Molding System

Abstract

The present invention relates to a molding system (1) for a low-pressure light alloy casting plant. The molding system (1) comprises a mold (S) including a lower half mold (S1) and an upper half mold (S2), and has a height extending along a main axis (XX). The molding system (1) comprises: (1) a first lower fixed plate (11) on which the lower half mold (S1) is accommodated; (2) a movable plate (12) on which the upper half mold (S2) is accommodated; (3) a second upper fixed plate (13) arranged above the movable plate (12); (4) a moving group (2) comprising an electric drive motor (20) and a transmission member (21) suitable for moving the movable plate (12) along the main axis (XX); (5) a casting ejection group (3) comprising an electric ejection motor (30) and an ejection member (31); and (6) a command unit suitable for controlling the operation of the electric drive motor (20) and the electric ejection motor (30).

Description

[Technical Field]

[0001] The present invention relates to a specific forming system for forming light alloy castings obtained by low-pressure casting, and in particular to a low-pressure light alloy casting plant equipped with said forming system. [Background technology]

[0002] In this specification, the term "casting" refers to a product obtained by molding. In other words, a "casting" is a product obtained after injecting molten metal into a mold and allowing it to solidify. Usually, a "casting" also includes a series of parts necessary for an optimal success of the casting operation, such as sprues, cast runners, wells, vacuum branches, foundry burrs, and / or others, which will be omitted in the following description. These operations are carried out in special machines or special plants that are not covered in this specification. Summary of the Invention [Problem to be solved by the invention]

[0003] In this specification, "light alloy" means an alloy of a metal such as aluminum, magnesium, or zinc.

[0004] Furthermore, in this specification, low pressure light alloy casting refers to a production mode in which a light alloy in the molten state is injected into a mold at a nominal pressure of about 1 to 2 bar, preferably close to 1 bar.

[0005] Thus, according to the above, the characteristics of the casting plant and forming system according to the invention are a function of the characteristics of the light alloy, such as temperature, viscosity, cooling time and its injection force.

[0006] The "castings" obtained by said foundry plants are therefore typically parts with structural and mechanical features applied in the automotive industry.

[0007] In the prior art, several molding system solutions are known, sometimes known as "presses". In known solutions, there is typically a mold consisting of two or more parts, known as half-moulds or shells. These parts, half-moulds or shells, are arranged in a working position and in an open position. In the working position, the mold is closed; that is, first molten metal is poured inside, then it is left to solidify, and a "casting" is obtained. In the open position, the mold parts open, allowing the "casting" to be removed. A new cycle can then be carried out.

[0008] In the prior art, numerous embodiments of molding systems are known, in which the control and movement of the molds is carried out by means of specific hydraulic drives.

[0009] On the other hand, hydraulic drives present a series of problems. It should be emphasized that hydraulic drives have uncontrollable movements. In fact, in hydraulic plants, the elements can only be placed in two positions: one with hydraulic action and one without hydraulic action.

[0010] Therefore, there is a strong need to avoid this problem, i.e., to have a molding system that allows complete control over the position of the various components.

[0011] SUMMARY OF THE INVENTION It is an object of the present invention to provide a forming system capable of meeting the aforementioned requirements in the particular context of low pressure light alloy casting forming operations. [Means for solving the problem]

[0012] This object is achieved by a forming system according to claim 1. Furthermore, this object is achieved by a low-pressure light alloy casting plant comprising said forming system according to claim 16. The dependent claims describe variants of the preferred embodiment which contain further advantageous aspects.

[0013] The present invention will now be described in detail with reference to the accompanying drawings. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a perspective view of a molding system according to the present invention in an open configuration in accordance with a preferred embodiment; [Figure 2a] FIG. 2 is a side view of the molding system of FIG. 1. [Figure 2b] FIG. 2 is a front view of the molding system of FIG. 1. [Figure 2c] FIG. 2 is a top view of the molding system of FIG. 1. [Figure 3] 2b is a cross-sectional view of the molding system at section AA of FIG. 2a. [Figure 4] 1 is a perspective view of a molding system according to a preferred embodiment of the present invention in a working or closed configuration; [Figure 5a] FIG. 5 is a side view of the molding system of FIG. 4. [Figure 5b] FIG. 5 is a front view of the molding system of FIG. [Figure 5c] FIG. 5 is a top view of the molding system of FIG. 4. [Figure 6] 5b is a cross-sectional view of the molding system at section AA in FIG. 5a. DETAILED DESCRIPTION OF THE INVENTION

[0015] In the above figures, the reference numeral 1 indicates as a whole a molding system 1 which is the subject of the present invention.

[0016] The molding system 1 is specifically designed to be part of a low-pressure light alloy casting plant, which itself is also the subject of the present invention. The low-pressure casting plant also comprises a light alloy casting injection system that is fluidly connectable to the molding system 1.

[0017] In particular, the molding system 1 extends in height along a main axis XX and comprises a base region R at its bottom, in which a light alloy casting injection system can be at least partially accommodated.

[0018] Furthermore, the molding system 1 includes a mold S and moves the mold S, as will be explained in detail below.

[0019] Specifically, the mold S comprises a lower mold half S1 and an upper mold half S2, which are mutually positionable between a working position and a closed position, in which the lower mold half S1 and the upper mold half S2 engage with each other and are positionable in a plurality of open positions axially spaced apart from one another along the main axis XX.

[0020] Preferably, one half mold is fixed and the other half mold is translationally movable.

[0021] Preferably, as will be explained in more detail below, the movable mold half is positionable in multiple axial positions.

[0022] Furthermore, according to a preferred embodiment, the lower half mold S1 comprises a plurality of slider elements S11, S12, S13, S14, which are positionable in a closed half mold position and in at least one open half mold position. Preferably, the slider elements S11, S12, S13, S14 are movable radially relative to the main axis XX such that they move in translation between a closed half mold position in which they are close to the main axis XX and an open half mold position in which they are remote from the main axis XX.

[0023] According to a preferred embodiment, as will be seen from the following description, the forming system 1 has preferred application in the production of castings of substantially axisymmetric shape, such as, for example, alloy wheels for vehicles.

[0024] According to the present invention, the forming system 1 comprises a first fixed plate 11 , a movable plate 12 and a second fixed plate 13 .

[0025] Preferably, the forming system 1 comprises a body structure 10 comprising said plates 11, 12, 13.

[0026] According to a preferred embodiment, the first fixing plate 11 and the second fixing plate 13 are joined to each other by a plurality of support beams 15 included in the main body structure 10. Preferably, the plurality of support beams 15 are arranged at equal angular intervals from each other, and preferably, there are four support beams 15.

[0027] According to the invention, the first fixed plate 11 is a lower plate adjacent to the base surface, said first fixed plate 11 defining a base region R with the base surface.

[0028] The lower half mold S1 is housed on a first fixed plate 11.

[0029] Furthermore, the first fixed plate 11 and the lower mold half S1 are fluidly connectable to a casting injection system. Preferably, there are indeed fluid passages 110 on the first fixed plate 11 through which the molten metal flows to reach the mold S. According to a preferred embodiment, said fluid passages 110 are made of a material with a high melting point, and for example comprise injectors made of a ceramic material.

[0030] Meanwhile, the upper half mold S2 is housed on the movable plate 12. The axial position of the movable plate 12 corresponds to the axial position of the upper half mold S2.

[0031] Finally, the second fixed plate 13 is placed on top. The second fixed plate 13 is located above the movable plate 12.

[0032] In other words, the movable plate 12 is housed between two fixed plates and a number of support beams 15 that join the two fixed plates together.

[0033] According to the invention, the forming system 1 comprises a moving group 2 suitable for moving the movable plate 12 along the main axis XX between a working position in which the mold S is closed and a number of raised positions in which the upper mold half S2 is separated from the lower mold half S1.

[0034] The moving group 2 comprises an electric drive motor 20 housed in the second fixed plate 13 and a transmission member 21. The transmission member 21 is operatively connected to the electric drive motor 20 and the movable plate 12 and is suitable for converting the rotational movement of the electric drive motor 20 into a translational movement.

[0035] According to a preferred embodiment, the electric drive motor 20 is of the brushless type.

[0036] Furthermore, according to a preferred embodiment, the transmission member 21 comprises a worm screw element 210 including a thrust end 211 that engages the movable plate 12 .

[0037] Preferably, an electric drive motor 20 engages and rotates the worm screw element 210 to translate the movable plate 12 along the main axis XX.

[0038] According to a preferred embodiment, the transmission member 21 further comprises a connecting element 220, preferably a belt or a chain, suitable for connecting the electric drive motor 20 to the worm screw element 210.

[0039] According to a preferred embodiment, the worm screw element 210 is arranged on the main axis XX.

[0040] Preferably, worm screw element 210 intersects second fixed plate 13 to allow translational movement of moving plate 12 and engagement of moving plate 12 with electric drive motor 20 .

[0041] According to a preferred embodiment, the moving group 2 also comprises a support structure 25 which engages the moving plate 12 and traverses the second fixed plate 13. Preferably, the support structure 25 serves to support the moving plate 12 and maintain it in place.

[0042] According to a preferred embodiment, the support structure 25 includes a plurality of guide elements 251, which extend parallel to the main axis XX and through the second fixed plate 13. Preferably, the support structure 25 also comprises a base frame 255 for supporting the guide elements 251. In other words, the guide elements 251 extend between the movable plate 12 and the base frame 255. Preferably, the support structure 25 translates together with the movable plate 12.

[0043] According to the invention, the molding system 1 also comprises a casting ejection group 3 housed on a movable plate 12. The casting ejection group 3 functions to perform operations on the casting by virtue of its removal from the upper mold half S2.

[0044] The casting ejection group 3 comprises an electric ejection motor 30 and an ejection member 31, which is operatively connected to the electric ejection motor 30, the movable plate 12 and the upper mold half S2 and can be moved by the electric ejection motor 30 to an ejection position where the casting is removed from the upper mold half S2.

[0045] Preferably, the electric ejection motor 30 is of the brushless type.

[0046] Preferably, the ejection member 31 comprises one or more mechanical jacks 310 controlled by the operation of an electric ejection motor 30. The movement of the mechanical jacks 310 is accompanied by the axial movement of a particular thrust pin 311, which is adapted to protrude and engage in an ejecting manner with the casting, thereby enabling it to be removed from the upper mold half S2.

[0047] Preferably, the ejection member 31 comprises two mechanical jacks 310 .

[0048] According to a preferred embodiment, the moulding system 1 comprises a lower half mould opening and closing group 4, which comprises a respective electric slider motor 40 for each slider element S11, S12, S13, S14.

[0049] Preferably, operation of each electric slider motor 40 accompanies opening and closing of the lower half mold S1. Specifically, the lower half mold opening and closing group 4 includes a respective command jack 41 for each slider element S11, S12, S13, S14. Each command jack 41 is operatively connected to a respective slider element and a respective electric slider motor 40.

[0050] According to a preferred embodiment, the moulding system 1 also comprises a casting collection group 5. The casting collection group 5 is a part group that can retrieve the castings 5 ​​that have been removed from the upper mould half S2 by the action of the casting ejection group 3.

[0051] Preferably, the casting collection group 5 comprises a collection plate 51 suitable for translation along a collection axis YY transverse to the main axis XX.

[0052] The casting recovery group 5 further comprises an electric recovery motor 50 operably connected to the recovery plate 51, which moves the recovery plate 51 to an advanced position or a retracted position, in which the recovery plate 51 is positioned on the main axis XX in the advanced position and the recovery plate 51 is away from the main axis XX in the retracted position.

[0053] Preferably, the electrical collection motor 50 is a brushless motor.

[0054] According to a preferred embodiment, the electric collection motor 50 has the purpose of commanding and controlling the drive in the drive state, so that the translation of the collection plate 51 into the advanced position corresponds to the raised position of the movable plate 12 and the upper mold half S1.

[0055] According to a preferred embodiment, the operation of the casting ejection group 3, and the subsequent removal of the casting from the upper mold half S2, is carried out only when the collection plate 51 is in the advanced position.

[0056] According to the present invention, the molding system 1 comprises a command unit operably connected to the moving group 2 and the casting ejection group 3, the command unit being suitable for commanding the operation of the electric drive motor 20 and the electric ejection motor 30.

[0057] According to a preferred embodiment, the command unit is also operatively connected to the bottom mold half opening and closing group 4 .

[0058] According to a preferred embodiment, the command unit is also operatively connected to the casting collection group 5.

[0059] According to the invention, a command unit is operatively connected to each electric motor included in each operatively connected group, preferably the command unit being suitable for controlling the driving of a plurality of said electric motors.

[0060] According to a preferred embodiment, the command unit controls the driving of the electric drive motor 20 and simultaneously the driving of the electric discharge motor 30. In other words, the command unit controls the ejection of the castings during the lifting of the top plate. Preferably, said command is executed after placing the collecting plate 51 in the forward position.

[0061] According to a preferred embodiment, the command unit is suitable to control the initiation of the lifting movement of the mobile plate 12 from the working position as soon as it commands the slider elements S11, S12, S13, S14 to open.

[0062] According to the present invention, some movements are commanded to move at a speed determined by the command unit, and other movements are commanded to move at a different speed.

[0063] According to a preferred embodiment, the operating mode of the command unit is configurable according to requirements. For example, preferably, the stroke of the moving parts included in the molding system 1 is a function of the size and type of the mold S and the casting. Similarly, the command unit executes the control operation of the electric motors and executes the movements depending on the size and type of the mold S and the casting.

[0064] According to a preferred embodiment, the command unit is suitable for controlling the switching off of the corresponding electric motors when a specific position is reached. According to a preferred embodiment, electric motors that are controlled to be switched off maintain their torque and therefore maintain their position. For example, the command unit is suitable for controlling the switching off of the electric slider motor 40 when the slider element is located in the closed lower half mold position. For example, the command unit is suitable for controlling the switching off of the electric drive motor 20 when the movable plate 12 is located in the working position.

[0065] According to a preferred embodiment, the moulding system 1 further comprises a heat shield, which is suitable for protecting the electric motor from the heat generated by the light alloy casting injection system.

[0066] Preferably, the heat shield includes a primary shield disposed on a first fixed plate 11 , a movable plate 12 , and a second fixed plate 13 .

[0067] Preferably, the heat shield includes a secondary shield disposed around the electric motor.

[0068] According to the above, it should be noted that when referring to an electric motor, this refers to a component including a drive part, e.g., a stator-rotor, and a command part, e.g., a command board. Preferably, a command unit is operably connected to each command board.

[0069] Innovatively, the molding system of the present invention is perfectly suited to fulfill its intended purpose.

[0070] Advantageously, the forming system that is the subject of the present invention has electrically operated components and does not require hydraulic devices.

[0071] Advantageously, the presence of hydraulic supply pipes or conduits, valve groups for hydraulic management, filter groups for cleaning the hydraulic oil, oil tanks, etc. is avoided. Thus, advantageously, the forming system is greatly simplified.

[0072] Advantageously, the molding system that is the subject of the present invention is adjustable as needed according to the specific dimensions and shape of the mold and / or the casting obtained or to be obtained.

[0073] Advantageously, the speed of movement is a function of the torque of the current electric motor and is therefore significantly faster than known solutions.

[0074] Advantageously, the speed of movement, stroke size, and the timing at which they are performed are specifically configurable according to the needs of the mold and casting.

[0075] Advantageously, the execution time of all of the operations can be optimized and the cycle time is significantly reduced compared to prior art hydraulic forming system solutions. Advantageously, some of the described movements can be performed simultaneously with each other. Advantageously, the cycle time of downstream light alloy injection and cooling operations is optimized.

[0076] Advantageously, the molding system that is the subject of the present invention is very safe and reliable.

[0077] Advantageously, the forming system that is the subject of the present invention is very compact.

[0078] Advantageously, the molding system that is the subject of the present invention has very low consumption.

[0079] Advantageously, the molding system that is the subject of the present invention has minimal or even zero environmental impact compared to known solutions.

[0080] Advantageously, the forming system that is the subject of the present invention requires minimal maintenance, unlike known hydraulic solutions, resulting in minimal and possibly no "machine downs".

[0081] Advantageously, the molding system of the present invention allows for high production capacities to be achieved.

[0082] Those skilled in the art may make some modifications to the embodiments of the molding system or replace elements with other functionally equivalent ones to meet their specific needs, and such modifications will fall within the scope of protection defined by the claims.

[0083] Furthermore, each variation described as belonging to a possible embodiment may be implemented independently of other variations described.

Claims

1. A molding system (1) for a low-pressure light alloy casting plant equipped with a light alloy casting injection system, The molding system (1) has a base area (R) arranged at the bottom, the height of which extends along a main axis (X-X), and the light alloy casting injection system can be at least partially accommodated within the base area (R), and the molding system (1) comprises a mold (S) including a lower half mold (S1) and an upper half mold (S2), The molding system (1) comprises: (1) a first lower stationary plate (11) in which the lower half mold (S1) is accommodated, the first lower stationary plate (11) and the lower half mold (S1) being fluidly connectable to the casting injection system; (2) a movable plate (12) on which the upper half mold (S2) is housed; (3) a second upper fixed plate (13) disposed above the movable plate (12); (4) a moving group (2) suitable for moving the movable plate (12) along the main axis (X-X) between a working position and a plurality of raised positions, in which the mold (S) is closed and in which the upper mold half (S2) is separated from the lower mold half (S1), an electric drive motor (20) housed in said second upper fixed plate (13); a transmission member (21) operatively connected to the electric drive motor (20) and the movable plate (12), and adapted to convert the rotational motion of the electric drive motor (20) into a translational motion; said moving group (2) including: (5) A casting ejection group (3) housed in a movable plate (12), an electric ejection motor (30); an ejection member (31) operatively connected to the electric ejection motor (30), the movable plate (12) and the upper half mold (S2), the ejection member (31) being movable by the electric ejection motor (30) to an ejection position where a casting is removed from the upper half mold (S2); a casting discharge group (3) including: (6) a command unit operatively connected to the moving group (2) and the casting ejection group (3), suitable for commanding the operation of the electric drive motor (20) and the electric ejection motor (30); Equipped with Forming system (1).

2. the command unit is suitable for simultaneously commanding the operation of the electric ejection motor (30) and the operation of the electric drive motor (20); A forming system (1) according to claim 1.

3. The electric drive motor (20) is of the brushless type. A forming system (1) according to claim 1 or 2.

4. The transmission member (21) includes a worm screw element (210) having a thrust end (211) that engages with the movable plate (12); The electric drive motor (20) engages with the worm screw element (21) to rotate the worm screw element (21), thereby translating the movable plate (12) along the main axis (X-X). A forming system (1) according to any one of claims 1 to 3.

5. The transmission member (21) further comprises a connecting element (220) suitable for connecting the electric drive motor (20) to the worm screw element (210). A forming system (1) according to claim 4.

6. The casting collection group (5) further comprises: a collecting plate (51) suitable for movement along a collecting axis (Y-Y) transverse to said main axis (XX); an electric collection motor (50) operatively connected to the collecting plate (51) for moving the collecting plate (51) between an advanced position and a retracted position, in which the collecting plate (51) is positioned on the main axis (X-X) in the advanced position and the collecting plate (51) is moved away from the main axis (X-X) in the retracted position; Equipped with A forming system (1) according to any one of claims 1 to 5.

7. the command unit is operatively connected to the electric collection motor (50) to command the operation of the electric collection motor (50) and to command the translation of the collection plate (51) to the advanced position corresponding to the raised position of the movable plate (12) and the upper half mold (S1); A forming system (1) according to claim 6.

8. the command unit is suitable for commanding the operation of the casting discharge group (3) when the collecting plate (51) is in the advanced position; A forming system (1) according to claim 7.

9. the lower half mold (S1) comprises a plurality of slider elements (S11, S12, S13, S14); a plurality of said slider elements (S11, S12, S13, S14) are positionable in a closed half-mold position and an open half-mold position; said molding system (1) comprising a lower half mold opening and closing group (4) comprising a respective electric slider motor (40) for each of said slider elements (S11, S12, S13, S14); A forming system (1) according to any one of claims 1 to 8.

10. the command unit is operatively connected to each of the electric slider motors (40) to command the operation of each of the electric slider motors (40) and the opening and closing of the lower half mold (S1); A forming system (1) according to claim 9.

11. the lower half mold opening / closing group (4) comprises, for each of the slider elements (S11, S12, S13, S14), a respective command jack (41) operatively connected to the respective slider element and to a respective electric slider motor (40); A forming system (1) according to claims 9 and 10.

12. a heat shield adapted to protect the electric drive motor and the electric ejection motor from heat generated by the light alloy casting injection system; A forming system (1) according to any one of claims 1 to 11.

13. the shielding includes a primary shielding arranged on the first fixed plate (11), the movable plate (12) and the second fixed plate (13), and / or a secondary shielding arranged around the electric drive motor and the electric discharge motor; A forming system (1) according to claim 12.

14. The stroke of the moving parts included in the molding system (1) varies depending on the size and type of the mold (S) and the casting. A forming system (1) according to any one of claims 1 to 13.

15. said command unit being configurable to perform actions or command said electric drive motor (20) and said electric ejection motor (30) depending on the size and type of said mould (S) and casting; A forming system (1) according to any one of claims 1 to 14.

16. A low pressure light alloy casting plant comprising a light alloy casting-injection system and a forming system (1) according to any one of claims 1 to 15.

Images