A double-bin precise feeding device specially used for casting machine

Abstract

The utility model discloses a kind of double-bin accurate feeding device specially used for casting machine, including shell, storage tank, gas path component, injector, controller, man-machine interface and two feeding mechanisms, storage tank has two independent bins, the lower end outlet of each bin is provided with feeding valve;Each feeding mechanism includes feeding pipe, material conveying pipeline, feeding motor, motor rotation circle number counting piece and feeding screw rod;Injector is set on the bottom plate of shell;Gas path component provides air pressure for injector;Feeding valve, gas path component, feeding motor and motor rotation circle number counting piece are respectively communicated with the controller.The double-bin accurate feeding device specially used for casting machine of the utility model can realize independent storage, rapid switching, accurate measurement and stable conveying of two inoculants, thereby improve production efficiency, guarantee product quality, meet flexible production demand.

Description

Technical Field

[0001] This utility model relates to the technical field of casting equipment in the foundry industry, specifically to a dual-hopper precision feeding device for casting machines. Background Technology

[0002] In modern casting production, the pouring machine is the core equipment for pouring molten iron. To improve the performance of castings, inoculants are often added to the molten iron stream during pouring. For foundries that produce both ductile iron and gray cast iron, due to their different process requirements, two different inoculants are usually required. Currently, most pouring machines are only equipped with a single inoculant hopper. When switching between ductile iron and gray cast iron products, any unused inoculant in the hopper must be manually cleaned and emptied before being replaced with another type of inoculant. This operating mode has the following significant drawbacks:

[0003] (1) Low production efficiency: When switching products, unused inoculants need to be emptied in time. The process of cleaning the silo and switching materials is cumbersome, which consumes a lot of manpower and downtime, seriously affecting the production cycle and overall equipment efficiency.

[0004] (2) High quality risk: If the cleaning is not thorough, the residual inoculant from previous types in the silos and pipelines will mix into the molten iron of subsequent products, causing contamination of the inoculant type. This may directly lead to abnormal metallographic structure and unqualified performance of the castings, resulting in serious quality problems. Moreover, frequent material switching exacerbates the loss of inoculant and increases the complexity of on-site material management.

[0005] Therefore, the existing single-hopper feeding method has become a bottleneck restricting multi-variety, flexible casting production. To solve the above problems, there is an urgent need to design a device that can integrate two inoculants and achieve rapid, cross-contamination-free, and precise switching and feeding to meet the demands of high-efficiency and high-quality production. Utility Model Content

[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide a dual-hopper precision feeding device specifically for casting machines. This device can solve the technical pain points of low efficiency, complicated cleaning, and easy mixing when switching inoculants in single-hopper systems. It enables independent storage, rapid switching, precise metering, and stable delivery of the two inoculants, thereby improving production efficiency, ensuring product quality, and meeting the needs of flexible production.

[0007] The technical solution to achieve the above objective is: a dual-hopper precision feeding device specifically designed for casting machines, comprising a shell, a storage tank, an air circuit assembly, an injector, a controller, a human-machine interface, and two feeding mechanisms, wherein:

[0008] The storage tank is located at the top of the shell, and the storage tank has two independent hoppers, each of which is equipped with a feeding valve at its lower outlet; the two hoppers are used to store inoculants respectively.

[0009] Each feeding mechanism includes a feeding pipe, a conveying pipe, a feeding motor, a motor rotation counter, and a feeding screw. The feeding pipe is horizontally arranged, the conveying pipe is vertically arranged, the upper end of the feeding pipe is connected to the conveying pipe, the feeding screw is rotatably arranged inside the feeding pipe, the feeding motor is installed on the inner wall of the housing, and the output end of the feeding motor is connected to the motor rotation counter and the feeding screw in sequence through a coupling.

[0010] The feeding pipes of the two feeding mechanisms are connected one-to-one to the lower outlets of the two silos, and the lower end of the conveying pipe of each feeding mechanism is connected to the mixing chamber of the injector; the feeding motor drives the feeding screw to quantitatively convey the inoculant in the silo to the conveying pipe.

[0011] The injector is disposed on the bottom plate of the housing, and the nozzle of the injector extends to the outside of the housing;

[0012] The air passage assembly is disposed inside the housing, and the air passage assembly provides air pressure to the injector, so that the inoculant delivered by the conveying pipeline is sprayed out through the injector.

[0013] The feeding valve, air circuit assembly, feeding motor, and motor rotation count plate communicate with the controller, and the controller communicates with the human-machine interface.

[0014] The aforementioned dual-hopper precision feeding device specifically designed for casting machines includes an air path assembly comprising dual cooling air paths and connected air delivery pipes. Each cooling air path is equipped with a vortex cooler, a temperature regulating solenoid valve one, a temperature detection probe, a temperature regulating solenoid valve two, a temperature sensor, and a selector valve. The air delivery pipe is equipped with an inlet pressure regulating valve, a delivery pressure proportional valve, a pipe blockage sensor, a thrust pressure sensor, and a pressure display. Each electrical component in the air path assembly communicates with the controller. The air delivery pipe is connected to the mixing chamber of the injector.

[0015] The above-mentioned dual-hopper precision feeding device for casting machines, wherein the feeding motor is a DC speed-regulating motor, the speed of which is controlled by a speed-regulating card, and the speed-regulating card communicates with the controller.

[0016] This utility model discloses a dual-hopper precision feeding device specifically designed for casting machines, which has the following significant advantages:

[0017] (1) Production efficiency is greatly improved: the online rapid switching of two inoculants is realized, eliminating the long downtime caused by traditional manual cleaning and material changing, and meeting the flexible production needs of multiple varieties and small batches;

[0018] (2) Reliable product quality assurance: The independent design of the dual material bins, combined with precise valve switching, fundamentally eliminates the risk of cross-contamination between the two inoculants, ensuring the stability of the casting material performance;

[0019] (3) Significantly improved feeding accuracy: The mechanical metering method of "DC speed regulating motor + precision feeding screw + rotation feedback" combined with the precise control of the controller achieves metering accuracy and repeatability superior to traditional volumetric or gravity feeding.

[0020] (4) Stable, intelligent and controllable operation: The gas circuit components (pressure, temperature and blockage monitoring) ensure the stable and smooth delivery process, and have fault self-diagnosis and alarm functions, which improve the automation level and reliability of the equipment. Attached Figure Description

[0021] Figure 1 This is a three-dimensional structural diagram (front view) of the dual-hopper precision feeding device for casting machines according to this utility model.

[0022] Figure 2 This is a three-dimensional structural diagram (rear view) of the dual-hopper precision feeding device for casting machines of this utility model.

[0023] Figure 3 This is a side view of the dual-hopper precision feeding device for casting machines according to this utility model;

[0024] Figure 4 This is a rear view of the dual-hopper precision feeding device for casting machines according to this utility model;

[0025] Figure 5 This is a schematic diagram of the structure of a DC speed-regulating motor;

[0026] Figure 6 This is a schematic diagram of the gas path assembly. Detailed Implementation

[0027] To enable those skilled in the art to better understand the technical solution of this utility model, its specific embodiments are described in detail below with reference to the accompanying drawings:

[0028] Please see Figure 1 , Figure 2 and Figure 3The preferred embodiment of this utility model is a dual-hopper precision feeding device specifically for casting machines, comprising a housing 1, a storage tank 2, an air circuit assembly 4, an injector 5, a controller 6, a human-machine interface (not shown in the figure), and two feeding mechanisms 3.

[0029] The storage tank 2 is located at the top of the shell 1. The storage tank 2 has two independent hoppers 21. Each hopper 21 is equipped with a feeding valve 22 at its lower outlet. The two hoppers 21 are used to store different inoculants.

[0030] Each feeding mechanism 3 includes a feeding pipe 31, a conveying pipe 32, a feeding motor 33, a motor rotation count plate 34, and a feeding screw 35. The feeding pipe 31 is horizontally arranged, and the conveying pipe 32 is vertically arranged. The upper end of the feeding pipe 31 is connected to the upper end of the conveying pipe 32. The feeding screw 35 is rotatably arranged inside the feeding pipe 31. The feeding motor 33 is installed on the inner wall of the housing 1, and the output end of the feeding motor 33 is connected to the motor rotation count plate 34 and the feeding screw 35 in sequence through a coupling 36.

[0031] The feeding pipes 31 of the two feeding mechanisms 3 are connected one-to-one to the lower outlets of the two silos 21. The lower end of the conveying pipe 32 of each feeding mechanism 3 is connected to the mixing chamber 51 of the injector 5. The feeding motor 33 drives the feeding screw 35 to quantitatively convey the inoculant in the silo 21 to the conveying pipe 32, and then convey it to the mixing chamber 51 of the injector 5 through the conveying pipe 32.

[0032] The injector 5 is disposed on the bottom plate of the housing, and the nozzle 52 of the injector 5 extends to the outside of the housing 1.

[0033] The air path assembly 4 is installed inside the housing 1. The air path assembly 4 provides stable air pressure to the injector 5, and sprays the inoculant delivered from the conveying pipeline out through the injector 5.

[0034] Feeding valve 22, air circuit assembly 4, feeding motor 33 and motor rotation count plate 34 communicate with controller 6 respectively, and controller 6 communicates with human-machine interface.

[0035] The feeding motor 33 is a DC speed-regulating motor, and its speed is controlled by a speed control card. The speed control card communicates with the controller 6, and the feeding motor 33 provides driving force for the feeding device of this utility model. The operator sets the inoculant addition amount per second on the human-machine interface. The human-machine interface sends the inoculant addition amount signal to the controller 6. After receiving the inoculant addition amount signal, the controller 6 controls the corresponding feeding valve 22 to open and outputs a working signal to the speed control card of the corresponding feeding motor 33. The speed control card then sends start and speed commands to the feeding motor 33, and the feeding motor 33 begins to rotate at a constant speed. The feeding motor 33 stops rotating when the start signal disappears.

[0036] When the feeding motor 33 rotates, it drives the coupling 36, which connects the motor rotation count plate 34 and the feeding screw 35. The feeding screw 35 comes in various specifications to meet specific needs. Different sizes of feeding screws 35 have different thread pitches, varying according to the feeding volume, resulting in different amounts of material conveyed per revolution. The rotation speed varies depending on the weight conveyed per second set by the operator. The motor rotation count plate 34 provides feedback on the motor rotation count to the controller 6. Different rotation speeds and different sizes of feeding screws are used to achieve the required conveying weight. This mechanical metering method, combining a DC speed-regulating motor, a precision feeding screw, and rotation count feedback, along with the precise control of the controller, achieves metering accuracy and repeatability superior to traditional volumetric or gravity feeding methods.

[0037] The air path assembly 4 includes dual cooling air paths and connected air delivery pipes. Each cooling air path is equipped with a vortex cooler 412, a temperature regulating solenoid valve 41, a temperature detection probe 49, a temperature regulating solenoid valve 410, a temperature sensor 411, and a selector valve 47. The air delivery pipe is equipped with an inlet pressure regulating valve 42, a delivery pressure proportional valve 43, a pipe blockage sensor 44, a thrust pressure sensor 45, and a pressure display 46. Each electrical component in the air path assembly communicates with the controller 6. The air delivery pipe is connected to the mixing chamber 51 of the injector 5. The selector valve 47 can be used to select which cooling air path to use.

[0038] The inoculant entering the mixing chamber 51 of the injector 5 is injected into the molten iron under the stable airflow provided by the gas path assembly 4. The core function of the gas path assembly 4 is to provide dry, constant-temperature, stable-pressure, and controllable compressed air for the delivery of the inoculant, and to monitor the delivery status in real time to ensure stable system operation. Its working principle and process are as follows: The entire gas path can be divided into three main stages: gas source processing and cooling, precise pressure control, and delivery execution and monitoring.

[0039] 1. First stage: Air source treatment and dual-path cooling:

[0040] The factory's main air source (compressed air) first enters this air circuit component 4. Compressed air usually contains moisture and oil and is at a high temperature. Directly using it to transport powdered inoculants can easily lead to clumping and pipe sticking.

[0041] The compressed air is first cooled by the vortex cooler 12. The vortex cooler 12 uses the principle of vortex tubes to cool the compressed air to below the dew point without any moving parts, causing a large amount of water vapor to condense and be discharged through an automatic drain. This is the first stage and the main cooling and drying process.

[0042] The temperature of the pre-cooled compressed gas is detected by temperature sensor 411, and the detection signal is fed back to controller 6. Controller 6 controls temperature regulating solenoid valve 41 and temperature regulating solenoid valve 410. These two valves achieve precise closed-loop control of the gas temperature by proportionally mixing the deeply cooled gas from the vortex cooler with the uncooled bypass hot gas, ensuring that the gas temperature remains stable at the set value (usually slightly higher than the ambient temperature to prevent secondary condensation). Temperature detection probe 49 is used to finally monitor the actual gas temperature entering the gas delivery pipeline. Thus, the system provides a dry and constant-temperature high-quality gas source.

[0043] 2. Second stage: Precise control and distribution of pressure:

[0044] The treated, temperature-controlled gas undergoes initial pressure stabilization via the inlet pressure regulating valve 42. Subsequently, the gas enters the core control valve of this gas circuit component 4—the delivery pressure proportional valve 43. This delivery pressure proportional valve 43 receives signals from the controller 6 and can steplessly and continuously adjust the output gas pressure precisely. The operator only needs to set the delivery pressure value on the human-machine interface, and the controller 6 will automatically drive the delivery pressure proportional valve 43 to reach and maintain that pressure. This is crucial for achieving "appropriate delivery pressure and ensuring smooth material feeding."

[0045] The regulated motive gas enters the mixing chamber 51 of the injector 5.

[0046] 3. The third stage: delivery execution, monitoring, and security protection.

[0047] The motive gas and the inoculant powder precisely pushed out from the "feeding mechanism 2" are mixed in the mixing chamber 51 of the injector 5 to form a uniform gas-solid two-phase flow, which is injected into the molten iron flow at high speed.

[0048] The pressure display 46 can display the current delivery pressure in real time for local monitoring.

[0049] The thrust pressure sensor 45 is usually installed on the air circuit or mechanical thrust point to monitor whether the delivery thrust is normal and serves as an auxiliary signal for system status diagnosis.

[0050] The pipe blockage sensor 44 is a critical safety sensor that can sensitively detect sudden pressure increases caused by pipe blockage. Once a blockage signal is detected, it immediately sends an emergency alarm to the controller 6. When the pipe blockage sensor 44 sends an emergency alarm to the controller 6, the controller will immediately execute safety interlock actions: immediately cut off the power to the feed motor 33 to stop feeding; it may also simultaneously close the main air valve or issue an audible and visual alarm. This effectively prevents the blockage from worsening, equipment overload, or even damage.

[0051] This utility model discloses a dual-hopper precision feeding device specifically designed for casting machines. During operation, the operator selects which hopper of inoculant to use on the human-machine interface and sets the feeding rate and conveying pressure. Controller 6 controls the corresponding feeding valve 22 to open, and controller 6 also controls the conveying pressure proportional valve 43 to adjust the power airflow in the air circuit assembly to the set pressure. The temperature control system (temperature regulating solenoid valve 1 41, temperature detection probe 49, temperature regulating solenoid valve 2 410, and temperature sensor 411) stabilizes the gas temperature at the set value. At the start of casting, the controller starts the corresponding feeding motor and opens the air circuit. The inoculant is precisely pushed and mixed with the constant pressure and temperature airflow in the ejector before being sprayed out. All sensors (pipe blockage sensor 44, thrust pressure sensor 45, pressure display 46, temperature detection probe 49, and temperature sensor 411) monitor in real time. If the pipe blockage sensor 44 is triggered during operation, controller 6 immediately stops and alarms, resuming operation after the fault is cleared.

[0052] This utility model discloses a dual-hopper precision feeding device specifically for casting machines. It employs a dual-hopper, dual-screw conveying structure, enabling seamless integration of different products using different inoculants. Utilizing a DC speed-regulating motor, speed controller, and motor rotation count plate, the controller achieves high-precision control of the feeding electrode. The material is conveyed quantitatively via a servo motor that drives the feeding screw through a coupling. Different sizes and specifications of screws can be used to meet the process requirements of varying dosages.

[0053] In summary, the dual-hopper precision feeding device for casting machines of this utility model can solve the technical pain points of low efficiency, complicated cleaning, and easy mixing when switching inoculants in single-hopper systems. It realizes independent storage, rapid switching, precise metering and stable delivery of two inoculants, thereby improving production efficiency, ensuring product quality and meeting the needs of flexible production.

[0054] Those skilled in the art should recognize that the above embodiments are only used to illustrate the present utility model and are not intended to limit the present utility model. Any changes or modifications to the above embodiments within the scope of the essential spirit of the present utility model will fall within the scope of the claims of the present utility model.

Claims

1. A dual-hopper precision feeding device specifically designed for casting machines, characterized in that, It includes a housing, storage tank, air circuit assembly, injector, controller, human-machine interface, and two feeding mechanisms, wherein: The storage tank is located at the top of the shell, and the storage tank has two independent hoppers, each of which is equipped with a feeding valve at its lower outlet; the two hoppers are used to store inoculants respectively. Each feeding mechanism includes a feeding pipe, a conveying pipe, a feeding motor, a motor rotation counter, and a feeding screw. The feeding pipe is horizontally arranged, the conveying pipe is vertically arranged, the upper end of the feeding pipe is connected to the conveying pipe, the feeding screw is rotatably arranged inside the feeding pipe, the feeding motor is installed on the inner wall of the housing, and the output end of the feeding motor is connected to the motor rotation counter and the feeding screw in sequence through a coupling. The feeding pipes of the two feeding mechanisms are connected one-to-one to the lower outlets of the two silos, and the lower end of the conveying pipe of each feeding mechanism is connected to the mixing chamber of the injector; the feeding motor drives the feeding screw to quantitatively convey the inoculant in the silo to the conveying pipe. The injector is disposed on the bottom plate of the housing, and the nozzle of the injector extends to the outside of the housing; The air passage assembly is disposed inside the housing, and the air passage assembly provides air pressure to the injector, so that the inoculant delivered by the conveying pipeline is sprayed out through the injector. The feeding valve, air circuit assembly, feeding motor, and motor rotation count plate communicate with the controller, and the controller communicates with the human-machine interface.

2. The dual-hopper precision feeding device for casting machines according to claim 1, characterized in that, The air circuit assembly includes dual cooling air circuits and connected air delivery pipes. Each cooling air circuit is equipped with a vortex cooler, a temperature regulating solenoid valve one, a temperature detection probe, a temperature regulating solenoid valve two, a temperature sensor, and a selector valve. The air delivery pipe is equipped with an intake pressure regulating valve, a delivery pressure proportional valve, a pipe blockage sensor, a thrust pressure sensor, and a pressure display. Each electrical component in the air circuit assembly communicates with the controller. The air delivery pipe is connected to the mixing chamber of the injector.

3. A dual-hopper precision feeding device specifically for casting machines according to claim 1, characterized in that, The feeding motor is a DC speed-regulating motor, and its speed is controlled by a speed-regulating card, which communicates with the controller.

Images