Casting method

Abstract

To provide casting equipment capable of efficiently carrying out a pre-shipment inspection.SOLUTION: A casting method includes: a pouring step of pouring molten metal within a ladle into a casting mold; an analysis method of analyzing at least one of the composition and physical property of a test piece produced on the basis of the molten metal collected from within the ladle; and an inspection step of carrying out an appearance inspection of a casting taken out from the casting mold. In the inspection step, at least one of the composition and physical property of the test piece obtained in the analysis step is displayed on a display.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to casting methods. [Background technology]

[0002] Patent Document 1 discloses a casting facility. In this casting facility, a ladle receives molten metal in a melting furnace and is transported to a pouring machine. Furthermore, multiple molds are formed by a molding machine, and each mold is transported to the pouring machine. The pouring machine pours the molten metal from the ladle into the transported mold. After pouring, the mold is cooled over time, and the molten metal solidifies and becomes a casting before reaching a mold disassembly device. The mold disassembly device disassembles the mold and removes the casting. The casting is then shipped as a finished product after undergoing post-processing. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2017 / 085765 Summary of the Invention [Problem to be solved by the invention]

[0004] Before a casting is shipped as a product, its appearance is inspected. The inspection is performed, for example, by a worker. The worker identifies which casting is the product as it is transported to the inspection area and determines whether the appearance of the casting meets product standards. Since a casting facility typically produces multiple types of products, the burden on workers at the pre-shipment inspection area may increase. The present disclosure provides a casting method that allows for efficient pre-shipment inspection. [Means for solving the problem]

[0005] A casting method according to one aspect of the present disclosure includes a pouring step of pouring molten metal from a ladle into a mold, an analysis step of analyzing at least one of the composition and physical properties of a test piece produced based on the molten metal collected from the ladle, and an inspection step of performing an appearance inspection of the casting removed from the mold, wherein at least one of the composition and physical properties of the test piece obtained in the analysis step is displayed on a display in the inspection step.

[0006] In this casting method, in the inspection process, at least one of the composition and physical properties of the test piece obtained in the analysis process is displayed on a display. Therefore, workers in the inspection process can recognize at least one of the composition and physical properties of the casting being inspected via the display. By allowing workers to recognize at least one of the composition and physical properties of the casting, the work of identifying the product corresponding to the casting being inspected becomes easier and more accurate, and the consistency between the composition, physical properties, and appearance of the casting can be confirmed. Therefore, this casting method allows for efficient pre-shipment inspection.

[0007] In one embodiment, the casting method includes a sampling step of sampling the molten metal in a ladle used in the pouring step to produce a test piece, and the analysis step may analyze at least one of the composition and physical properties of the test piece produced in the sampling step. With this configuration, since the molten metal in the pouring step is sampled, it is possible to reduce differences between the analysis results and the composition and physical properties of the casting to be inspected.

[0008] In one embodiment, the casting method includes a cooling step of cooling the mold into which the molten metal has been poured in the pouring step, and a disassembly step of removing the casting from the mold cooled in the cooling step, and the inspection step may involve performing an external inspection of the casting removed in the disassembly step.

[0009] In one embodiment, in the inspection step, the timing of the visual inspection of the casting may be synchronized with the timing of displaying at least one of the composition and physical properties of the test piece on a display. By configuring in this manner, the casting method allows an operator to easily understand the correspondence between the casting to be inspected and the analysis results of the casting. [Effects of the Invention]

[0010] According to various aspects and embodiments of the present disclosure, pre-shipment inspection can be efficiently performed. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is a flowchart of a casting method according to an exemplary embodiment. [Figure 2] FIG. 2 is a diagram illustrating the casting equipment in each step of the manufacturing method of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, exemplary embodiments of the present disclosure will be described with reference to the drawings. In the following description, the same or equivalent elements are designated by the same reference numerals, and redundant description will not be repeated.

[0013] FIG. 1 is a flowchart of a casting method according to an exemplary embodiment. The casting method M shown in FIG. 1 is carried out in a casting facility that produces castings. As shown in FIG. 1, the casting method M includes a melting step (step S10), a melting and transporting step (step S12), a pouring step (step S14), a sampling step (step S16), an analyzing step (step S18), a cooling step (step S20), a disassembling step (step S22), a finishing step (step S24), and an inspection step (step S26). Each step will be described below with reference to FIG. 2. FIG. 2 is a diagram illustrating the casting facility in each step of the manufacturing method shown in FIG. 1.

[0014] [Dissolving step (step S10)] As shown in Figures 1 and 2, the melting process is carried out first. In the melting process, a melting furnace 10 uses heat to melt the molten material to obtain a starter molten metal. The molten metal produced in the melting furnace 10 is poured into a processing ladle. The processing ladle is transported by a receiving cart 11. The processing ladle is transported to a transfer position and emptied into a ladle suitable for pouring (pouring ladle). Transferring means transferring the molten metal to another ladle. The pouring ladle is transported by a transport cart 12. The operations of the melting furnace 10, receiving cart 11, and transport cart 12 are controlled by a molten metal transport PLC (Programmable Logic Controller) 21.

[0015] A ladle serial number is assigned to the processing ladle before it is tapped, for example, when materials for adjusting the composition of the molten metal are added. The molten metal transport PLC 21 associates information about the tapped molten metal (molten metal information) with the ladle serial number when the molten metal is tapped from the melting furnace 10 to the processing ladle. Address information that identifies the location is assigned in advance to locations to which the ladle can be moved. The molten metal transport PLC 21 maintains a relationship between the ladle serial number and the address information. For example, if a ladle assigned the ladle serial number "1" is located at a location indicated by address information "2," the molten metal transport PLC 21 associates the ladle serial number "1" with the address information "2." The molten metal transport PLC 21 updates the relationship each time the ladle is moved. For example, when a ladle assigned ladle serial number "1" moves from the position indicated by address information "2" to the position indicated by address information "3," the molten metal transport PLC 21 associates ladle serial number "1" with address information "3." In this way, by shifting the ladle serial number in the data in accordance with the ladle's movement, the molten metal transport PLC 21 can identify a ladle located at any location and refer to the molten metal information associated with the ladle serial number of that ladle. Note that when the molten metal in the processing ladle is transferred to the pouring ladle, the molten metal transport PLC 21 passes the ladle serial number of the processing ladle to the pouring ladle and shifts the ladle serial number in accordance with the movement of the pouring ladle.

[0016] The molten metal transport PLC 21 transmits the ladle serial number and the molten metal information corresponding to the ladle serial number to the control device 100. The control device 100 is a PLC or computer that controls the casting equipment, and physically is configured as a typical computer system including a CPU (Central Processing Unit), main storage devices such as RAM (Random Access Memory) and ROM (Read Only Memory), input devices such as a touch panel and keyboard, output devices such as a display, and auxiliary storage devices such as a hard disk.

[0017] [Molten metal transport process (step S12)] Once the melting process is complete, the molten metal transport process is carried out. In this process, the transport vehicle 12 transports the pouring ladle. The pouring ladle is transported by the transport vehicle 12. In addition to the emptying position described above, the transport vehicle 12 can also stop at a ladle exchange position where the pouring ladle is transported to the pouring machine 14. The operation of the transport vehicle 12 is controlled by the molten metal transport PLC 21 described above.

[0018] The pouring ladle (working ladle) filled with molten metal is transferred from the transport vehicle 12 to the ladle changer 13 at the ladle change position. The ladle changer 13 exchanges the working ladle with the empty pouring ladle (empty ladle). The operation of the ladle changer 13 is controlled by the pouring PLC 22.

[0019] [Pouring process (step S14)] Once the molten metal transport process is completed, the pouring process is carried out. In the pouring process, the pouring machine 14 pours the molten metal from the pouring ladle into the molds. In the pouring process, molten metal is poured from one pouring ladle into multiple molds. Multiple molds made by a molding machine (not shown) are lined up in a row and transported one mold at a time to the pouring machine 14. The pouring machine 14 pours the molten metal from the pouring ladle into the molds being transported. The operation of the pouring machine 14 is controlled by the pouring PLC 22.

[0020] The pouring PLC 22 can acquire the ladle serial number and the molten metal information corresponding to the ladle serial number via the management device 100. Therefore, the pouring PLC 22 can acquire the molten metal information of the molten metal to be poured based on the ladle serial number assigned to the pouring ladle used during pouring. A mold serial number is assigned to the mold before pouring, for example, during production using a molding machine. The pouring PLC 22 associates the molten metal information with the mold serial number at the time of pouring. Address information identifying the location is assigned in advance to locations to which the mold can be moved. The pouring PLC 22 maintains the relationship between the mold serial number and the address information. For example, if a mold assigned the mold serial number "1" is located at the location indicated by the address information "2," the pouring PLC 22 associates the mold serial number "1" with the address information "2." The pouring PLC 22 updates the relationship each time the mold is moved. For example, when a mold assigned mold serial number "1" moves from the position indicated by address information "2" to the position indicated by address information "3," the pouring PLC 22 associates mold serial number "1" with address information "3." In this way, by shifting the mold serial number in the data in accordance with the movement of the mold, the pouring PLC 22 can identify a mold located at any location and refer to the molten metal information associated with the mold serial number of that mold. The pouring PLC 22 transmits the mold serial number and the molten metal information corresponding to the mold serial number to the management device 100.

[0021] [Sampling step (step S16)] The sampling process is performed before, after, or during the pouring process. In the sampling process, the pouring machine 14 samples the molten metal in the pouring ladle used in the pouring process under the control of the pouring PLC 22 to generate a test piece (TP). The pouring PLC 22 associates a test piece number with the ladle serial number.

[0022] [Analysis step (step S18)] The analysis process is carried out in the material inspection site 15 after the sampling process. In the analysis process, an operator analyzes at least one of the composition and physical properties of the test piece. The analysis results are sent to the management device 100 together with the test piece number and the ladle serial number. The management device 100 stores the molten metal information corresponding to the ladle serial number in association with the analysis results.

[0023] [Cooling process (step S20)] The cooling process is performed after the pouring process. The cooling process can be performed in parallel with the sampling and analysis processes. In the cooling process, the cooling line 16 transports the mold over time and cools the molten metal in the mold. This forms a casting in the mold. The operation of the cooling line 16 is controlled by the mold making PLC 23.

[0024] [Disassembly process (step S22)] The break-out process is carried out after the cooling process. In the break-out process, a break-out device 17 disassembles the mold one frame at a time and removes the castings. The operation of the break-out device 17 is controlled by the mold making PLC 23. The removed castings are placed in cases, and are transported in cases by a case transfer device 18 to the finishing device 19. The case transfer device 18 is controlled by the post-processing PLC 24.

[0025] The post-processing PLC 24 can acquire the mold serial number and the molten metal information corresponding to the mold serial number via the management device 100. Therefore, the post-processing PLC 24 can acquire the molten metal information corresponding to the mold disassembled in the disassembly process based on the mold serial number. The post-processing PLC 24 associates the molten metal information with the case serial number when the casting is placed in the case. Address information identifying the location is assigned in advance to locations where the case can be moved. The post-processing PLC 24 maintains the relationship between the case serial number and the address information. For example, if a case assigned the case serial number "1" is located at the location indicated by the address information "2," the post-processing PLC 24 associates the case serial number "1" with the address information "2." The post-processing PLC 24 updates the relationship each time the case is moved. For example, when a case assigned the case serial number "1" moves from the position indicated by the address information "2" to the position indicated by the address information "3," the post-processing PLC 24 associates the case serial number "1" with the address information "3." In this way, the post-processing PLC 24 shifts the case serial number in the data in accordance with the movement of the case, thereby identifying the case located at any location and being able to refer to the molten metal information associated with the case serial number of that case. The post-processing PLC 24 transmits the case serial number and the molten metal information corresponding to the case serial number to the management device 100.

[0026] [Finishing process (step S24)] The finishing process is carried out after the disassembly process. In the finishing process, sand adhering to the casting is removed using a blasting device or the like, and the surface of the casting is polished using a polishing device or the like. The operation of these devices is controlled by the post-processing PLC 24.

[0027] [Inspection process (step S26)] The inspection process is performed at the inspection site 20 after the finishing process and the analysis process. In the inspection process, workers perform an external inspection of the casting. The external inspection includes visual checks of shape, sand removal, color, and dimensions. A display 101 connected to a management device 100 is installed at the inspection site 20. During the inspection process, the display 101 at the inspection site 20 displays the analysis results of the test piece based on the display control of the management device 100. The management device 100 identifies molten metal information based on the case serial number of the case transported to the inspection site 20, identifies the analysis results associated with the molten metal information, and displays the analysis results on the display 101. This allows workers at the inspection site 20 to recognize at least one of the composition and physical properties of the test piece obtained in the analysis process.

[0028] In the inspection process, management device 100 can synchronize the timing of the visual inspection of the casting with the timing of displaying the analysis results on display 101. The timing of the visual inspection of the casting may be the timing when an operator operates a work start button, or the timing when a sensor detects that a case has been carried into inspection site 20, or the timing when a sensor detects that an operator has positioned themselves in the work space of inspection site 20. In response to acquiring the timing of the visual inspection of the casting, management device 100 causes the analysis results to be displayed on display 101. This synchronizes the timing of the visual inspection of the casting with the timing of displaying the analysis results on display 101.

[0029] (Summary of the embodiment) In casting method M, in the inspection step (step S26), at least one of the composition and physical properties of the test piece obtained in the analysis step (step S18) is displayed on display 101. Therefore, an operator in the inspection step can recognize at least one of the composition and physical properties of the casting to be inspected via display 101. By allowing an operator to recognize at least one of the composition and physical properties of the casting, the operator can easily and accurately identify the product corresponding to the casting to be inspected, and can confirm the consistency between the composition, physical properties, and appearance of the casting. Therefore, this casting method allows for efficient inspection before shipping.

[0030] Furthermore, since the molten metal is sampled in the pouring step (step S14), it is possible to reduce the discrepancy between the analysis results and the composition and physical properties of the casting to be inspected.

[0031] Furthermore, in the inspection process (step S26), the timing of the visual inspection of the casting is synchronized with the timing of displaying at least one of the composition and physical properties of the test piece on the display 101, so casting method M allows workers to easily understand the correspondence between the casting being inspected and the analysis results of that casting.

[0032] Although exemplary embodiments have been described above, the present invention is not limited to the above exemplary embodiments and various omissions, substitutions, and modifications may be made. For example, if only a small number of ladles are used, the ladle serial numbers may not be used. Furthermore, although the exemplary embodiments illustrate a configuration in which each PLC communicates via the management device 100, each PLC may also communicate directly. [Explanation of symbols]

[0033] S14...Pouring process, S16...Sampling process, S18...Analysis process, S20...Cooling process, S22...Disassembly process, S26...Inspection process, 101...Display.

Claims

1. A pouring process of pouring molten metal from a ladle into a plurality of molds; an analyzing step of analyzing the composition of a test piece produced based on the molten metal sampled from the ladle used in the pouring step; a cooling step of cooling the plurality of molds into which the molten metal has been poured in the pouring step; a disassembly step in which each casting is removed from each mold cooled in the cooling step and each removed casting is placed in a case; an inspection step of inspecting the appearance of the castings in each case transported to an inspection area where a display is placed; Including, In the pouring step, the mold serial number of each mold is associated with molten metal information corresponding to the ladle serial number of the ladle; In the analyzing step, molten metal information corresponding to the ladle serial number of the ladle is associated with the composition of the test piece; In the disassembly process, molten metal information identified based on the mold serial number of each mold is associated with a case serial number; In the inspection step, molten metal information is acquired based on the case serial number of each case, a composition of the test piece associated with the acquired molten metal information is acquired, and the acquired composition of the test piece is displayed on the display during the visual inspection. Casting method.

2. a sampling step of sampling the molten metal in the ladle used in the pouring step to generate the test piece; The casting method according to claim 1 , wherein the analyzing step analyzes a composition of the test piece produced in the sampling step.

3. 3. The casting method according to claim 1, wherein in the inspection step, the timing of the appearance inspection of the casting and the timing of displaying the composition of the test piece on the display are synchronized.

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