Casting equipment for casting metal casting material and method for casting metal casting material

Abstract

The present invention relates to a casting installation (1) for casting metal casting material, the casting installation (1) comprising a melt pool container (2) for providing the casting material in a liquid state, a casting device (4) embodied to force the casting material into a casting die of the casting device (4), and a measuring container (5) that can be transferred from the melt pool container (2) to the casting device (4) and is embodied in particular as a measuring pipette, whereby the measuring container (5) is used to take a measurable amount of casting material from the melt pool container (2) into a receiving space (8) of the measuring container (5) and deliver it to the casting device (4), the measuring container (5) being connected to the exhaust device (11) of the casting installation (1), whereby the exhaust device (11) is used to evacuate the receiving space (8) to create a negative pressure in the receiving space (8) in order to receive a predetermined amount of the casting material in the receiving space (8). In order to achieve a high operating capacity, it is provided that the casting installation (1) comprises a conditioning station (3) having an induction unit (7), and that before using the measuring vessel (5) to deliver the casting material to the casting device (4), it is possible to particularly selectively move the measuring vessel (5) to the conditioning station (3), whereby the induction unit (7) can be used to electromagnetically stir the casting material in order to convert it into a thixotropic state. The present invention further relates to a method for casting metal casting material.

Description

[Technical Field]

[0001] The present invention relates to a casting installation for casting metal casting material, the casting installation comprising a molten pool container for providing the casting material in a liquid state, a casting device embodied for forcing the casting material into a casting die of the casting device, and a measuring container that can be transferred from the molten pool container to the casting device and is embodied in particular as a measuring pipette, whereby a measurable amount of casting material is taken from the molten pool container into a receiving space of the measuring container and delivered to the casting device, the measuring container being connected to an exhaust device of the casting installation, which is used to receive a predetermined amount of casting material in the receiving space, thereby evacuating the receiving space and creating a negative pressure in the receiving space.

[0002] The present invention further relates to a method for casting metal casting material, comprising using a measuring container, in particular a measuring pipette, to take a measured amount of casting material from a molten pool container having liquid casting material into a receiving space of the measuring container or to supply solid casting material to the receiving space, then moving the measuring container from the molten pool container to a casting device and delivering the casting material from the receiving space to the casting device, thereby using the casting device to press the casting material delivered to the casting device into a casting die of the casting device, and while taking in the liquid casting material using the measuring container, evacuating the receiving space with an exhaust device, thereby creating a negative pressure in the receiving space in order to receive a predetermined amount of casting material in the receiving space.

[0003] A known casting equipment for casting liquid metal casting material is typically configured to use a measuring pipette, which can be moved by a robotic arm, to extract a predetermined amount of casting material from a crucible by evacuating the measuring pipette. The robotic arm then moves the measuring pipette to a die casting machine, which then supplies the casting material from the measuring pipette to a casting chamber of the die casting machine. The die casting machine then injects the casting material supplied to the casting chamber into a casting die of the die casting machine, thereby producing a part by cooling the casting material within the casting die. The purpose of the crucible is typically to provide a molten pool of liquid casting material. The purpose of the measuring pipette is typically to transfer a specified amount of liquid casting material from the crucible to the die casting machine and deliver it to the casting chamber while reducing the effects of oxidation and reducing loss of casting material. In this way, a measured amount of liquid casting material can actually be supplied to the die casting machine, and a part can be produced by injecting the liquid casting material into the casting die using the die casting machine.

[0004] Casting equipment for thixocasting (also known as thixo-molten casting) is another type of casting equipment. This typically involves using a scoop to scoop the liquid casting material from a crucible into a conditioning crucible, then subjecting the casting material in the conditioning crucible to conditioning, thereby converting the liquid state into a thixotropic state. Conditioning typically involves cooling and stirring the casting material in the conditioning crucible, often with the use of a stirring tool, which typically shears the casting material to achieve a thixotropic or solid-liquid phase. This typically results in the casting material forming a pulp-like casting material body in the conditioning crucible. The thixotropic casting material is then typically poured from the crucible into the casting chamber of a die-casting machine, which is typically designed to force the thixotropic casting material into a casting die without turbulence. Casting equipment designed for thixocasting typically produces near-net-shape parts with high precision. Compared to liquid die casting equipment, thixotropic die casting equipment usually requires a complicated process route and a space-intensive setup. Summary of the Invention

[0005] This is addressed by the present invention.The object of the present invention is to specify a foundry installation of the type mentioned at the outset, which has improved operational capabilities.

[0006] Furthermore, it is an object of the invention to specify a method for casting metal casting materials of the type mentioned at the outset, which has improved handling capabilities.

[0007] According to the invention, this object is achieved by a casting installation of the type mentioned at the outset, in that the casting installation comprises a conditioning station with an induction unit, and before the casting material is delivered to the casting device using the metering container, it is possible, in particular selectively, to move the metering container to the conditioning station, whereby the casting material can be electromagnetically stirred using the induction unit in order to convert the casting material into a thixotropic state.

[0008] The present invention is based on the idea of ​​utilizing an embodiment of a casting installation for liquid casting based on a metering container that can be transferred from a melt pool container to a casting device. The metering container is designed to transfer a metered amount of casting material from the melt pool container into its evacuable receiving space to achieve thixotropic casting, especially thixotropic die casting. In this way, the casting installation for liquid casting can be used cost-effectively and especially selectively for thixotropic casting. This can be achieved by using the metering container for conditioning the casting material. Conditioning typically refers to processing the casting material with the aim of converting it, especially from its liquid phase, into a thixotropic phase. It has been shown that the thixotropic phase of the casting material can be achieved by electromagnetically stirring the, especially liquid, casting material in the receiving space. The metering container is preferably a measuring pipette. If the casting installation includes a conditioning station with an induction unit for electromagnetically stirring the casting material in the receiving space using the induction unit, the thixotropic state of the casting material can be achieved in the receiving space. Typically, the weighing vessel can be moved to an adjustment position relative to the induction unit, and in this adjustment position, the casting material in the receiving space can be electromagnetically stirred using the induction unit. In this way, the weighing vessel can be used to introduce the casting material into the weighing vessel, particularly the receiving space, while reducing interaction with the ambient atmosphere, particularly reducing the effects of oxidation; then, the casting material can be converted into a thixotropic state; and the casting material can be delivered to a casting device using the weighing vessel. Therefore, a high operating capacity of the casting facility can be achieved.

[0009] A melt pool container, which may be, for example, a crucible, is typically embodied to contain the liquid casting material, particularly as a melt pool, or to provide for the removal of said casting material using a measuring container. Typically, after using the measuring container to take in a particularly measured amount of casting material from the melt pool container and, in particular, after using an induction unit to electromagnetically stir the casting material in the receiving space, the measuring container can be moved to a casting device, thereby delivering the casting material from the receiving space to the casting device. The melt pool container and the casting device are typically separate objects and / or arranged to be spaced apart from each other. The induction unit is typically controlled, in particular in a closed loop, so that the temperature and / or solid content of the casting material in the receiving space can be adjusted using the induction unit. It has been shown to be advantageous for the solid content to be less than 20%, in particular between 0.1% and 20%, preferably between 1% and 15%, and particularly preferably between 3% and 10%. This type of solid content allows for particularly trouble-free operation of the thixotropic material when handling it using the measuring container when it is located in the receiving space.

[0010] Advantageously, the casting installation comprises an electronic control device for controlling the casting installation, in particular for closed-loop control. For this purpose, the electronic control device typically comprises a microcontroller. The electronic control device can be embodied to control, in particular for closed-loop control, the casting installation, in particular as a function of the casting material composition, preferably in an automated manner.

[0011] The casting equipment typically comprises a transfer mechanism, which can transfer the weighing vessel in a controlled manner, preferably in a closed-loop controlled manner. In particular, the weighing vessel can be transferred from the molten pool vessel to the conditioning station and / or the casting device by the transfer mechanism. The transfer mechanism can be embodied to move the weighing vessel along one or more movement axes, in particular oriented perpendicular to one another. The transfer mechanism can be, for example, a swivel arm or a portal robot. The weighing vessel is typically mechanically connected to the transfer mechanism, in particular so that it can be detached from the transfer mechanism. The transfer mechanism can be controlled by an electronic control device, in particular in a closed-loop controlled manner, and in particular can be suitably coupled to the electronic control device.

[0012] The metering vessel typically includes an evacuable receiving space for creating a negative pressure in the receiving space by evacuating the receiving space using an exhaust device. Evacuating the receiving space for the purpose of receiving the casting material typically defines the casting material being sucked into the receiving space. The metering vessel, particularly the receiving space, is typically configured so that the casting material can be supplied to the receiving space from the bottom of the metering vessel, particularly the receiving space, for receiving the casting material in the receiving space, and / or can be discharged from the receiving space via the bottom of the metering vessel, particularly the receiving space, for discharging the casting material from the receiving space. Typically, the casting material can be supplied to and / or discharged from a lower region, particularly the lowest region, of the receiving space. The metering vessel is typically configured so that, when the receiving space is partially filled with the casting material, an atmospheric volume sealed from the environment of the metering vessel exists above the casting material. Typically, an exhaust device is connected to guide gas into the atmospheric volume for evacuating the gas from the atmospheric volume using the exhaust device. Advantageously, the exhaust device is connected to the upper part of the receiving space, particularly in the uppermost region of the receiving space, to conduct gas into the receiving space. The receiving space typically forms a cavity that can be closed using a closing means of the metering container. The receiving space is usually formed by a receiving space wall that preferably essentially completely surrounds the receiving space. Typically, the receiving space wall of the metering container is at least partially, preferably essentially entirely, formed from a ceramic material. The metering container can be embodied to draw in a metered amount of liquid casting material into the receiving space by at least partially immersing the metering container in the liquid casting material contained by the molten pool container or in the molten pool. The molten pool is typically formed from the liquid casting material. Advantageously, the metering container has an outer wall that is at least partially embodied inertly, so that the inert part of the outer wall is immersed in the molten pool in such a way that a chemical reaction between the part and the molten pool does not essentially occur, thereby allowing the metering container to draw in the casting material from the molten pool. Typically, the outer wall of the metered vessel is formed at least in part, and preferably essentially entirely, from a ceramic material.The metering vessel is typically embodied to take in liquid casting material, in particular from a molten pool vessel, into the receiving space, and the metering vessel is typically embodied to deliver free-flowing thixotropic casting material from the receiving space, in particular to a casting device, typically to a casting chamber of the casting device.

[0013] The metering container typically includes a casting material opening for receiving the casting material into the metering container, particularly the receiving space, and / or for delivering the casting material from the metering container, particularly the receiving space, via the casting material opening. Conveniently, the metering container can be embodied to supply the casting material to the receiving space via the casting material opening and / or to deliver the casting material from the receiving space via the casting material opening. The casting material opening is typically connected to the receiving space so as to guide the casting material. The metering container can include a controllable, particularly closed-loop, closing means for closing and / or opening the casting material opening. The closing means can be controlled by a control device, particularly closed-loop, and can be suitably coupled to an electronic control device, in particular. When the casting material opening is open, the casting material can be supplied to the receiving space via the casting material opening or delivered from the receiving space via the casting material opening. In particular, when the casting material opening is closed, the closing means can essentially prevent the casting material from passing through the casting material opening. The closing means is preferably a closing plug. Therefore, it is advantageous for the metering container to include a casting material opening that can be closed using a controllable closing means, in particular a closing plug that can be moved in a controlled manner, to supply casting material to the receiving space through the casting material opening when the casting material opening is open. Conveniently, the metering container can include multiple casting material openings. In particular, the metering container can include a first casting material opening for receiving liquid casting material into the receiving space through the first casting material opening and a second casting material opening for delivering free-flowing casting material through the second casting material opening. The first casting material opening and / or the second casting material opening can be embodied as described in relation to the casting material opening. The first casting material opening and the second casting material opening can be opened and closed separately from each other in a controllable manner, preferably with closed-loop control, typically using one or more closing means, which can be embodied as described herein.In particular, separate closure means are associated with the first and second casting material openings, whereby the closure means can be used to open and close the respective casting material openings. The metered container can be embodied for metered intake of casting material into the metered container, in particular the receiving space, and / or for metered delivery of casting material from the metered container, in particular the receiving space.

[0014] To use the metering container to receive the liquid casting material from the weld pool container, the casting material opening is preferably immersed in the liquid casting material or the weld pool provided by the weld pool container. Thus, the casting material can be received through the casting material opening into a receiving space, particularly below the surface of the weld pool. The metering container is typically embodied in a suitable manner. In this way, the effects of oxidation can be effectively reduced, particularly prevented. It is advantageous for the casting material opening of the metering container to be arranged in a base region of the metering container, preferably facing downwards. As a result, the casting material can actually be received into the receiving space by immersing the base region, particularly the casting material opening, into the liquid casting material or the weld pool. It is advantageous for the metering container to be embodied in such a way that the free-flowing casting material can automatically flow out of the receiving space when the casting material opening is open. The metering container can be controlled by an electronic control device, particularly in a closed loop, and can be suitably coupled to the electronic control device.

[0015] The exhaust device typically includes a vacuum pump for evacuating the receiving space and, in particular, for creating a negative pressure in the receiving space. Typically, when the casting material opening is immersed in the molten pool, the exhaust of the receiving space, in particular the creation of a negative pressure in the receiving space, allows the casting material to be supplied to the receiving space through the casting material opening and, in particular, sucked into the receiving space. The exhaust device, in particular the vacuum pump, is typically connected to the receiving space, in particular by an exhaust line, for conducting gas. The gas can be drawn out of the receiving space via the exhaust line, in particular by suction using the exhaust device. The exhaust line is preferably connected to the receiving space at an upper portion thereof. The exhaust device may be part of a measuring vessel. The exhaust device may be embodied to variably control, in particular in a closed loop, the negative pressure in the receiving space, in particular when the casting material is received in the receiving space. In this way, the suction force acting on the casting material in the receiving space can be controlled, in particular in a closed loop, for the intake of the casting material into the receiving space and / or the discharge of the casting material from the receiving space, respectively. The exhaust system may be controlled by an electronic control unit, in particular in a closed loop, and in particular may be suitably coupled to an electronic control unit.

[0016] It is advantageous if the casting facility includes a gas supply device, by means of which a gas, in particular an inert gas such as argon, is supplied to the receiving space. The gas supply can thereby be carried out in a controlled manner, in particular by closed-loop control. The gas supply device can be connected to a metered vessel, in particular to the receiving space, via a gas supply line to conduct the gas. The gas supply device can be controlled by an electronic control device, in particular by closed-loop control, and in particular can be suitably coupled to the electronic control device, in particular for transmitting control signals.

[0017] The metering vessel advantageously includes a fill level measuring device for determining the fill level, particularly the fill volume, of the casting material in the receiving space. The fill level measuring device can be embodied to measure the weight and / or the fill height of the casting material in the receiving space. The fill level measuring device can be embodied with one or more measurement sensors. Immersion of the metering vessel into a molten pool located in the molten pool vessel for the purpose of drawing casting material from the molten pool into the metering vessel, particularly the receiving space, can be performed in response to the determination of the fill level of the receiving space using the fill level measuring device. Drawing and / or delivery of casting material from the metering vessel, particularly the receiving space, can be performed in response to the determination of the fill level of the receiving space using the fill level measuring device.

[0018] It is practical for the receiving space to include a first receiving space segment having a cross-sectional area that narrows in the casting material discharge direction of the receiving space. The casting material opening is typically located downstream of the first receiving space segment in the casting material discharge direction of the receiving space. Conveniently, the first receiving space segment can communicate with the casting material opening or a casting material channel that forms the casting material opening. The casting material discharge direction of the receiving space typically refers to the flow direction of the casting material within the receiving space as it is discharged from the receiving space through the casting material opening. The first receiving space segment can be located downstream of the second receiving space segment in the casting material discharge direction of the receiving space, and the second receiving space segment has an essentially constant cross-sectional area. For example, the second receiving space segment can be formed by a wall portion in the shape of a cylindrical sleeve, and / or the first receiving segment can be formed by a wall segment in the shape of a conical sleeve, particularly a frustoconical sleeve. The wall segment is typically part of the receiving space wall of the receiving space. Typically, the metering vessel, in particular the receiving space wall and / or the outer surface of the metering vessel, preferably the sleeve surface, is formed so as to mainly, in particular essentially, comprise or consist of ceramic material.

[0019] It is practical for the casting material opening to be formed by a casting material channel, which is connected to the receiving space in a manner that allows the casting material to flow therethrough. The casting material can be supplied to and / or discharged from the receiving space via the casting material channel. The casting material channel typically has an average cross-sectional area through which the casting material can flow, which is smaller than the average cross-sectional area of ​​the receiving space, in particular the receiving space segments. The cross-sectional area of ​​the receiving space, in particular the receiving space segments, is typically oriented perpendicular to the casting material delivery direction of the receiving space. The casting material channel typically connects to the receiving space at the bottom of the receiving space in a manner that allows the casting material to flow therethrough. The casting material channel and / or the casting material opening can be formed by a tubular neck of the measuring container, which protrudes, in particular downwards, from the base body of the measuring container. The receiving space is typically located primarily, preferably essentially, within the base body of the measuring container. It is advantageous for the neck to have an outer diameter that narrows in the direction of protrusion of the neck. The protrusion direction typically refers to the direction in which the neck protrudes outward from the base body. Typically, the longitudinal extension of the neck is oriented parallel to the projection direction, which is preferably downward, which typically means the direction in which the metering vessel is at least partially immersed in the liquid casting material or molten pool for the purpose of using the metering vessel to capture the casting material.

[0020] The metering vessel is advantageously designed for delivering a free-flowing thixotropic casting material, in particular to a casting apparatus. The metering vessel is advantageously designed for delivering a free-flowing metallic casting material, in particular a thixotropic casting material, having a solids content of more than 0.1%, in particular between 0.1% and 20%, preferably between 1% and 15%, and particularly preferably between 3% and 10%, from the receiving space to the casting apparatus, typically via the casting material opening. Thus, a thixotropic casting material having this type of solids content can be delivered from the metering vessel to the casting apparatus with little or no obstruction. In particular, a corresponding design of the casting material opening, in particular the casting material channel, is necessary for delivering a casting material having this type of solids content from the receiving space. This is particularly important because otherwise clogging with the thixotropic casting material may occur in the metering vessel, in particular in the region of the casting material opening.

[0021] Advantageously, the casting material opening can be opened in a controllable manner, in particular in a closed-loop manner, so that a free-flowing metallic casting material having a solids content of more than 3%, preferably between 3% and 20%, particularly preferably between 3% and 15%, can be delivered from the receiving space to the casting device via the casting material opening. The casting material opening can be controlled, in particular in a closed-loop manner, using an electronic control device.

[0022] It is advantageous if the ratio of the average diameter of the receiving space to the diameter of the casting material opening is 2 to 15, particularly 3 to 12, preferably 5 to 10, and particularly preferably 5 to 8. As a result, less disturbance in the operation of the metering vessel with the thixotropic material can be achieved in the metering vessel while simultaneously reducing the effects of oxidation. The diameter of the receiving space is typically measured perpendicular to the direction of casting material discharge of the receiving space. The diameter of the casting material opening is typically measured perpendicular to the direction of casting material discharge of the casting material opening, in which direction the casting material flows through the casting material opening as it is discharged from the receiving space for discharge through the casting material opening.

[0023] The casting material delivery direction of the receiving space typically refers to the flow direction of the casting material within the receiving space when the casting material is discharged from the receiving space for delivery through the casting material opening.

[0024] Typically, the induction unit defines a treatment receptacle into which the weighing vessel can be at least partially inserted for electromagnetic stirring of the casting material in the receiving space, so that the weighing vessel is at least partially surrounded by the induction unit. The treatment receptacle and the weighing vessel are advantageously embodied so that their shapes match each other. The treatment receptacle typically defines an adjustment position for the weighing vessel. The weighing vessel can be inserted into the treatment receptacle in a contactless manner, usually at an adjustment station, in particular at the induction unit. Typically, the weighing vessel is inserted into the treatment receptacle using a movement mechanism.

[0025] The induction unit is preferably formed by one or more inductors, particularly induction coils. The inductors typically define a treatment receptacle. Each inductor may be an induction coil including multiple coil windings. The electromagnetic induction field is typically generated by a current flow through the coil windings. The area covered by the coil windings typically defines the treatment receptacle. The coil windings are usually arranged on the envelope of a rotating body, such as a cylindrical or conical body. For example, the induction unit may be formed by a cylindrical induction coil including multiple coil windings, and the particularly enclosed area covered by the coil windings is the treatment receptacle. The inductors are typically embodied to generate an electromagnetic induction field and thereby electromagnetically stir the casting material in the receiving space at the adjustment position of the measuring vessel. Typically, stirring the casting material is defined as shearing the casting material, with the aim of achieving a thixotropic state of the casting material, particularly with a specified solid content. Advantageously, the guide unit is embodied in such a way that the metering vessel in the adjusted position is surrounded by the guide unit in all directions perpendicular to the direction of insertion of the metering vessel into the treatment receptacle.

[0026] It is advantageous if the measuring vessel can be inserted into the treatment receptacle so that at least 20%, particularly at least 50%, and preferably at least 65% of the volume of the receiving space is located inside the treatment receptacle. As a result, a specific solid content of the casting material in the receiving space can be efficiently adjusted. It is particularly advantageous if at least 75%, particularly at least 85%, and preferably at least 90% of the volume of the receiving space is located inside the treatment receptacle. In particular, this allows essentially the entire receiving space to be located inside the treatment receptacle. In this way, the conversion of the casting material to a thixotropic state can be controlled with high precision, particularly in a closed loop.

[0027] The measuring vessel can be inserted into the treatment receptacle in a controlled manner, preferably in a closed-loop manner, so that at least 20%, particularly at least 50%, and preferably at least 65% of the fill volume of the receiving space is located inside the treatment receptacle. As a result, a defined solids content of the casting material in the receiving space can be efficiently adjusted. It is particularly advantageous if at least 75%, particularly at least 85%, and preferably at least 90% of the fill volume of the receiving space is located inside the treatment receptacle. In particular, essentially the entire fill volume of the casting material in the receiving space can be located inside the treatment receptacle. The fill volume of the receiving space refers to the volume of the receiving space occupied by the casting material. The fill volume can be conveniently determined using a fill level measuring device. In this way, the conversion of the casting material to a thixotropic state can be controlled with particularly high precision, particularly in a closed-loop manner. The insertion into the treatment receptacle can typically be performed in a controlled manner, particularly in a closed-loop manner, depending on the fill volume of the receiving space. This can be done using an electronic control device.

[0028] Typically, by controlling, in particular by closed-loop control, the conditioning station, in particular the induction unit, it is possible to adjust the temperature and / or solids content of the casting material in the receiving space in the conditioning position of the metering vessel. Typically, in the conditioning position of the metering vessel, the casting material in the receiving space is cooled, in particular simultaneously with electromagnetic stirring of the casting material, and / or is actively cooled, in order to achieve a thixotropic state of the casting material. The conditioning station, in particular the induction unit, can be controlled by an electronic control device, in particular controlled in a closed loop, and in particular can be suitably coupled to the electronic control device, typically via an electronic control line.

[0029] Advantageously, the conditioning station includes a cooling device that can cool the casting material in the receiving space, in the case of a weighing vessel introduced to the conditioning station or at the conditioning position of the weighing vessel, simultaneously with electromagnetic stirring of the casting material, particularly using an induction unit. As a result, a thixotropic state of the casting material can be achieved particularly efficiently. Cooling by the cooling device can be performed in a controlled manner, particularly by closed-loop control, typically using an electronic control device. The cooling device can be formed by one or more cooling elements through which a cooling fluid can flow, preferably arranged and embodied so that the cooling elements can at least partially surround the weighing vessel at the position of the weighing vessel introduced to the conditioning station or at the conditioning position of the weighing vessel. The cooling element can also be a cooling channel, which can be embodied as part of a cooling circuit.

[0030] Advantageously, the induction unit can be embodied as a movable unit, so that it can move to some extent in conjunction with the weighing vessel. As a result, adjustment of the casting material in the receiving space, in particular electromagnetic stirring, can be performed during the movement of the weighing vessel. This allows for a coordinated movement when the weighing vessel is at least partially inserted into the treatment receptacle. Therefore, high efficiency can be achieved. The induction unit can be movable by a movement device of the casting installation, in particular in a controlled manner, preferably by closed-loop control. The movement device can be realized by a movement mechanism. Alternatively, passive movement of the induction unit in conjunction with the weighing vessel can be advantageous, for example, in that a mechanical connection between the weighing vessel and the conditioning station, in particular the induction unit, can be realized. It may be possible to activate or deactivate the mechanical connection in a controlled manner, in particular by closed-loop control.

[0031] The casting apparatus typically comprises a casting chamber to which the casting material can be delivered using a measuring container. The casting die of the casting apparatus is typically arranged downstream of the casting chamber, and the casting material can then be forced from the casting chamber into the casting die using a pressing element, particularly a plunger, of the casting apparatus. The casting apparatus is typically a die-casting apparatus and / or a forming apparatus, particularly a die-forging apparatus. The casting apparatus can be controlled by, particularly controlled in a closed loop, an electronic control device, and particularly can be suitably coupled to, the electronic control device.

[0032] The control, in particular the closed-loop control, of the weighing vessel, the transfer mechanism, the adjusting station and / or the casting device can be effected, in particular by a separate electronic control device, which is in particular part of the casting installation. The weighing vessel, the transfer mechanism, the adjusting station and / or the casting device can be suitably coupled to the electronic control device, usually for the transmission of control signals via electrical control lines in each case.

[0033] According to the present invention, the object of the present invention is achieved in a method for casting a metal casting material of the type mentioned at the beginning by, before delivering the casting material to a casting apparatus, optionally transferring a measuring container to a conditioning station having an induction unit, and then using the induction unit to electromagnetically stir the casting material in the receiving space in order to convert the casting material to a thixotropic state. This method can be implemented in the casting installation described herein. By using the measuring container for conditioning and converting the casting material in the receiving space of the measuring container to a thixotropic state, it is possible to efficiently cast a thixotropic casting material. In this way, a high operating capacity can be achieved. Typically, after converting the casting material in the receiving space to a thixotropic state, the casting material is delivered to the casting apparatus by the measuring container, and the thixotropic casting material is then forced into a casting die of the casting apparatus. The force-feeding typically occurs without any turbulence. The measuring container is typically a measuring pipette, or a measuring pipette embodied in such a way that the liquid casting material is sucked into its receiving space by creating a negative pressure.

[0034] The metering vessel allows the liquid casting material to be drawn into the receiving space of the metering vessel, preferably from a molten pool vessel, in particular in a metered amount. Alternatively, in most cases where the amount of casting material is smaller and / or more costly, it may be advantageous to supply the solid casting material, typically in pieces, to the receiving space of the metering vessel, typically with a metered amount of casting material. Usually, during or when drawing in the liquid casting material using the metering vessel and / or during or when drawing in the solid casting material using the metering vessel, the receiving space is evacuated using an exhaust device so that a negative pressure is created in the receiving space, in particular for the purpose of drawing in the metered amount of casting material therein.

[0035] In particular, it is advantageous if, in the first method sequence, the thixotropic state of the casting material in the receiving space is converted by the conditioning station, and the thixotropic casting material is delivered to the casting device using a measuring vessel; or alternatively, in the second method sequence, the thixotropic state of the casting material in the receiving space is not converted by the conditioning station, and the casting material is delivered in a liquid state from the casting vessel to the casting device. Typically, the casting material delivered to the casting device is respectively injected into the casting die using the casting device. In the first method sequence, the thixotropic state of the casting material is typically forced into the casting die by the casting device. In the second method sequence, the liquid state of the casting material is typically forced into the casting die by the casting device. The first and second method sequences can each be realized as described herein. The casting installation can be suitably embodied to perform the first and / or second method sequences. The first and second method sequences can be performed consecutively. In the first method sequence, in contrast to the second method sequence, the weighing vessel is typically not moved to a conditioning station or adjustment position for electromagnetic stirring of the casting material in the receiving space. The first and second method sequences can be performed using different casting dies of the casting apparatus. The first and second method sequences can have the same or different compositions of the casting material. Conveniently, the casting installation can include multiple weld pool vessels, and the weighing vessel can be moved to different weld pool vessels to receive the casting material from each weld pool vessel. It is advantageous for different casting material compositions, particularly casting materials with different weld pool compositions, to be contained or provided in each case in various weld pool vessels, typically in a liquid state or as weld pools.

[0036] The method for casting metal casting material can be implemented within the scope of the casting installation in accordance with the features and advantages described herein, in particular in the preceding paragraphs. The same applies to the casting installation with respect to the method.

[0037] It is advantageous to adjust the solids content of the casting material in the receiving space by means of the adjusting station to between 0.1% and 20%, in particular between 1% and 20%, preferably between 3% and 15%. This type of solids content makes it possible to achieve a particularly trouble-free operation of the thixotropic material, in particular in terms of handling it using a measuring container when it is located in the receiving space.

[0038] To convert the casting material into a thixotropic state, it is advantageous to actively cool the casting material in the receiving space simultaneously with the electromagnetic stirring, so that the thixotropic state of the casting material in the receiving space can be achieved particularly efficiently, which can be achieved by a cooling device in the conditioning station.

[0039] It is advantageous if the casting equipment is controlled in an automated manner, in particular in a closed loop. This can be achieved by an electronic control device that can be implemented for this purpose. The control, in particular the closed loop control, can be performed depending on the amount of casting material and / or the casting material composition of the casting material. It is particularly advantageous if the adjustment station, in particular the induction unit, is controlled in an automated manner, in particular in a closed loop, depending on the material composition, in particular the alloy composition, of the casting material, in order to adjust the thixotropic state of the casting material, in particular to a predetermined solid content. For this purpose, an electronic control device can be implemented. This can be efficiently achieved, since a high degree of reproducibility can be achieved by using a measuring vessel for adjustment. In particular, the influence of oxidation is usually negligible, and / or the receiving space is usually maximally isolated from the environment, making it possible to precisely control the transformation of the casting material into the thixotropic state in the receiving space.

[0040] The casting material is typically a metal alloy, especially a light metal alloy, and preferably a magnesium-based alloy, an aluminum-based alloy, or a copper-based alloy.

[0041] Liquid casting material typically refers to a casting material at a temperature above the liquidus temperature of the casting material. Thixotropic casting material typically refers to a casting material in a semi-molten state or at a temperature between the liquidus and solidus temperatures of the casting material. Typically, the molten pool vessel, the conditioning station, the casting apparatus, and the metering vessel are separate entities and / or arranged so as to be spaced apart from one another.

[0042] Additional features, advantages, and benefits of the present invention will become apparent from the following description of exemplary embodiments. [Brief explanation of the drawings]

[0043] [Figure 1] A schematic diagram of the casting equipment is shown. [Figure 2] 1 shows microscope images of the material structure of a part produced in a casting facility with and without the use of the casting facility's conditioning station. [Figure 3] 1 shows microscope images of the material structure of a part produced in a casting facility with and without the use of the casting facility's conditioning station. DETAILED DESCRIPTION OF THE INVENTION

[0044] FIG. 1 schematically illustrates a casting installation 1 and a method sequence for casting a metal casting material. The casting installation 1 includes a melt pool container 2, a conditioning station 3, a casting device 4, and a weighing container 5 that can be moved using a transfer mechanism 6. FIG. 1 illustrates the interaction of the weighing container 5 with the melt container, the conditioning station 3, and the casting device 4, respectively. The melt pool container 2 is embodied to contain or provide liquid casting material. The weighing container 5 can be selectively transferred from the melt pool container 2 to the conditioning station 3 and the casting device 4 using the transfer mechanism 6. The transfer mechanism 6 can be, for example, a pivot arm. The weighing container 5 allows a predetermined amount of liquid casting material to be taken into a receiving space 8 of the weighing container 5 from the melt pool container 2, and then the weighing container 5 can be selectively transferred to the conditioning station 3 using the transfer mechanism 6, thereby allowing electromagnetic stirring of the casting material in the receiving space 8 using an induction unit 7 of the conditioning station 3 in order to convert the casting material from a liquid state to a thixotropic state. Electromagnetic stirring is typically performed while the casting material in the receiving space 8 is cooling. The metering container 5 is then moved to the casting device 4 using a transfer mechanism 6, thereby allowing the thixotropic casting material to be delivered from the receiving space 8 to the casting device 4, typically to a casting chamber 9 of the casting device 4. The casting material delivered to the casting chamber 9 is then pressed against a casting die of the casting device 4 using a pressing element 10, particularly a plunger, of the casting device 4, thereby allowing the casting material to cool in the casting die to produce a part. The metering container 5 is connected to an exhaust device 11, which allows the receiving space 8 to be evacuated, thereby creating a negative pressure in the receiving space 8 in order to receive, particularly suck, the casting material into the receiving space 8. The exhaust device 11 is typically connected to conduct gas to the receiving space 8 via an exhaust line 12, thereby evacuating the receiving space 8 via the exhaust line 12. The measuring container 5 typically has a casting material opening 13 connected to guide the casting material into the receiving space 8 for receiving the casting material therethrough and / or for delivering the casting material therefrom.Typically, it is provided that the casting material opening 13 is immersed in liquid casting material located in the molten pool vessel 2 in order to take in the casting material into the receiving space 8 via the casting material opening 13. In this way, a measured amount of casting material can be taken in using the measuring vessel 5 while reducing the effects of oxidation, which can then be used, in particular selectively, for casting liquid casting material in the casting device 4 or for casting thixotropic casting material in the casting device 4.

[0045] The induction unit 7 is typically formed by an induction coil including a plurality of coil windings. The induction coil forms a treatment receptacle into which the metering vessel 5 can be at least partially inserted in order to electromagnetically stir the casting material in the receiving space 8. It is practical to insert the metering vessel 5 into the treatment receptacle so that at least 20% of the volume of the receiving space 8, preferably at least 20% of the volume filled with casting material, of the receiving space 8 is located inside the treatment space. In this way, a specific, in particular predefined, solid phase content in the casting material in the thixotropic state can be set.

[0046] To deliver the thixotropic casting material in the receiving space 8 to the casting device 4, the thixotropic casting material is delivered to the casting device 4, in particular to its casting chamber 9, via the casting material opening 13. For this purpose, it is advantageous if the ratio between the average diameter of the receiving space 8 and the diameter of the casting material 13 is between 2 and 15. Alternatively, it is advantageous if the thixotropic casting material has a solids content, preferably cumulatively, of more than 3%, in particular between 3% and 20%, delivered from the receiving space 8 to the casting device 4 via the casting material opening 13. In this way, handling of the thixotropic casting material, in particular delivery, can be achieved with minimal disruption using the measuring container 5.

[0047] FIGS. 2 and 3 show microscopic images of the material structure of parts produced using the casting equipment 1 of FIG. 1 with and without the use of the conditioning station 3 of the casting equipment 1. The microscopic images show, as an example, the material structure of a part produced using the casting equipment 1 with an AlSi7 alloy as the casting material. FIG. 2 shows the material structure of a part produced without the use of the conditioning station 3, i.e., by injecting the liquid casting material into the casting die using the casting device 4. FIG. 3 shows the material structure of a part produced using the conditioning station 3, i.e., by using the conditioning station 3 to convert the casting material in the receiving space 8 into a thixotropic state and achieving a solid content of 5%, and then using the casting device 4 to force the thixotropic casting material into the casting die. In the microscopic image of FIG. 2, a dendritic grain structure can be seen. In contrast, in the image of FIG. 3, a spherical cone structure can be seen.

[0048] By using the measuring vessel 5 to introduce liquid casting material into the evacuable receiving space 8 of the measuring vessel 5, then using the induction unit 7 of the conditioning station 3 to electromagnetically stir the casting material in the receiving space 8, thereby converting the casting material from a liquid state to a thixotropic state, and then sending the thixotropic casting material to the casting device 4 for introduction into the casting die, it is possible to achieve thixotropic casting or parts produced by thixotropic casting at low cost and with reduced oxidation effects. In particular, the casting equipment 1 can be used selectively, particularly for casting with liquid casting material and / or for casting with thixotropic casting material. As a result, the casting equipment 1 can have a high operating capacity. (Other possible items) (Item 1) A casting installation (1) for casting a metal casting material, said casting installation (1) comprising a melt pool container (2) for providing the casting material in a liquid state, a casting device (4) embodied for forcing the casting material into a casting die of the casting device (4), and a measuring container (5) that can be transferred from said melt pool container (2) to said casting device (4) and that is embodied in particular as a measuring pipette, whereby said measuring container (5) is used to take a measurable amount of casting material from said melt pool container (2) into a receiving space (8) of said measuring container (5) and deliver it to said casting device (4), said measuring container (5) being connected to an exhaust device (11) of said casting installation (1). The casting installation (1) uses the exhaust device (11) to evacuate the receiving space (8) and create a negative pressure in the receiving space (8) in order to receive a predetermined amount of the casting material in the receiving space (8). The casting installation (1) comprises an adjustment station (3) having an induction unit (7), and before using the measuring container (5) to deliver the casting material to the casting device (4), the casting installation (1) is particularly selectively able to move the measuring container (5) to the adjustment station (3), thereby electromagnetically stirring the casting material using the induction unit (7) in order to convert the casting material into a thixotropic state. (Item 2) Item 1. The casting equipment (1) according to item 1, wherein the measuring vessel (5) comprises a casting material opening (13) that can be closed using a controllable closing means, in particular a closing plug, whereby casting material is supplied to the receiving space (8) via the casting material opening (13) when the casting material opening (13) is open. (Item 3) 3. The casting equipment (1) according to item 2, wherein the casting material opening (13) of the measuring vessel (5) is arranged in a base region of the measuring vessel (5). (Item 4) 4. The casting equipment (1) according to item 2 or 3, wherein the casting material opening (13) is formed by a tubular neck of the measuring container (5), which protrudes from a base body of the measuring container (5). (Item 5) 5. The casting installation (1) according to any one of claims 1 to 4, wherein the measuring vessel (5) is designed to deliver a free-flowing metallic casting material having a solids content of more than 0.1%, in particular between 0.1% and 20%, preferably between 1% and 15%, particularly preferably between 3% and 10%, from the receiving space (8) to the casting device (4). (Item 6) 6. The casting installation (1) according to any one of claims 1 to 5, wherein the induction unit (7) defines a treatment receptacle into which the measuring vessel (5) can be at least partially inserted for electromagnetic stirring of the casting material in the receiving space (8), so that the measuring vessel (5) is at least partially surrounded by the induction unit (7). (Item 7) 7. The casting installation (1) according to item 6, wherein the induction unit (7) is formed with one or more inductors, in particular induction coils, which define the treatment receptacle. (Item 8) 8. The casting installation (1) according to item 6 or 7, wherein the measuring vessel (5) can be inserted into the treatment receptacle (8) so that at least 20%, in particular at least 50%, of the volume of the receiving space is located inside the treatment receptacle (8). (Item 9) 9. The casting installation (1) according to any one of the preceding claims, wherein the conditioning station comprises a cooling device capable of cooling the casting material in the receiving space (8) simultaneously with the electromagnetic stirring of the casting material, in particular using the induction unit (7), in the case of the measuring vessel (5) guided to the conditioning station. (Item 10) 10. The casting installation (1) according to any one of items 1 to 9, wherein the cooling device can be formed by one or more cooling elements through which a cooling fluid can flow, the cooling elements being arranged and embodied in such a way that the elements can at least partially surround the weighing vessel (5), preferably at the position of the weighing vessel (5) introduced into the adjustment station. (Item 11) 11. The casting installation (1) according to any one of claims 1 to 10, wherein the induction unit (7) can be embodied as movable, so that the induction unit (7) can move to some extent in conjunction with the measuring vessel (5). (Item 12) A method for casting a metal casting material, comprising: using a measuring container (5), in particular a measuring pipette, to take a measured amount of casting material from a molten pool container (2) having liquid casting material into a receiving space (8) of the measuring container (5) or to supply solid casting material into the receiving space (8), and then moving the measuring container (5) from the molten pool container (2) to a casting device (4) and delivering the casting material from the receiving space (8) to the casting device (4), thereby using the casting device (4) to deliver the casting material delivered to the casting device (4) to a casting die of the casting device (4). and while taking in liquid casting material using the measuring vessel (5), the receiving space (8) is evacuated using an exhaust device (11), thus creating a negative pressure in the receiving space (8) for the purpose of receiving a predetermined amount of casting material in the receiving space (8), wherein, before delivering the casting material to the casting device (4), the measuring vessel (5) is moved to a conditioning station (3) having an induction unit (7), and thereafter the casting material in the receiving space (8) is electromagnetically stirred by the induction unit (7) in order to convert the casting material into a thixotropic state. (Item 13) 13. The method according to item 12, wherein the solid content of the casting material in the receiving space (8) is adjusted by the adjusting station (3) between 0.1% and 20%. (Item 14) 14. The method according to item 12 or 13, wherein the casting material in the receiving space (8) is actively cooled simultaneously with the electromagnetic stirring, thereby converting the casting material to the thixotropic state. (Item 15) 15. The method according to any one of items 12 to 14, wherein the conditioning station (3), in particular the induction unit (7), is controlled in an automated manner, in particular in a closed loop, depending on the material composition of the casting material, in order to adjust the thixotropic state of the casting material, in particular with a predefined solid phase content.

Claims

1. 1. A casting installation for casting a metal casting material, comprising: a melt pool container for providing the casting material in a liquid state; a casting device embodied for forcing the casting material into a casting die of the casting device; and a measuring container, in particular embodied as a measuring pipette, that can be transferred from the melt pool container to the casting device, whereby a measurable amount of casting material is taken from the melt pool container into a receiving space of the measuring container and delivered to the casting device using the measuring container; the measuring container being connected to an exhaust device of the casting installation, whereby the receiving space is evacuated using the exhaust device to form a negative pressure in the receiving space in order to receive a predetermined amount of the casting material in the receiving space;

2. 2. The casting installation according to claim 1, wherein the measuring vessel comprises a casting material opening that can be closed using a controllable closing means, in particular a closing plug, whereby casting material is supplied to the receiving space via the casting material opening when the casting material opening is open.

3. The casting facility of claim 2 , wherein the casting material opening of the measuring vessel is located in a base region of the measuring vessel.

4. 3. The casting installation of claim 2, wherein the casting material opening is defined by a tubular neck of the measuring vessel, the neck protruding from a base body of the measuring vessel.

5. 2. The casting installation according to claim 1, wherein the measuring vessel is embodied for delivering a free-flowing metallic casting material having a solids content of more than 0.1%, in particular between 0.1% and 20%, preferably between 1% and 15%, particularly preferably between 3% and 10%, from the receiving space to the casting device.

6. 2. The casting installation according to claim 1, wherein the induction unit defines a treatment receptacle into which the weighing vessel can be at least partially inserted for electromagnetic stirring of the casting material in the receiving space, so that the weighing vessel is at least partially surrounded by the induction unit.

7. 7. A casting installation according to claim 6, wherein the induction unit is formed with one or more inductors, in particular induction coils, which define the treatment receptacle.

8. 7. The casting installation according to claim 6, wherein the measuring vessel can be inserted into the treatment receptacle so that at least 20%, in particular at least 50%, of the volume of the receiving space is located inside the treatment receptacle.

9. 2. The casting installation according to claim 1, wherein the conditioning station comprises a cooling device capable of cooling the casting material in the receiving space in the case of the measuring vessel guided to the conditioning station, in particular simultaneously with the electromagnetic stirring of the casting material using the induction unit.

10. 10. The casting installation according to claim 9, wherein the cooling device can be formed by one or more cooling elements through which a cooling fluid can flow, the cooling elements being arranged and embodied in such a way that the cooling elements can at least partially surround the weighing vessel, preferably at the position of the weighing vessel introduced to the conditioning station.

11. 11. A casting installation according to any one of claims 1 to 10, wherein the induction unit can be embodied in a mobile manner, so that it can move to some extent in conjunction with the weighing vessel.

12. 1. A method for casting metal casting material, comprising: using a measuring container, in particular a measuring pipette, to take a measured amount of casting material from a molten pool container having liquid casting material into a receiving space of the measuring container, or to supply solid casting material to the receiving space; then moving the measuring container from the molten pool container to a casting device and delivering the casting material from the receiving space to the casting device, thereby using the casting device to press the casting material delivered to the casting device into a casting die of the casting device; while taking in the liquid casting material using the measuring container, evacuating the receiving space using an exhaust device, thereby creating a negative pressure in the receiving space for receiving a predetermined amount of casting material in the receiving space; and before delivering the casting material to the casting device, moving the measuring container to a conditioning station having an induction unit, and then electromagnetically stirring the casting material in the receiving space by the induction unit to convert the casting material into a thixotropic state.

13. 13. The method of claim 12, wherein the solid content of the casting material in the receiving space is adjusted by the adjusting station to between 0.1% and 20%.

14. The method of claim 12 , further comprising actively cooling the casting material in the receiving space simultaneously with the electromagnetic stirring, thereby converting the casting material to the thixotropic state.

15. 15. The method according to any one of claims 12 to 14, wherein the conditioning station, in particular the induction unit, is controlled in an automated manner, in particular in a closed loop, depending on the material composition of the casting material, in order to adjust the thixotropic state of the casting material, in particular with a predefined solid phase content.

Images