Casting equipment

Abstract

To provide a casting facility which manufactures castings with good quality.SOLUTION: A casting facility comprises a pouring machine which is molded by a molding machine and pours molten metal in a ladle into a casting mold transported to a pouring place. The pouring machine has: a plan acquisition part which acquires a plan temperature range of the molten metal in the casting mold transported to a pouring position from the molding machine; a temperature sensor which detects a temperature of a molten metal flow during pouring of the molten metal into the casting mold transported to the pouring position; and a temperature determination part which determines whether or not a temperature of the molten metal flow detected by the temperature sensor falls within the plan temperature range acquired by the plan acquisition part. The pouring machine stops pouring of the molten metal into the casting mold when it is determined by the temperature determination part that the temperature of the molten metal flow does not fall within the plan temperature range.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to casting equipment.

Background Art

[0002] Patent Document 1 discloses casting equipment. In this casting equipment, a ladle receives molten metal in a melting furnace and is conveyed to a pouring machine. A plurality of molds are molded by a molding machine and are conveyed to the pouring machine one by one. In the pouring machine, the molten metal in the ladle is poured into the conveyed mold.

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 has room for improvement in order to produce better castings. The present disclosure provides casting equipment for producing high-quality castings.

Means for Solving the Problems

[0005] The casting equipment according to one aspect of the present disclosure includes a pouring machine. The pouring machine pours the molten metal in the ladle into the mold that is molded by the molding machine and conveyed to the pouring site. The pouring machine has a plan acquisition unit, a temperature sensor, and a temperature determination unit. The plan acquisition unit acquires the planned temperature range of the molten metal of the mold conveyed to the pouring position from the molding machine. The temperature sensor detects the temperature of the pouring flow during pouring into the mold conveyed to the pouring position. The temperature determination unit determines whether the temperature of the pouring flow detected by the temperature sensor is within the planned temperature range acquired by the plan acquisition unit. When the temperature determination unit determines that the temperature of the pouring flow is not within the planned temperature range, the pouring machine stops pouring into the mold.

[0006] To produce high-quality castings, molten metal with the specified viscosity must be poured into the mold. There is a correlation between the temperature and viscosity of the molten metal. Therefore, in this casting equipment, the pouring machine is controlled based on the temperature of the molten metal. The planned temperature range of the molten metal in the mold, once it is transported to the pouring position, is obtained from the molding machine. The temperature of the pouring flow is detected during the pouring of the molten metal into the mold. If it is determined that the temperature of the pouring flow is outside the planned temperature range, pouring into the mold is stopped. In this way, the casting equipment can avoid producing castings with molten metal that is not at the planned temperature, i.e., molten metal that is not at the planned viscosity. Thus, this casting equipment can produce high-quality castings by pouring molten metal with the planned viscosity into the mold.

[0007] In one embodiment, the casting equipment may further include a conveying device. The conveying device conveys the ladle to the pouring machine. The planning acquisition unit further acquires the planned material number of the mold that has been conveyed to the pouring position from the molding machine. The pouring machine further includes a material acquisition unit and a material determination unit. The material acquisition unit acquires a material number from the conveying device that identifies the material of the molten metal in the ladle. The material determination unit determines whether the planned material number acquired by the planning acquisition unit matches the material number acquired by the material acquisition unit. If the material determination unit determines that the planned material number and the material number do not match, the pouring machine stops pouring the molten metal into the mold.

[0008] To produce high-quality castings, it is necessary to pour molten metal with the intended composition into the mold. Therefore, in this casting equipment's pouring machine, the planned material number of the mold, once it has been transported to the pouring position, is obtained from the molding machine. The material number identifying the molten metal in the ladle is also obtained from the conveying device. If it is determined that the planned material number and the material number do not match, pouring into the mold is stopped. In this way, the casting equipment can avoid producing castings with molten metal that does not have the intended material number, i.e., molten metal with the intended composition. Therefore, by pouring molten metal with the intended composition into the mold, this casting equipment can produce high-quality castings.

[0009] In one embodiment, the planning unit may further acquire, based on information acquired from the molding machine, a ladle tilting pattern for pouring into a mold transported to the pouring position, and the change in the weight of the ladle over time when pouring according to the ladle tilting pattern. The pouring machine refers to a storage unit that stores a correction value for correcting the tilting motion of the ladle, and pours molten metal into the mold transported to the pouring position based on the ladle tilting pattern acquired by the planning unit and the correction value stored in the storage unit. The pouring machine further includes a load cell and an update unit. The load cell measures the weight of the ladle while pouring molten metal into the mold transported to the pouring position. The update unit updates the correction value stored in the storage unit so that the deviation between the weight of the ladle measured by the load cell and the weight of the ladle measured by the load cell acquired by the planning unit becomes smaller.

[0010] To produce high-quality castings, molten metal must be poured into the mold with a consistent flow. To achieve this consistent flow, the machine operation (ladle tilt pattern) of the pouring machine and the time change in the weight of the ladle, which are synchronized with the pouring performed by a skilled worker, should be memorized and reproduced. Therefore, in this casting equipment, the ladle tilt pattern for pouring into the mold transported to the pouring position and the time change in the weight of the ladle when pouring with that ladle tilt pattern are further acquired. A memory unit storing correction values ​​to compensate for the ladle tilting motion is referenced, and molten metal is poured into the mold transported to the pouring position based on the ladle tilt pattern and the correction values. The weight of the ladle is measured during pouring into the mold. The measured weight of the ladle is compared with the weight of the ladle measured by the load cell among the acquired time changes in the weight of the ladle, and the correction value stored in the memory unit is updated. In this way, the casting equipment can compare the weight of the ladle when pouring molten metal using a planned ladle tilting pattern (pouring by a skilled worker) with the actual weight of the ladle, and provide feedback to ensure that the next pour is carried out according to plan. Therefore, this casting equipment can produce high-quality castings by pouring molten metal into the mold with a stable force. [Effects of the Invention]

[0011] According to various aspects and embodiments of this disclosure, high-quality castings can be manufactured. [Brief explanation of the drawing]

[0012] [Figure 1] Figure 1 is a plan view showing a part of a casting facility according to an exemplary embodiment. [Figure 2] Figure 2 is a side view of a pouring machine according to an exemplary embodiment. [Figure 3] Figure 3 is a front view of a pouring machine according to an exemplary embodiment. [Figure 4] Figure 4 is a diagram illustrating the axial configuration of a pouring machine according to an exemplary embodiment. [Figure 5] Figure 5 is a block diagram of the control system for the hot water pouring equipment. [Figure 6] Figure 6 is a diagram illustrating the layout of a pouring pot. [Figure 7] Figure 7(A) is a graph showing the relationship between the tilt angle and the correction value of the tilt velocity, and Figure 7(B) is a graph showing the change in tilt velocity over time. [Modes for carrying out the invention]

[0013] Illustrative embodiments of the present disclosure will be described below with reference to the drawings. In the following description, the same or equivalent elements will be denoted by the same reference numerals, and redundant descriptions will not be repeated.

[0014] [Overview of the casting equipment] Figure 1 is a plan view showing a part of a casting facility according to an exemplary embodiment. The casting facility 1 shown in Figure 1 dispenses a portion of the molten metal obtained from the melting furnace into a ladle, transports the ladle containing the molten metal to a pouring machine, and pours the molten metal from the transported ladle into a mold using the pouring machine. As shown in Figure 1, the casting facility 1 includes, as an example, a melting furnace 2. The melting furnace 2 obtains molten metal by melting the molten material with heat. There may be one melting furnace 2 or multiple melting furnaces 2. In the example in Figure 1, two melting furnaces 2 are installed side by side. A corresponding molten material input device is installed side by side with the melting furnace 2, and the molten material is introduced into the furnace by the molten material input device. The operation of the melting furnace 2 and the molten material input device is controlled by a melting block control device 60 (Figure 5), which will be described later. A temperature sensor is provided in the melting furnace 2. The temperature sensor acquires the temperature of the molten metal. The melting furnace 2 can obtain a quantity of molten metal at once that is sufficient to dispense multiple times into the receiving ladle, which will be described later.

[0015] The molten metal melted in the melting furnace 2 is poured into the processing ladle LD1. The processing ladle LD1 is placed on the receiving trolley 4 and moves along the receiving trolley rail R1. Before receiving the molten metal, the receiving trolley 4 moves to the position of the primary inoculation device 3 to adjust the composition of the raw molten metal, and the material to adjust the composition of the raw molten metal is added to the processing ladle LD1 by the primary inoculation device 3. After that, the receiving trolley 4 moves to the receiving position, and the molten metal is poured from the melting furnace 2 into the processing ladle LD1. The receiving trolley 4 moves to the emptying position, and the molten metal in the processing ladle LD1 is transferred to the pouring ladle LD2. Emptying means transferring the molten metal to another ladle. When the molten metal is transferred from the processing ladle LD1 to the pouring ladle LD2, additive materials are added to the pouring ladle LD2 by the secondary inoculation device 5, and the composition of the molten metal is adjusted. The molten metal receiving trolley 4 and the secondary inoculation device 5 are controlled by the molten metal transport block control device 50 (Figure 5), which will be described later.

[0016] The pouring ladle LD2 is placed on the transport trolley 6 and transported along the transport trolley rail R2. In addition to the empty replacement position described above, the transport trolley 6 can also stop at the ladle replacement position where the pouring ladle LD2 is transported to the pouring machine 10. The operation of the transport trolley 6 is controlled by the molten metal transport block control device 50 (Figure 5).

[0017] The ladle pouring pot LD2 (actual pot) containing molten metal is transferred from the transport cart 6 to the pot exchanger 9 at the front stage (pot exchange position) of the pouring machine 10. In the pot exchanger 9, the exchange between the actual pot and the ladle pouring pot LD2 (empty pot) that has become empty after pouring is realized. For example, by sliding the pouring machine 10, the exchange between the actual pot and the empty pot is realized. For example, when the pouring machine 10 slides in front of the roller conveyor 8, the empty pot is transferred from the pouring machine 10 to the roller conveyor 8. When the pouring machine 10 slides in front of the roller conveyor 7, the actual pot is transferred from the roller conveyor 7 to the pouring machine 10.

[0018] The pouring machine 10 pours the molten metal stored in the ladle pouring pot LD2 into the mold MD. The pouring machine 10 is provided on the side of the pouring zone 14 (an example of a pouring site). In the pouring zone 14, the mold conveyor transfers a plurality of molds MD shaped by a molding machine (not shown) arranged in a row and conveys them one by one. The pouring machine 10 pours the molten metal in the ladle pouring pot LD2 into the mold MD being conveyed in the pouring zone 14.

[0019] In the pouring zone 14, tracks for the mold MD are laid, and at both ends of the tracks, a set of mold feeding devices 11 (pusher and cushion), which are mold conveyor devices, are arranged. The pusher constituting the mold feeding device 11 has the function of pushing out the mold MD, and the cushion constituting the mold feeding device 11 has the function of receiving the pushed-out mold MD. The mold MD can be sent out without gaps by the pusher and the cushion. The mold feeding device 11 sends out the mold MD one by one. In FIG. 1, only the mold feeding device (cushion) at the front end of the track is shown, and the illustration of the mold feeding device (pusher) arranged at the rear end of the track is omitted.

[0020] When the mold MD reaches the front end of the rail in the pouring zone 14, it is transferred to the adjacent cooling zone 15 by the traverser 13. In the cooling zone, while cooling the product after pouring in the mold MD, the mold MD is conveyed to a mold opening device (not shown). In the cooling zone 15, a rail for the mold MD is laid, and at both ends of the rail, a set of mold feeding devices 12 (pusher and cushion) are arranged in the same manner as in the pouring zone 14. In FIG. 1, only the mold feeding device (pusher) at the rear end of the rail is shown, and the illustration of the mold feeding device (cushion) arranged at the front end of the rail is omitted. The operation of the mold feeding device 12 is the same as the operation of the mold feeding device 11. By the mold feeding device 12, the mold MD in the cooling zone 15 is conveyed in the direction opposite to the conveying direction of the mold MD in the pouring zone 14. The mold MD after pouring is cooled over time on the rail, and the molten metal solidifies into a casting before reaching the mold opening device. The conveyance of the mold MD is controlled by a molding line control device 30 (FIG. 5) described later. When it is necessary to synchronize the pouring machine 10 with the conveyance of the mold MD, an encoder, a length measuring sensor, etc. are arranged on the rail in the pouring zone 14. The pouring machine 10 is controlled to synchronize with the conveyance of the mold MD based on the conveyance speed and position of the mold MD obtained using the sensor.

[0021] [Details of the Pouring Machine] FIG. 2 is a side view of a pouring machine according to an exemplary embodiment. FIG. 3 is a front view of a pouring machine according to an exemplary embodiment. FIG. 4 is a diagram for explaining the shaft configuration of a pouring machine according to an exemplary embodiment. In FIGS. 2 and 3, the rail for the mold MD is omitted, and only the mold MD is shown.

[0022] As shown in Figures 2 to 4, the pouring machine 10 is equipped with a pouring cart 101. The pouring cart 101 carries the pouring ladle LD2 and travels along the pouring rail R3. Above the pouring machine 10, a cable rail R4 is provided parallel to the pouring rail R3. Power supply cables and signal cables are laid on the cable rail R4. The power supply cables and signal cables are connected to the pouring cart 101 via the cable rail R4. As a result, power is supplied to the pouring cart 101 via the power supply cables. In addition, communication between the pouring cart 101 and various devices of the pouring equipment is possible via the signal cables.

[0023] The pouring cart 101 is equipped with a travel motor M1. The wheels of the pouring cart 101 rotate when driven by the travel motor M1, and the pouring cart 101 travels on the pouring rail R3 (in the Y direction in the figure). This allows the pouring ladle LD2 to move along the mold row. Furthermore, the pouring ladle LD2 is supported so as to be tiltable by a tilting mechanism ME1. The tilting mechanism ME1 is equipped with a tilting motor SM1 as a drive source and tilts the pouring ladle LD2 around a tilting axis K that extends in the Y direction in the figure (in the θ direction in the figure). Furthermore, the pouring ladle LD2 is supported so as to be raised and lowered by a lifting mechanism ME2. The lifting mechanism ME2 is equipped with a lifting motor SM2 as a drive source and raises and lowers the tilting mechanism ME1 (in the Z direction in the figure). As a result, the pouring ladle LD2 is raised and lowered together with the tilting mechanism ME1, and pouring can be performed from a predetermined height. Furthermore, the pouring ladle LD2 is supported so as to be movable by the forward / backward movement mechanism ME3. The forward / backward movement mechanism ME3 is equipped with a movement motor SM3 as a drive source and moves the lifting mechanism ME2 (in the X direction in the figure). As a result, the pouring ladle LD2, together with the tilting mechanism ME1 and the lifting mechanism ME2, can move in a direction toward or toward the mold MD. Thus, the pouring ladle LD2 mounted on the pouring machine 10 can be moved to any position in the XYZ direction in the figure and tilted at any tilting angle. Molten metal is poured from the outlet P of the pouring ladle LD2 into the mold MD by the tilting mechanism ME1, the lifting mechanism ME2 and the forward / backward movement mechanism ME3. Note that the tilting motor SM1, the lifting motor SM2 and the movement motor SM3 are servo motors as an example.

[0024] The pouring machine 10 has a non-contact thermometer 103 (an example of a temperature sensor) that measures the temperature of the molten metal to be poured. The non-contact thermometer 103 calculates the temperature of the molten metal using the amount of bicolor infrared radiation detected by, for example, the sensor head of a bicolor thermometer. The measurement position of the non-contact thermometer 103 is set to be the outlet P (tip of the nozzle) of the pouring ladle LD2. This allows the non-contact thermometer 103 to measure the temperature of the pouring flow.

[0025] The pouring machine 10 may also be equipped with an inoculation device 104. The inoculation device 104 drives a cutting motor M2 to operate a screw, cuts out material to adjust the composition of the molten metal, and supplies the cut material to the mold MD during pouring. This adjusts the composition of the molten metal.

[0026] The pouring machine 10 may have a test piece sampling unit 105 that receives molten metal from the pouring ladle LD2 for test pieces. The test piece sampling unit 105 is equipped with a sampling motor M3 for operating the sampling ladle and takes test pieces from the molten metal in each pouring ladle LD2 for material inspection.

[0027] The pouring machine 10 may have a load cell 106 for measuring the weight of the molten metal in the pouring ladle LD2. The load cell 106 is positioned to detect the weight of the pouring ladle LD2 (for example, a position that detects the load on the forward / backward movement mechanism ME3). The weight of the molten metal is obtained by subtracting the weight of the empty ladle from the weight of the actual ladle.

[0028] The pouring cart 101 is equipped with a pouring block control device 40 for controlling the above-mentioned components. The pouring block control device 40 controls the above-mentioned components according to preset settings. The pouring block control device 40 can also receive operator input via the control panel 107 and control the above-mentioned components based on the operator input.

[0029] [Control system for casting equipment] Figure 5 is a block diagram of the pouring equipment. As shown in Figure 5, the control system 100 includes a molding block control device 20, a molding line control device 30, a pouring block control device 40, a molten metal transport block control device 50, and a melting block control device 60. The devices in the figure are PLCs or computers, and physically they are configured as a normal computer system including a CPU (Central Processing Unit), main memory 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.

[0030] The molding block control device 20 stores the molding plan and operates the molding machine based on the molding plan. The molding plan includes mold information. The mold information is information associated with the mold and includes a serial number for identifying the mold, information about the model used in the mold (molding model number), and the planned casting weight. The planned casting weight is a preset weight of molten metal poured into the mold.

[0031] The molding line control device 30 controls the mold feeders 11 and 12 and stores a plurality of transport positions fixedly assigned to the mold row, associating them with mold information corresponding to the molds located at each transport position. In other words, the molding line control device 30 stores the transport positions associating them with the mold information. The molding line control device 30 updates the mold information associated with each transport position in response to the frame feed by the mold feeders 11 and 12.

[0032] The melting block control device 60 centrally manages information for the melting process. The melting block control device 60 is connected to the melting furnace 2, the melting material input device, temperature sensors, etc. For the first melting of the day, the melting block control device 60 determines the melting material based on the day's production plan and inputs the determined melting material into the melting material input device. The melting block control device 60 is connected to the molten metal transport block control device 50 and they exchange information with each other. The melting block control device 60 acquires information from the melting material input device and temperature sensors, etc., and stores melting information related to the raw molten metal for each melting furnace 2.

[0033] The molten metal transport block control device 50 assigns a ladle serial number to the processing ladle LD1 that receives the raw molten metal. The ladle serial number is a number assigned to a ladle and counted up. For example, the ladle serial number is reset to zero when the casting equipment 1 starts up (for example, at the start of operation for the day). For example, the ladle serial number is counted up when the alloy material for primary inoculation is put into the processing ladle LD1 by the primary inoculation device 3. The ladle serial number is a key code for information retrieval, linked to primary inoculation, secondary inoculation, molten metal receiving information, etc.

[0034] The molten metal transport block control device 50 shifts the ladle serial number according to the position of the ladle. For example, when the receiving trolley 4 starts from the primary inoculation device 3, the molten metal transport control device 51 transfers the ladle serial number assigned by the primary inoculation device 3 to the processing ladle LD1 of the receiving trolley 4. The molten metal transport block control device 50 transfers the ladle serial number of the processing ladle LD1 of the receiving trolley 4, which is located at the emptying position, to the pouring ladle LD2 of the transport trolley 6, in response to the transfer from the processing ladle LD1 to the pouring ladle LD2 (i.e., when the transfer is completed).

[0035] The molten metal transport block control device 50, at the moment a ladle is brought in from the transport trolley 6 to the roller conveyor 7 of the ladle exchange device 9, takes over the ladle serial number of the ladle on the transport trolley 6 as the ladle serial number of the ladle in question. At the moment the ladle is moved from the roller conveyor 7 of the ladle exchange device 9 to the pouring machine 10, the molten metal transport block control device 50 outputs the ladle serial number of the ladle on the roller conveyor 7 to the pouring block control device 40, which will be described later. In this way, the molten metal transport block control device 50 shifts the ladle serial number in accordance with the movement of the ladle. Note that the ladle serial number is released from its association with the ladle when the ladle becomes empty and is refilled with molten metal.

[0036] The molten metal transport block control device 50 stores molten metal receiving information. This information includes, for example, the type of molten metal, the time of tapping, the weight of the molten metal received, the temperature of the molten metal received, the furnace number, the number of times the molten metal is received, the number of melting cycles, and the temperature elapsed after receiving the molten metal. The number of times the molten metal is received is the number of times the molten metal is replenished to the ladle. In the melting furnace, the number of tapping cycles is expressed as the number of times the molten metal is received, and in the receiving cart, it is expressed as the number of times the molten metal is received. The molten metal transport block control device 50 stores the ladle serial number of the ladle on the receiving cart 4 in association with the molten metal receiving information. Here, the ladle serial number is associated with the furnace number and the number of tapping cycles. The molten metal transport block control device 50 stores the ladle serial number, furnace number, and number of tapping cycles in association with the ladle serial number when the raw molten metal is tapped from the melting furnace 2 to the processing ladle LD1. The molten metal transport block control device 50 also obtains the material number from the melting block control device 60 and stores it in association with the ladle serial number. The material number is a letter or number pre-assigned to each material.

[0037] The pouring block control device 40 is connected to the molding block control device 20, molding line control device 30, and molten metal transport block control device 50 described above, and is capable of communicating with them. The non-contact thermometer 103 and load cell 106 described above are connected to the pouring block control device 40, and the measurement results are output to the pouring block control device 40. The pouring block control device 40 controls the operation of the pouring machine 10. The pouring block control device 40 controls the tilting motor SM1, the lifting motor SM2, and the moving motor SM3 to tilt the pouring ladle LD2 around the outlet P while keeping the position of the outlet P of the pouring ladle LD2 constant.

[0038] The pouring block control device 40 includes a pouring control unit 41, a plan acquisition unit 42, a temperature determination unit 43, a molten metal information acquisition unit 44, a material determination unit 45, and a storage unit 46.

[0039] The pouring control unit 41 controls the operation of the pouring cart of the pouring machine 10, and collects the pouring results and stores them as pouring information. The pouring control unit 41 stores multiple pouring positions and mold information corresponding to the molds located at each pouring position in association with each position. The pouring position is the position where the pouring machine 10 pours the molten metal. The first pour at the start of operation each day is manually positioned, and subsequent pours are automatically positioned based on the previous pouring position.

[0040] The planning unit 42 acquires mold information from the molding line control device 30, which includes multiple transport positions and mold information corresponding to the molds located at each transport position. The planning unit 42 acquires updated information from the molding line control device 30 in response to the frame feeding by the mold feeding devices 11 and 12. As a result, the pouring machine 10 can grasp the mold information of the molds located at each pouring position.

[0041] The planning acquisition unit 42 is configured to allow referencing of pre-set pouring conditions for each model. The pouring conditions are stored in association with the molding model number. The planning acquisition unit 42 grasps the pouring conditions for the mold based on the molding model number acquired from the molding line control device 30. The pouring conditions include the planned material number (composition of the molten metal), ladle tilt pattern number, pouring pattern number, and planned temperature range of the molten metal. The planned material number is a pre-set material number. The ladle tilt pattern is a pattern that shows the relationship between mechanical operation (e.g., pouring speed, tilt angle) and pouring time (time change of mechanical operation). The ladle tilt pattern is minute time operation data for three axes: the tilt axis (θ direction in the figure) for rotation around the tip of the ladle nozzle, the front-back axis (X direction in the figure), and the lifting axis (Z direction in the figure). The minute time is 0.2 seconds as an example. The ladle tilt pattern number is a letter or number assigned to identify the ladle tilt pattern. The pouring pattern is data in which pouring weight data is added to each of the ladle tilting pattern data described above. The pouring weight data is the pouring weight at regular intervals from the start of pouring during teaching. In other words, the pouring pattern is a pattern that shows the relationship between pouring weight and pouring time (the change in the weight of the ladle over time). The pouring pattern number is a letter or number assigned to identify the pouring pattern, and the planned pouring pattern number is a pre-set pouring pattern number.

[0042] The temperature determination unit 43 determines the temperature of the molten metal in order to pour it with the planned viscosity. The viscosity of the molten metal decreases with temperature. It is considered that the viscosity of the molten metal should be similar to that of water. If the temperature of the molten metal is lower than the planned temperature, it may lead to poor flow of the molten metal, and conversely, if the temperature of the molten metal is higher than the planned temperature, it may lead to deterioration of the material. The non-contact thermometer 103 detects the temperature of the pouring flow while the molten metal is being poured into the mold MD that has been transported to the pouring position. The temperature determination unit 43 determines whether the temperature of the pouring flow detected by the non-contact thermometer 103 is within the planned temperature range obtained by the plan acquisition unit 42. If the temperature determination unit 43 determines that the temperature of the pouring flow is within the planned temperature range, the pouring control unit 41 continues pouring into the mold MD. If the temperature determination unit 43 determines that the temperature of the pouring flow is not within the planned temperature range, the pouring control unit 41 stops pouring into the mold MD. The pouring ladle LD2 from which pouring has been stopped is returned to the melting area. This allows for pouring without poor water circulation or material changes.

[0043] The molten metal information acquisition unit 44 (an example of a material acquisition unit) acquires molten metal information and stores it in the storage unit 46. When the ladle is brought into the pouring machine 10, the molten metal information acquisition unit 44 acquires the ladle serial number of the ladle from the molten metal transport block control device 50. The molten metal information is information obtained during the pouring process and includes, as an example, the ladle serial number, elapsed time of receiving the molten metal, pouring weight, pouring time, material number, pouring temperature, fading start time, and test piece serial number. When pouring is completed, the molten metal information acquisition unit 44 stores the molten metal information in the storage unit 46 based on the mold serial number.

[0044] The material determination unit 45 determines the material number in order to pour the molten metal with the initially planned composition. The material determination unit 45 determines whether the planned material number (mold information) obtained by the plan acquisition unit 42 matches the material number (molten metal information) obtained by the molten metal information acquisition unit 44. If the material determination unit 45 determines that the planned material number and the material number match, the pouring control unit 41 continues pouring the molten metal into the mold MD. If the material determination unit 45 determines that the planned material number and the material number do not match, the pouring control unit 41 stops pouring the molten metal into the mold MD. The pouring ladle LD2 from which pouring has been stopped is returned to the melting area. The material determination unit 45 may also make the determination when the actual ladle arrives at the pouring machine 10. In this case, defective molten metal is eliminated at an earlier stage (before pouring).

[0045] The pouring control unit 41 stores in advance patterns of machine operation and pouring weight (ladle tilting pattern and the pouring pattern corresponding to the ladle tilting pattern) that are matched to the pouring of molten metal by a skilled worker, in order to pour the molten metal with a stable force, and reproduces the stored contents. As an example, the pouring control unit 41 controls the pouring using the tilting speed of the pouring ladle LD2 as the control variable. Figure 6 is a diagram illustrating the overview of a pouring ladle. As shown in Figures 6(A) to (C), an example of the pouring ladle LD2 is a cylindrical ladle. Figure 6(B) is a diagram showing the surface position of the molten metal at every 4° tilting angle. As shown in Figure 6(B), it can be seen that in the case of a cylindrical ladle, the surface area of ​​the molten metal changes with each tilting angle. In other words, the volume of the ladle decreases with each pour, and the amount of molten metal dispensed when tilted increases. For this reason, the pouring control unit 41 needs to adjust the amount of molten metal dispensed. The pouring control unit 41 acquires the shape of the ladle in advance and is set to operate according to that shape.

[0046] The memory unit 46 stores correction values ​​for adjusting the amount of molten metal dispensed as described above. Figure 7(A) is a graph showing the relationship between the tilt angle and the correction value of the tilt speed. In the graph shown in Figure 7(A), the horizontal axis is the tilt angle and the vertical axis is the correction value of the tilt speed. The correction value of the tilt speed is the reciprocal of the surface area calculated with the surface area when the molten metal is filled in a horizontal state set to 1 for each tilt angle shown in Figure 6(B). The pouring control unit 41 refers to the memory unit 46 which stores the correction values ​​and pours molten metal into the mold MD that has been transported to the pouring position based on the ladle tilt pattern acquired by the planning acquisition unit 42 and the correction values ​​stored in the memory unit 46. Figure 7(B) is a graph showing the change in tilt speed over time in the ladle tilt pattern from the start of pouring to draining. In the graph shown in Figure 7(B), the horizontal axis is time and the vertical axis is the tilt speed. Time t0 is the start time of pouring, time t1 is the time when a constant speed is reached, time t2 is the start time of dispensing, time t3 is the time when stabilization is required, time t4 is the time when the water is drained, and time t5 is the end time of pouring. The period T4 from time t3 to time t4 is the teaching period in which the experience of a skilled worker is required, as described above.

[0047] The pouring control unit 41 obtains the weight of the pouring ladle LD2 from the load cell 106 while pouring molten metal into the mold MD that has been transported to the pouring position, and compares the weight of the pouring ladle LD2 measured by the load cell 106 with the weight of the pouring ladle LD2 measured by the load cell 106 in the time change of the weight of the pouring ladle LD2 obtained by the planning acquisition unit 42 (pouring pattern). The pouring control unit 41 updates the correction value stored in the memory unit 46 so that the weight of the pouring ladle LD2 measured by the load cell 106 matches the weight of the pouring ladle LD2 measured by the load cell 106 in the pouring pattern (so that the deviation is small) (an example of the update unit). The correction value for correcting the tilting motion is the value obtained by converting the deviation between the weight of the pouring ladle LD2 obtained by the planning acquisition unit 42 and the weight of the pouring ladle LD2 measured by the load cell 106 into a tilting speed. As a result, the pouring control unit 41 receives feedback of a correction value so that it can operate with the planned ladle tilting pattern. Note that the correction value for correcting the tilting motion is not limited to the tilting speed, but may also be the tilting angle. In this case, the correction value is the value obtained by converting the deviation between the weight of the pouring ladle LD2 acquired by the planning acquisition unit 42 and the weight of the pouring ladle LD2 measured by the load cell 106 into a tilting angle.

[0048] (Summary of the embodiments) To produce high-quality castings, molten metal with the specified viscosity must be poured into the mold MD. There is a correlation between the temperature and viscosity of the molten metal. Therefore, the pouring machine 10 is controlled based on the temperature of the molten metal. The planned temperature range of the molten metal in the mold MD, which has been transported to the pouring position, is obtained from the molding machine. The temperature of the pouring flow is detected during the pouring of molten metal into the mold MD. If it is determined that the temperature of the pouring flow is not within the planned temperature range, the pouring of molten metal into the mold MD is stopped. In this way, the casting equipment can avoid producing castings with molten metal that is not at the planned temperature, that is, molten metal that is not at the planned viscosity. Thus, the casting equipment can produce high-quality castings by pouring molten metal with the planned viscosity into the mold.

[0049] To produce high-quality castings, it is necessary that molten metal with the correct composition is poured into the mold MD. Therefore, in the casting equipment's pouring machine 10, the planned material number of the mold MD, which has been transported to the pouring position, is obtained from the molding machine via the molding line control device 30. The material number identifying the material of the molten metal in the pouring ladle LD2 is obtained from the molten metal transport block control device 50. If it is determined that the planned material number and the material number do not match, pouring into the mold MD is stopped. In this way, the casting equipment can avoid producing castings with molten metal that does not have the correct material number, i.e., molten metal with the correct composition. Thus, by pouring molten metal with the correct composition into the mold MD, the casting equipment can produce high-quality castings.

[0050] To produce high-quality castings, molten metal must be poured into the mold MD at a stable rate. To achieve stable pouring, the machine operation (ladle tilting pattern) of the pouring machine 10 and the time change in the weight of the pouring ladle LD2, which are synchronized with the pouring performed by a skilled worker, should be memorized, and the pouring performed by the skilled worker should be reproduced. For this reason, the casting equipment further acquires the ladle tilting pattern for pouring into the mold MD transported to the pouring position, and the time change in the weight of the pouring ladle LD2 when pouring with the ladle tilting pattern. A memory unit 46 that stores correction values ​​for correcting the ladle tilting motion is referenced, and molten metal is poured into the mold MD transported to the pouring position based on the ladle tilting pattern and the correction values. The weight of the pouring ladle LD2 is measured while pouring into the mold MD. The measured weight of the pouring ladle LD2 is compared with the weight of the pouring ladle LD2 measured by the load cell 106 during the time change of the weight of the pouring ladle LD2 obtained, and the correction value stored in the memory unit 46 is updated. In this way, the casting equipment can compare the weight of the pouring ladle LD2 when pouring with the planned ladle tilting pattern (pouring by a skilled worker) with the actual weight of the pouring ladle LD2, and provide feedback so that the next pouring goes according to plan. Therefore, the casting equipment can produce high-quality castings by pouring molten metal into the mold MD with a stable force.

[0051] 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 decision to stop pouring may be made before transporting the pouring ladle LD to the pouring machine 10. For example, a comparison between the planned temperature and the measured temperature of the molten metal, and a comparison between the planned material number and the material number of the molten metal may be performed in the transport device or ladle exchange device. This prevents the loading of defective molten metal into the pouring machine 10. [Explanation of Symbols]

[0052] 1...Casting equipment, 2...Melting furnace, 3...Primary inoculation device, 4...Molten metal receiving cart, 5...Secondary inoculation device, 6...Transport cart, 9...Ladle replacement device, 10...Pouring machine, 40...Pouring block control device, 41...Pouring control unit (example of update unit), 42...Plan acquisition unit, 43...Temperature determination unit, 44...Molten metal information acquisition unit (example of material acquisition unit), 45...Material determination unit, 46...Storage unit, 103...Non-contact thermometer (example of temperature sensor), 106...Load cell.

Claims

1. A pouring machine that pours molten metal from a ladle into a mold that has been formed by a molding machine and transported to a pouring area, The aforementioned pouring machine is A planning acquisition unit that acquires the planned temperature range of the molten metal of the mold that has been transported to the pouring position from the molding machine, A temperature sensor for detecting the temperature of the pouring flow during pouring of molten metal into the mold that has been transported to the pouring position, wherein the measurement position is set to be the outlet of the ladle nozzle, A temperature determination unit determines whether the temperature of the pouring flow detected by the temperature sensor is within the planned temperature range obtained by the planning acquisition unit, It has, If the temperature determination unit determines that the temperature of the pouring flow is not within the planned temperature range, the pouring machine will stop pouring the molten metal into the mold. The aforementioned planning unit, based on the information acquired from the molding machine, further acquires the ladle tilting pattern for pouring into the mold transported to the pouring position and the change in the weight of the ladle over time when pouring with the ladle tilting pattern. The pouring machine refers to a storage unit that stores a correction value for the tilting speed that corrects the tilting motion of the ladle, and pours molten metal into the mold that has been transported to the pouring position based on the ladle tilting pattern acquired by the planning unit and the correction value stored in the storage unit. The aforementioned pouring machine is A load cell for measuring the weight of the ladle during the pouring of molten metal into the mold that has been transported to the pouring position, An update unit updates the correction value stored in the storage unit so as to reduce the deviation between the weight of the ladle measured by the load cell and the weight of the ladle at the time of measurement by the load cell, which is obtained by the planning acquisition unit. A casting facility further possessing the following.

2. The system further comprises a conveying device for transporting the ladle to the pouring machine, The aforementioned plan acquisition unit further acquires the planned material number of the mold that has been transported to the pouring position from the molding machine, The aforementioned pouring machine is A material acquisition unit that obtains a material number from the conveying device to identify the material of the molten metal in the ladle, A material determination unit that determines whether the planned material number obtained by the plan acquisition unit matches the material number obtained by the material acquisition unit, It further possesses, The casting equipment according to claim 1, wherein the pouring machine stops pouring molten metal into the mold if the material determination unit determines that the planned material number does not match the material number.

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