeder also includes a verification component 13 and a display screen 14. The verification component 13 is electrically connected to the input terminal of the controller 7, and the display screen 14 is electrically connected to the output terminal of the controller 7.

[0046] Preferably, the display screen 14 is a touch screen, which serves as a human-machine interface and transmits data with the controller 7 via RS422 communication mode.

[0047] Specifically, the verification component 13 is used to correct the linearity between the rotational speed of gear 52 and the alloy flow rate. The specific verification method is as follows: after setting the motor frequency, the first motor 3 runs at the motor frequency for 10 seconds, the weight of the alloy material is weighed with a balance within 10 seconds, the material feeding speed per second (g / s) is calculated and entered into the verification data table on the display screen 14, the data is automatically saved to the memory of the controller 7, and the controller 7 corrects the rotational speed-flow rate correspondence according to the verification data to ensure the flow rate accuracy.

[0048] Specifically, the display screen 14 serves as a human-machine interface, enabling the following operations: setting the target feeding speed (e.g., 1.00~6.99g / s), selecting the alloy particle size (e.g., 0.2~0.7mm, 0.25~0.85mm), setting the amount of alloy added to the tail mold (1.0~2.0 times the normal amount), displaying real-time pressure / material level / pouring status (green for normal, red for abnormal), and triggering manual testing / sweeping of sensors.

[0049] Specifically, the controller 7 is fixed in the electrical cabinet and electrically connected to the frequency converter 11, pressure sensor 8, level gauge 10, photoelectric detection switch 12, alarm 9, and display screen 14 respectively; the output of the frequency converter 11 is connected to the first motor 3 to realize motor speed regulation.

[0050] Specifically, before the equipment is put into operation, the flow linearity needs to be verified. The steps are as follows: Step 1: Add alloy particles of the target size (e.g., 0.25~0.85mm) to hopper 1, and verify the material level after ensuring it is higher than the threshold of the level gauge 10. Step 2: The first motor 3 runs at a frequency of 5Hz for 10 seconds and then stops automatically; weigh the weight of the alloy flowing out within 10 seconds using a balance (record as m1), calculate the feeding speed per second v1=m1 / 10 (g / s), and input v1 into the verification table cell corresponding to "5Hz"; Step 3: Repeat step 2 to complete the weighing and speed calculations at frequencies of 10Hz, 15Hz...120Hz in sequence. Input all data into the calibration table. The data is automatically saved to the memory of controller 7. Controller 7 completes the speed-flow linearity correction. Step 4: After the verification is completed, set the addition amount (e.g., 2.50g / s), and the first motor 3 runs at the corrected speed for 10 seconds. Weigh the material. If the error between the added material and the set value (25.00g) is less than 1%, the verification is qualified. If the error is greater than 3%, repeat the above verification steps.

[0051] The working process of a continuous alloy feeder is as follows: After the equipment is powered on, the level gauge 10 detects the remaining amount in the hopper 1, the pressure sensor 8 detects the pressure in the feed pipe 4, and the display screen 14 displays the "not poured" status; if the material level is insufficient or the pressure is abnormal, the alarm 9 will immediately sound an alarm, and after the controller 7 receives the pouring start signal, it drives the frequency converter 11 to output the corresponding frequency, and the first motor 3 drives the gear 52 to rotate; the alloy particles fall into the gap between the gear 52 through the filter screen 15 and the switch valve 16, and are sent to the feed pipe 4 as the gear 52 rotates; compressed air enters the feed pipe 4 through the air inlet, accelerating the flow of the alloy particles to the discharge pipe 62, and finally falls into the molten iron in the pouring ladle nozzle through the ceramic protective sleeve 63, completing the synchronous addition; During operation, the photoelectric detection switch 12 detects in real time whether the alloy is flowing out normally, and the pressure sensor 8 monitors whether the pipeline is blocked. If there is a material shortage or blockage, the alarm 9 will sound an alarm, and the corresponding parameter on the display screen 14 will turn red. When pouring to the last three molds, the controller 7 increases the motor frequency of the first motor 3 through the frequency converter 11 according to the preset "last three mold addition amount" (such as 1.5 times the normal amount) to increase the alloy addition amount and compensate for the performance loss caused by the drop in molten iron temperature. After pouring is completed, the controller 7 receives the pouring stop signal and drives the first motor 3 to stop running. If maintenance is required, the switch valve 16 is closed to cut off the alloy flow, and the components such as the feeding pipe 4 and the air blowing assembly 6 can be cleaned.

[0052] If a malfunction occurs during operation, and pressure sensor 8 detects pressure exceeding the set value (e.g., 12 Pa), alarm 9 will sound, and the pressure display on screen 14 will turn red. The operator must shut off the compressed air source, disassemble the feed pipe 4, clear any blockages, and reinstall it. If level gauge 10 detects that the remaining material in hopper 1 is less than the set value, alarm 9 will sound, and the level display on screen 14 will turn red. The operator must open the hopper 1 cover, add alloy particles to level gauge 10 to restore the normal signal, and the alarm will automatically deactivate. If photoelectric detection switch 12 does not detect alloy particles blocking the light, alarm 9 will sound, and the material shortage detection on screen 14 will turn red. The operator must check whether switch valve 16 is open and whether hopper 1 is empty.

[0053] In this embodiment, the feeding speed accuracy of the continuous alloy feeder can reach ±2%, the alloy oxidation and burn-off rate is reduced by 35%, the operator does not need to be in close contact with the pouring area, the accident rate is reduced to zero, and it is fully adapted to the needs of the automated casting production line for automotive parts.

[0054] Obviously, the above embodiments of this utility model are merely examples for clearly illustrating the present utility model, and are not intended to limit the implementation of the present utility model. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of the claims of this utility model.

Claims

1. A continuous alloy feeder, characterized in that, include: Hopper, support frame, first motor, feeding pipe and feeding assembly; The hopper is fixedly mounted on the top of the support. The feeding assembly includes a housing and a gear. The upper end of the housing is connected to the lower end of the hopper, and the lower end of the housing is connected to the feeding pipe. The gear is disposed inside the housing, and the first motor drives the gear to rotate inside the housing.

2. The continuous alloy feeder according to claim 1, characterized in that, It also includes an air blowing assembly, which is disposed at the lower end of the feed pipe and communicates with the feed pipe.

3. The continuous alloy feeder according to claim 2, characterized in that, The side of the air blowing assembly is provided with a compressed air inlet, and the compressed air inlet is connected to the feed pipe.

4. The continuous alloy feeder according to claim 3, characterized in that, The air blowing assembly also includes a discharge pipe, which is connected to the compressed air inlet.

5. The continuous alloy feeder according to claim 1, characterized in that, It also includes a controller and a pressure sensor, the pressure sensor being disposed inside the feed pipe and electrically connected to the input terminal of the controller.

6. The continuous alloy feeder according to claim 5, characterized in that, It also includes an alarm, which is electrically connected to the output of the controller.

7. The continuous alloy feeder according to claim 5, characterized in that, It also includes a level gauge, which is located near the bottom of the hopper and is electrically connected to the input of the controller.

8. The continuous alloy feeder according to claim 5, characterized in that, It also includes a frequency converter, which is electrically connected to the output terminal of the controller and the first motor respectively.

9. The continuous alloy feeder according to claim 5, characterized in that, It also includes a detection switch, which is disposed between the housing and the feed tube.

10. The continuous alloy feeder according to claim 5, characterized in that, It also includes a verification component and a display screen, wherein the verification component is electrically connected to the input terminal of the controller and the display screen is electrically connected to the output terminal of the controller.

Images