Molding system and molding method

Abstract

This invention provides a technology that improves the flexibility of layout in casting equipment related to mold forming. [Solution] The molding system comprises a mold-making machine that molds upper and lower molds and pushes the upper and lower molds onto a platen trolley located at the mold extrusion position among a plurality of transported platen trolleys, and a jacket covering device that covers the upper and lower molds on the platen trolley located at the mold extrusion position with a jacket.

Description

Technical Field

[0001] The present disclosure relates to a molding system and a molding method.

Background Art

[0002] Patent Document 1 discloses casting equipment. The casting equipment includes a pouring line and a cooling line arranged in parallel with the pouring line. In the pouring line and the cooling line, a surface plate carriage is pitch-fed. The mold is molded by a mold stripping molding machine. The mold is placed on the surface plate carriage located at the loading position among the surface plate carriages that convey the pouring line. The surface plate carriage with the mold placed thereon is pitch-conveyed and reaches a transfer device arranged downstream of the loading position. The transfer device is arranged across the pouring line and the cooling line. The transfer device peels the jacket and the weight from the mold in the cooling line and transfers the peeled jacket and weight to the mold in the pouring line.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The casting equipment described in Patent Document 1 may not be introduced into a factory with limited space. For example, when the pouring line and the cooling line cannot be arranged in parallel, it becomes difficult to arrange the transfer device for the jacket and the weight. The present disclosure provides a technique for improving the degree of freedom in layout in casting equipment related to mold stripping molding.

Means for Solving the Problems

[0005] A molding system relating to one aspect of this disclosure comprises a mold-making machine that molds upper and lower molds and pushes the upper and lower molds onto a platen trolley located at the mold extrusion position among a plurality of transported platen trolleys, and a jacket covering device that covers the upper and lower molds on the platen trolley located at the mold extrusion position with a jacket.

[0006] A molding method relating to another aspect of this disclosure comprises the steps of molding upper and lower molds, pushing the upper and lower molds onto a platen trolley located at the mold extrusion position among a plurality of transported platen trolleys, and covering the upper and lower molds on the platen trolley located at the mold extrusion position with a jacket. [Effects of the Invention]

[0007] According to this disclosure, a technology is provided that improves the degree of freedom in the layout of casting equipment related to mold making. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a schematic top view showing an example of the configuration of a casting facility equipped with a molding system according to one embodiment. [Figure 2] Figure 2 is a schematic front view showing an example of the configuration of the casting equipment shown in Figure 1. [Figure 3] Figures 3(A) to 3(D) illustrate the operation of the first jacket lifter at the mold extrusion position. [Figure 4] Figures 4(A) to 4(F) illustrate the operation of the second jacket lifter and the weight lifter in the disassembly position. [Modes for carrying out the invention]

[0009] Embodiments of this disclosure will be described in detail below with reference to the drawings. In the description of the drawings, identical elements are denoted by the same reference numerals, and redundant descriptions are omitted. The dimensional ratios in the drawings do not necessarily correspond to those in the description. The terms "top," "bottom," "left," and "right" are based on the illustrated state and are for convenience only. In the drawings, the X and Y directions are horizontal, and the Z direction is vertical.

[0010] Figure 1 is a schematic top view showing an example of the configuration of a casting facility equipped with a molding system according to one embodiment. Figure 2 is a schematic front view showing an example of the configuration of the casting facility shown in Figure 1. The casting facility 100 shown in Figures 1 and 2 is equipment for manufacturing cast products and is installed in a factory or the like. The casting facility 100 comprises a molding system 1 and a pouring machine 2. The molding system 1 includes a series of devices involved in the molding process. In the casting facility 100, the mold is molded by the molding system 1, transported to the pouring machine 2, and poured. After the poured mold cools, it is disassembled and the cast product is removed.

[0011] As shown in Figures 1 and 2, the molding system 1 includes a molding machine 10. The molding machine 10 is a mold-removing molding machine that compresses foundry sand to form a mold. The molding machine 10 is connected to the control unit 11 in a communicative manner. The molding machine 10 starts molding when it receives a molding start signal from the control unit 11. The molding machine 10 puts foundry sand into a mold in which the model (pattern) is placed and compresses the sand in the mold to solidify it. The molding machine 10 obtains a mold by removing the pattern from the solidified sand. The molding machine 10 molds an upper mold and a lower mold, respectively, and aligns the upper and lower molds to form upper and lower molds M. The molding machine 10 pushes the upper and lower molds M out with a cylinder or the like and transfers them to a conveyor line. The molding machine 10 transmits a signal to the control unit 11 indicating that the upper and lower molds M have been transferred.

[0012] The transport line is equipment for transporting the upper and lower molds M. The transport line receives the upper and lower molds M from the molding machine 10 and transports them toward the pouring machine 2 downstream in the transport direction. The transport line has, for example, a rail and a plurality of surface plate trolleys B that run on the rail. The transport line transports the upper and lower molds M by placing them on each of the plurality of surface plate trolleys B. The upper and lower molds M are pushed out to the surface plate trolley located at the mold extrusion position among the plurality of surface plate trolleys B. The mold extrusion position is the position where the molding machine 10 hands over the upper and lower molds M to the transport line, and is, for example, a position P0 opposite the molding machine 10.

[0013] The molding system 1 includes a first jacket lifter 12 (an example of a jacket covering device). The first jacket lifter 12 covers the upper and lower molds M with jackets J. Jackets J are frames with an inner surface. The inner surface of jackets J has the same inclination as the sides of the upper and lower molds M and adheres closely to the sides of the upper and lower molds M. This suppresses misalignment between the upper and lower molds due to impacts during transport of the upper and lower molds M. It also suppresses collapse or lifting of the upper mold during pouring.

[0014] The first jacket lifter 12 is a device for moving the jacket J up and down. The first jacket lifter 12 includes, for example, a lifting mechanism and a plurality of arms. The lifting mechanism is a drive mechanism such as a cylinder or an electric motor, which moves the plurality of arms up and down. The plurality of arms are equipped with a clamping mechanism for holding the jacket J. The first jacket lifter 12 places the jacket J over the upper and lower molds M on a surface plate trolley located at the mold extrusion position. The first jacket lifter 12 is positioned, for example, above position P0, and waits with the jacket J raised before the upper and lower molds M are extruded. In response to the upper and lower molds M being extruded onto the surface plate trolley, the jacket J is lowered and placed over the upper and lower molds M.

[0015] The first jacket lifter 12 may move the weight W up and down together with the jacket J. The weight W is a heavy object placed on the upper and lower molds. By using the weight W, the lifting of the upper mold during pouring is suppressed. The first jacket lifter 12 can place the jacket J over the upper and lower molds M and the weight W on the upper and lower molds M by moving the jacket J up and down with the weight W and jacket J stacked on top of each other. Depending on the required quality of the cast product, the weight W may not be used. Details of the operation of the first jacket lifter 12 will be described later. Hereinafter, the base plate trolley in the state before pouring, with the upper and lower molds M placed on it and the jacket J and weight W positioned on the upper and lower molds M, will be referred to as the base plate trolley in state T1.

[0016] Multiple platen carts B are arranged at equal intervals on a rail, for example. The multiple platen carts B are transported in predetermined frame portions by intermittent drive. The predetermined frame portion may be one or multiple frames. Each platen cart is transported in the X direction by a first transport device 13 (an example of a transport device) and a second transport device 14 (an example of a transport device). The first transport device 13 is a pusher device provided at one end of the rail, and the second transport device 14 is a cushion device provided at the other end of the rail. The transport line is connected to the control unit 11 in a communicative manner. In response to receiving a frame feed signal from the control unit 11, the transport line transports the multiple platen carts B in predetermined frame portions. When the transport of the predetermined frame portion is completed, the transport line transmits a frame feed completion signal to the control unit 11.

[0017] The platen cart in state T1 arrives at the pouring zone where the pouring machine 2 is located, via the transport line. The pouring machine 2 is a device that pours molten metal into the upper and lower molds M, and is equipped with, for example, nozzles for injecting molten metal into the upper and lower molds M. The pouring machine 2 is communicatively connected to the control unit 11. In response to receiving a pouring signal from the control unit 11, the pouring machine 2 pours molten metal into the upper and lower molds M related to the platen cart in state T1. Hereinafter, the platen cart in the state where the upper and lower molds M have been placed after pouring, and the jacket J and weights W have been positioned in the upper and lower molds M, will be referred to as the platen cart in state T2.

[0018] The platen cart in state T2 is moved to the cooling lane for cooling of the molten metal. The cooling lane is located below the casting lane where the molding, pouring, and dismantling processes are carried out. The casting lane and the cooling lane may be arranged side by side, not just vertically, but also in the XY plane. The platen cart in state T2 is moved to the lower (first floor) cooling lane by the first lifter 15 (an example of a conveying device). In the cooling lane, each platen cart in state T2 is conveyed in the Y direction by the third conveying device 16 (an example of a conveying device) and the fourth conveying device 17 (an example of a conveying device). The third conveying device 16 is a pusher device provided at one end of the rail, and the fourth conveying device 17 is a cushioning device provided at the other end of the rail. The platen cart in state T2 is moved to the upper (second floor) casting lane by the second lifter 18 (an example of a conveying device). As a result, the platen trolley in state T2 moves upstream of the molding machine 10 in the casting lane.

[0019] The platen cart in state T2 arrives at the mold-unmolding zone where the mold-unmolding device 24 is located, via the transport line. The mold-unmolding device 24 is a device that removes the cast products from the upper and lower molds M. The mold-unmolding device 24 is communicatively connected to the control unit 11. The mold-unmolding device 24 starts unmolding in response to receiving a mold-unmolding start signal from the control unit 11. When the platen cart in state T2 arrives at position P39, the weight W on the platen cart is lifted by the weight lifter 19. The weight lifter 19 is a device that moves the weight W up and down. The weight lifter 19 comprises, for example, a lifting mechanism and multiple arms. The lifting mechanism is a drive mechanism such as a cylinder or an electric motor, which moves the multiple arms up and down. The multiple arms are equipped with a clamping mechanism for holding the weight W. Details of the operation of the weight lifter 19 will be described later.

[0020] The weight W lifted by the weight lifter 19 is cleaned by the weight cleaning device 20. The weight cleaning device 20 is a device for cleaning the upper or lower surface of the weight W and includes, for example, a scraper and / or a brush. The scraper has a blade for removing sand and foreign matter adhering to the upper or lower surface of the weight W, and the brush has bristles for removing fine sand. The weight cleaning device 20 may include an air blow.

[0021] Subsequently, the surface plate carriage moves in the Y direction by a conveying device 21 such as a traverser. As a result, the upper and lower molds M from which the weight W has been removed are conveyed to the position where the second jacket lifter 22 is arranged. The second jacket lifter 22 removes the jacket J from the upper and lower molds M on the surface plate carriage. The second jacket lifter 22 includes, for example, a lifting mechanism and a plurality of arms. The lifting mechanism is a driving mechanism such as a cylinder or an electric motor, and operates the plurality of arms up and down. The plurality of arms include a clamping mechanism for holding the jacket J. Details of the operation of the second jacket lifter 22 will be described later.

[0022] The jacket J lifted by the second jacket lifter 22 is cleaned by the jacket cleaning device 23. The jacket cleaning device 23 is a device for cleaning the inner or outer surface of the jacket J and includes, for example, a scraper and / or a brush. The jacket cleaning device 23 may include an air blow.

[0023] The upper and lower molds M, from which the jackets J and weights W have been removed, are transferred from the base plate trolley to the mold dismantling device 24. The jackets J and weights W are returned to the now-empty base plate trolley. Hereinafter, the base plate trolley in the state with the jackets J and weights W in place will be referred to as the base plate trolley in state T3. When the base plate trolley in state T3 reaches position P0, which is the mold extrusion position, the jackets J and weights W are lifted by the first jacket lifter 12. This makes the base plate trolley ready to place the upper and lower molds M on. Due to the above configuration and operation, the pair of base plate trolley, jackets J and weights W remains unchanged and identical. The unchanging pair of base plate trolley, jackets J and weights W makes it easier to track the manufacturing history, improving quality control and traceability. In addition, by streamlining maintenance and stabilizing the production process, manufacturing costs can be reduced and product quality can be stabilized.

[0024] The control unit 11 is a device that oversees the casting process of the casting equipment 100. The control unit 11 is configured, for example, as a PLC (Programmable Logic Controller). The control unit 11 may also be configured as a computer system including a processor such as a CPU (Central Processing Unit), memory such as RAM (Random Access Memory) and ROM (Read Only Memory), input / output devices such as a touch panel, mouse, keyboard, and display, and communication devices such as a network card.

[0025] The control unit 11 associates information related to the molding process with the upper and lower molds M (e.g., mold identifiers) as shift data. The shift data is associated with position information within the mold row and is shifted each time the mold moves (is transported). Shifting means changing the association with the position information within the mold row. For example, when the upper and lower molds M1 are manufactured and extruded, the upper and lower molds M1 and position P0 are associated and stored. Subsequently, when the upper and lower molds M2 are manufactured and extruded, the upper and lower molds M2 and position P0 are associated and stored, and the position of the upper and lower molds M1 is shifted and stored in association with position P1. In this way, the control unit 11 can manage the upper and lower molds M and their positions in relation to the data.

[0026] The control unit 11 may manage pairs of platen carts, jackets J, and weights W using shift data. For example, each platen cart may have an RFID (Radio Frequency Identification) tag attached, and the control unit 11 stores the pair information read from the RFID tag by a reader in its storage device, associating it with the shift data. The RFID tag may be attached to either the jacket J or the weights W. The RFID tag may also be a two-dimensional code. Alternatively, the control unit 11 may write the pair information read from the RFID tag by a reader to the RFID tag, associating it with the shift data. Alternatively, the control unit 11 may virtually assign numbers to the platen carts in advance, and each time a frame is transported, it may determine the number of the platen cart that received the upper and lower molds M in the data, and associate the determined number with the shift data. The control unit 11 may associate only one platen cart with the shift data and identify other platen carts based on the number of frames transported.

[0027] Figures 3(A) to 3(D) illustrate the operation of the first jacket lifter at the mold extrusion position. As shown in Figure 3(A), the base plate trolley B1 in state T3 is transported below the first jacket lifter 12, that is, to position P0, which is the mold extrusion position. The jacket J1 and weight W1 are placed on the base plate trolley B1. Subsequently, as shown in Figure 3(B), the jacket J1 and weight W1 are lifted from the base plate trolley B1 by the first jacket lifter 12. As a result, the base plate trolley B1 becomes empty. Subsequently, as shown in Figure 3(C), the upper and lower molds M1 are extruded onto the base plate trolley B1 by the molding machine 10. Subsequently, as shown in Figure 3(D), the jacket J1 is placed over the upper and lower molds M1 on the base plate trolley B1 and the weight W1 is placed on top. In this way, since the jacket J is placed over the upper and lower molds M1 and the weight W1 is placed on them before the surface plate trolley B1 starts moving, displacement of the upper and lower molds due to the impact of transport can be avoided.

[0028] Figures 4(A) to 4(F) illustrate the operation of the second jacket lifter and the weight lifter in the disassembly position. The disassembly position includes both the position below the second jacket lifter 22 and the position P39 below the weight lifter 19 (see Figure 2). As shown in Figure 4(A), the platen trolley B1 in state T2 is transported to the position P39 below the weight lifter 19. The upper and lower molds M1, the jacket J1, and the weight W1 are placed on the platen trolley B1. Subsequently, as shown in Figure 4(B), the weight W1 is lifted from the upper and lower molds M1 by the weight lifter 19. Then, the upper and / or lower surfaces of the weight W1 are cleaned by the weight cleaning device 20. Subsequently, as shown in Figure 4(C), the platen trolley B1 is transported in the Y direction and positioned below the second jacket lifter 22. Next, the jacket J1 is removed from the upper and lower molds M1 by the second jacket lifter 22. Then, the inner and / or outer surfaces of the jacket J1 are cleaned by the jacket cleaning device 23. Subsequently, as shown in Figure 4(D), the upper and lower molds M1 are transferred from the base plate trolley B1 to the mold removal device 24. This leaves the base plate trolley B1 empty. Next, as shown in Figure 4(E), the jacket J1 is placed on the base plate trolley B1. Subsequently, as shown in Figure 4(F), the weight W1 is placed on top of the jacket J1. In this way, the quality of the cast product can be improved by cleaning the jacket J1 and the weight W1 upstream of the molding machine 10.

[0029] [Summary of Embodiments] In molding system 1, the jacket J is placed over the upper and lower molds M on a platen trolley located at position P0, which is the mold extrusion position. Therefore, there is no need to place a device to place the jacket J across the lane. Thus, molding system 1 can improve the layout flexibility of the casting equipment 100 related to mold casting. Furthermore, the movement of the platen trolley begins after the jacket J is placed over the molds. Thus, molding system 1 can avoid displacement of the upper and lower molds due to the impact of transport. Moreover, if a device to place the jacket J over the molds is placed across the lane, it is necessary to align not only the molding machine 10 and the transport line, but also the device that places the jacket J over the molds and the transport line. In contrast, since molding system 1 places the jacket J over the molds at the extrusion position of the molding machine 10, it is only necessary to align the molding machine 10 and the transport line, and the number of aligning steps is sufficient. Thus, molding system 1 can improve the efficiency of manufacturing cast products.

[0030] [Differentiation] Although various exemplary embodiments have been described above, the invention is not limited to the exemplary embodiments described above, and various omissions, substitutions, and modifications may be made. For example, the first jacket lifter 12 does not need to be integrated with the molding machine 10. In other words, the first jacket lifter 12 may have a dedicated frame and be supported by a dedicated frame.

[0031] [Summary of the embodiments of this disclosure] This disclosure includes the following aspects:

[0032] (Clause 1) The molding system includes a mold-making machine that molds upper and lower molds and pushes the upper and lower molds onto a mold-extrusion position among multiple transportable mold-making machines, A jacket covering device that covers the upper and lower molds on a surface plate trolley located at the mold extrusion position, It is equipped with.

[0033] In this molding system, jackets are placed over the upper and lower molds on a platen trolley located at the mold extrusion position. Therefore, there is no need to place a device to place the jackets J across the lane. Thus, the molding system can improve the layout flexibility of casting equipment related to mold punching. Furthermore, the movement of the platen trolley begins after the jackets are placed over the molds. Therefore, displacement of the upper and lower molds due to the impact of transport can be avoided.

[0034] (Article 2) In the molding system described in Clause 1, the jacket covering device may cover the upper and lower molds with jackets and also place weights on the upper and lower molds. In this case, the jackets and weights can be applied to the upper and lower molds simultaneously.

[0035] (Article 3) The molding system described in Clause 1 or 2 may further include a weight cleaning device positioned upstream of the mold-removing molding machine in the transport direction of a plurality of platen trolleys for cleaning the weights. In this case, the molding system can apply the cleaned weights to the upper and lower molds immediately after molding.

[0036] (Article 4) The molding system described in any one of clauses 1 to 3 may further include a jacket cleaning device positioned upstream of the mold-making machine in the transport direction of multiple platen trolleys, for cleaning the inner surface of the jacket. In this case, the molding system can apply the cleaned jacket to the upper and lower molds immediately after molding.

[0037] (Article 5) The molding system described in any one of clauses 1 to 4 further comprises a transport device for transporting a plurality of base plate trolleys, and a control unit connected to the transport device and a mold-removing molding machine, wherein the control unit generates shift data relating the transport position to information about the mold, and may associate data for at least one of the base plate trolleys, jackets, and weights with the shift data. In this case, since at least one of the base plate trolleys, jackets, and weights can be easily identified, the molding system 1 can quickly provide information that is effective for defect countermeasures.

[0038] (Article 6) A molding method relating to another aspect of this disclosure comprises the steps of molding upper and lower molds, pushing the upper and lower molds onto a platen trolley located at the mold extrusion position among a plurality of transported platen trolleys, and covering the upper and lower molds on the platen trolley located at the mold extrusion position with a jacket. This molding method achieves the same effects as the molding system described above. [Explanation of Symbols]

[0039] 1... Molding system, 11... Control unit, 20... Weight cleaning device, 23... Jacket cleaning device (an example of a jacket covering device), 13... First conveying device (an example of a conveying device), 14... Second conveying device, 15... First lifter, 16... Third conveying device, 17... Fourth conveying device, 18... Second lifter, B... Multiple surface plate trolleys, B1... Surface plate trolley, J, J1... Jacket, M, M1, M2... Upper and lower molds, W, W1... Weights.

Claims

1. A mold-making machine that forms upper and lower molds and pushes the upper and lower molds onto a mold-extrusion position among multiple conveying mold-making machine trolleys, A jacket covering device for covering the upper and lower molds on the base plate trolley located at the mold extrusion position, A molding system equipped with the following features.

2. The molding system according to claim 1, wherein the jacket covering device covers the upper and lower molds with the jacket and places weights on the upper and lower molds.

3. The molding system according to claim 2, further comprising a weight cleaning device positioned upstream of the mold-making machine in the transport direction of the plurality of surface plate trolleys for cleaning the weights.

4. The molding system according to any one of claims 1 to 3, further comprising a jacket cleaning device positioned upstream of the mold-making machine in the transport direction of the plurality of surface plate trolleys for cleaning the inner surface of the jacket.

5. A conveying device for transporting the aforementioned multiple surface plate trolleys, The conveying device and the control unit connected to the mold-making machine, Furthermore, The molding system according to claim 2 or 3, wherein the control unit generates shift data relating the transport position and information relating to the mold, and associates data of at least one of the base plate trolley, the jacket, and the weight with the shift data.

6. The process involves creating upper and lower molds and then pushing the upper and lower molds onto a surface plate trolley located at the mold extrusion position among a plurality of surface plate trolleys being transported, A step of covering the upper and lower molds on the base plate trolley located at the mold extrusion position with jackets, A molding method comprising the following features.

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