WO2015072323A1 - Casting facility - Google Patents

Abstract

Provided is a casting facility with which the occurrence of trouble and manufacturing defects in the casting process can be prevented. This casting facility is equipped with: a mold forming line (10) that forms a casting mold; a melting line (20) that produces molten metal to be poured into the casting mold; and a pouring line (30) that pours the molten metal into the casting mold. This casting facility also is equipped with: a touch panel (12), which is arranged in the mold forming line (10) and is for entering whether a casting mold is a good product or a defective product; an automatic pouring device (31) which is arranged in the pouring line (30) and, on the basis of an input on the touch panel (12), automatically pours molten metal into only those casting molds that have been determined to be good products; and a touch panel (32), which is arranged in the pouring line (30) and, on the basis of an input on the touch panel (12), displays whether a casting mold in the pouring line (30) is a good product or a defective product.

Description

Casting equipment

The present invention relates to a casting facility.

Patent Document 1 discloses a conventional casting facility. This casting equipment includes a molding line for molding a mold, a melting line for producing a molten metal poured into the mold, and a pouring line for pouring the molten metal into the mold. The melting line is a process of adjusting the molten metal components by introducing the required amount of the alloy component material and the molten metal melted in the melting furnace into the processing ladle, and a process of transferring the molten metal from the processing ladle to the pouring ladle. have. The pouring line is equipped with an automatic pouring device for pouring the molten metal from the pouring ladle into the mold after confirming whether the molten metal in the pouring ladle is the component of the molten metal to be poured. . For this reason, this casting equipment can respond to the mold forming speed of the mold and can pour an appropriate molten metal according to the mold.

JP 2012-166271 A

However, the casting equipment of Patent Document 1 is not intended to cause defective molds in the molding line. Pouring molten metal into a defective mold and casting it will result in product defects. Moreover, when molten metal is poured into a defective mold, the molten metal may leak out. For example, if you give information on good or defective molds to the pouring device and automate the pouring device so that the molten metal is not poured when the mold is defective, the worker in charge of the pouring line It is impossible to judge whether the molten metal is not poured because the mold is defective or whether the molten metal is not poured into the mold due to a malfunction of the automatic pouring device. In this case, the operator may switch the automatic pouring device to manual and pour molten metal into a defective mold.

The present invention has been made in view of the above-described conventional situation, and it is an object to be solved to provide a casting facility capable of preventing troubles and product defects in the casting process.

The casting equipment of the present invention is a casting equipment comprising a molding line for molding a mold, a melting line for producing a molten metal poured into the mold, and a pouring line for pouring the molten metal into the mold,
An input device that is installed in the molding line and inputs whether the mold is a non-defective product or a defective product;
An automatic pouring device that is installed in the pouring line and that automatically pours molten metal only to the mold that is determined to be non-defective, based on an input to the input device;
And a display device that is installed in the pouring line and displays whether the mold on the pouring line is a good product or a defective product based on an input to the input device. .

In this casting facility, whether a mold is a good product or a defective product is input to an input device installed in the molding line, and an automatic pouring device installed in the pouring line is determined to be a good product based on the input. The molten metal is automatically poured only into the mold. Moreover, whether the mold on the pouring line is a non-defective product or a defective product is displayed on a display device installed in the pouring line based on an input to the input device. For this reason, if the automatic pouring device does not pour the molten metal into the defective mold, the worker in charge of the pouring line does not pour the molten metal because the mold is defective. I can recognize that. Accordingly, it is possible to prevent the operator from switching the automatic pouring device to manual and pouring the molten metal into the defective mold.

Therefore, the casting equipment of the present invention can prevent troubles and product defects in the casting process.

It is a block diagram which shows the whole casting equipment of Example 1. FIG. It is a block diagram which shows the molding line of the casting installation of Example 1, a melting line, and the pouring line. It is explanatory drawing which shows the flow from a molten metal to pouring. Production plan data. It is an input screen for inputting non-defective or defective product information of the mold. It is a display screen of the touch panel (touch panel) installed in the melting line which displayed the mold information. It is a display screen of the touch panel installed in the pouring line which displayed mold information.

Next, Example 1 that embodies the casting equipment of the present invention will be described with reference to the drawings.

<Example 1>
As shown in FIG. 1, the casting facility of the first embodiment includes a molding line 10, a melting line 20, a pouring line 30, a demolition line 40, a finishing / inspection line 50, and a processing line 60. Further, as shown in FIG. 2, this casting facility is based on a management computer 70 for registering a production plan, a database server 71 connected to the management computer 70, and a database server 71. Equipment control device 80 for controlling various devices constituting each line, and a plurality of touch panels 11, 12, 21, 32 installed on each line. Each touch panel 11, 12, 21, 32 is a display device and an operation device.

The molding line 10 performs a kneading process, a sanding process, a curing process, a mold releasing process, a core storing process, and a coalescence (frame alignment) process in this order to mold a mold made of a sand mold. These steps are executed by the facility control device 80 automatically controlling the operation of various devices constituting the molding line 10 based on a production plan to be described later.

In the kneading step, the foundry sand to which a resin and a curing agent are added is kneaded. In the sanding process, the kneaded foundry sand is put into one casting frame in which two casting models having the same shape are arranged in parallel. In the curing step, the foundry sand thrown into the casting frame is cured. In the die cutting process, the cast model is extracted from the casting frame. By these steps, the upper mold and the lower mold are formed separately. The upper mold and the lower mold each have two cavities having the same shape. Further, the upper die is provided with a gate and a vent hole communicating with the cavity. In the core storing step, one core having the same shape is arranged in each of the two cavities formed in the lower mold. The core is manufactured through a core firing process and a core assembly process. In the coalescence process, the upper mold is combined with the lower mold on which the core is arranged. In this way, a mold having a core disposed in the cavity is completed. One casting mold can be used to cast two castings having the same shape.

In the die-cutting process, a molding serial number is automatically assigned to each pair of upper mold and lower mold to be combined. Further, in the core storing step, a product serial number corresponding to each cast product to be cast is given. The molding serial number and the product serial number are registered in the database server 71 and managed.

In the melting line 20, the molten metal that is poured into the mold cavity is manufactured. The melting line 20 performs a measurement process, a melting process, a process, and a hot water process in this order. These processes are also executed by the facility control device 80 automatically controlling the operation of various devices constituting the melting line 20 based on a production plan to be described later. In the measuring step, various casting metals, additives, and the like are automatically measured so that 3 tons (t) of molten metal can be melted at once in a melting furnace (electric furnace). In the melting step, various casting metals and the like charged in the melting furnace are melted. In the treatment and tapping process, as shown in FIG. 3, the 3 t molten metal in the melting furnace (electric furnace) is divided into three times, and t is poured into the treatment ladle one by one, and alloy component materials etc. according to the production plan to be described later After adjusting the ingredients by adding, the molten metal in the treatment ladle is transferred to the pouring ladle.

The hot water pouring line 30 is provided continuously to the molding line 10 and has a three-dimensional warehouse and an automatic pouring device 31 as shown in FIG. The three-dimensional warehouse temporarily stores a specific mold molded by the molding line 10 based on a production plan to be described later. The automatic pouring device 31 is based on a production plan to be described later and information input on the touch panel of the molding line 10 (non-defective product information or defective product information), and only a casting ladle is automatically determined to be a non-defective product. Pour the molten metal from. That is, the molten metal is poured from the pouring ladle into the mold gate. The pouring line 30 has a slow cooling process in which the molten metal poured into the mold is gradually cooled (slowly cooled) in the mold and solidified. As a result, a cast product is formed in the mold.

In the open frame line 40, the open frame step, the out-of-frame slow cooling step, the external shot step, and the primary inspection step are executed in this order, and the cast product is taken out from the mold. In the unpacking process, the mold is broken and the cast product is taken out. In the out-of-frame annealing process, the cast product taken out from the mold is gradually cooled. In the external shot process, the foundry sand adhering to the outer surface of the cast product is removed by shot blasting. In the primary inspection process, the quality of the outer surface of the cast product is inspected by the operator's visual inspection.

In the finishing / inspection line 50, a deburring process, an internal shot process, a secondary inspection process, and a milling process are performed in this order. In the deburring process, burrs formed on the cast product are removed. In the internal shot process, the foundry sand 13 adhering to the inner surface of the cast product is removed by shot blasting. In the secondary inspection process, the quality of the cast product is finally inspected by the operator's visual inspection. In the milling process, a predetermined part of the cast product is cut. In the processing line 60, a cast product is processed and completed and shipped.

Next, the production of cast products based on the production plans for the molding line 10, the melting line 20, and the pouring line 30 of the casting equipment having such a configuration will be described. First, a production plan that combines a molding plan and a melting plan is created. As shown in FIG. 4, this production plan is made into tabular data (hereinafter referred to as production plan data). In this production plan data, the molding order number indicates the molding order. The product number indicates the product number of the cast product. The dissolution order number indicates the dissolution order. Charge No. Indicates a unit of molten metal produced in a 3 t melting furnace (electric furnace). That is, the charge No. The number shown in (1) indicates how many times the molten metal is melted in the melting furnace on the production day. Process No. Indicates a unit for discharging hot water from the melting furnace by 1 ton. That is, the process No. The numbers shown in the figure indicate how many times the molten metal is discharged with respect to the molten metal melted at once in the melting furnace. The stock flag is a flag indicating whether or not the mold molded by the molding line 10 is temporarily stored in the three-dimensional warehouse, and indicates that 1 is stored. For example, the data described in the first stage of the production plan data is a molding plan. The first mold in the molding order is for casting a casting product number: DUMMY-1. It is stored in. In addition, the data described in the first stage of the production plan data is as follows. As a melting plan, the molten metal poured into this mold is discharged 14th, and melted for the second time in the melting furnace. It is shown that it is the first to be tapped from.

Next, the production plan data is stored in the database server 71 using the management personal computer 70 as shown in FIG. The database server 71 is accessed from the touch panel 11 installed on the molding line 10 and the touch panel 21 installed on the melting line 20 to obtain production plan data on the production day. By displaying the acquired production plan data on the touch panels 11 and 21, it is set as the production instruction to the operator of each line.

Then, the production plan data on the day of production is transferred to the equipment control device 80, and the operation of various devices constituting each line is automatically controlled based on the production plan data. At this time, in the core storing step of the molding line 10, the operator determines whether the molds (upper mold, lower mold, and core) are acceptable (good or defective), and “good” displayed on the touch panel 12. Alternatively, the determination result is input by operating the “bad” operation button (see FIG. 5). The input determination result is transferred to the equipment control device 80. The input determination result is registered in the database server 71 and associated with the molding serial number. In addition, the input of the determination result to the touch panel 12 is an operation signal of various devices constituting the molding line 10. For this reason, until a determination result is input with the touch panel 12, various apparatuses do not operate and each process maintains a stopped state.

The determination result of whether the mold is a good product or a defective product can be confirmed on the touch panels 21 and 32 installed in the melting line 20 and the pouring line 30. As shown in FIG. 6, when the operator presses the display button, the touch panel 21 installed in the melting line 20 displays information on the molds (up to 10) lined up in the pouring line 30 at that time. The information displayed on the touch panel 21 is a charge number. (Unit of molten metal produced in a 3t melting furnace), treatment no. (Unit for 1 t of hot water discharged from melting furnace), product number, material of molten metal, plan weight (weight of molten metal poured into each mold), and good / bad molds. These pieces of information are displayed in a horizontal row on the display screen of the touch panel 21 and are displayed in the order of the molds arranged in the pouring line 30 from the top down.

From these pieces of information, the 1 t molten metal that is the first molten metal in the melting furnace on the production day, discharged to the treatment ladle for the first time, and transferred to the pouring ladle is lined up in the pouring line 30. It can be seen that each method weight is poured into the first to fourth molds of the mold. Similarly, the 1 t molten metal which is the first molten metal in the melting furnace on the production day and which has been discharged into the treatment ladle for the second time and transferred to the pouring ladle is the mold lined up in the pouring line 30. It can be seen that the weight of each method is poured into the fifth to eighth molds. In addition, the 1 t molten metal that was first melted in the melting furnace on the day of the production, was poured into the treatment ladle and transferred to the pouring ladle for the third time, and the molten metal that was lined up in the pouring line 30 It can be seen that the weight of each method is poured into the ninth and tenth molds. The flow until the molten metal melted in the melting furnace is poured into each mold is shown in FIG. The number of molds that can be poured with 1 ton of molten metal transferred to the pouring ladle is such that the total weight of the molds is less than 1 ton, so that the molten metal remaining in the pouring ladle is reduced as much as possible. It is determined by the production plan. For this reason, even if there is a defective mold, the molten metal of 1t is discharged from the melting furnace to the treatment ladle with the mold included, and the information to transfer the molten metal from the treatment ladle to the pouring ladle is displayed. Has been. Therefore, when there is a defective mold, the molten metal in the pouring ladle remains. The molten metal remaining in the pouring ladle is discharged.

The worker determines the timing of the hot water by looking at the information displayed on the touch panel 21 installed in the melting line 20. If the hot water discharge timing is early, the temperature of the molten metal decreases before the pouring and the molten metal becomes defective. For this reason, when an operator looks at this information, the hot water can be discharged with good timing.

The automatic pouring device 31 is manufactured by the melting line 20 only for the molds that are automatically determined to be non-defective based on the production plan and the information input on the touch panel 12 of the molding line 10 (non-defective product or defective product information). Pour the molten metal. That is, the molten metal is poured from the pouring ladle into the mold gate. The pouring line 30 has a slow cooling process in which the molten metal poured into the mold is gradually cooled (slowly cooled) in the mold and solidified. As a result, a cast product is formed in the mold.

As shown in FIG. 7, the touch panel 32 installed in the pouring line 30 displays information on the molds flowing into the pouring line 30 in an accumulated manner. The information displayed on the touch panel 32 is given to CH (charge No. described above), process (process No. mentioned above), product number, product serial 1 (one cast product cast by one mold). (Product serial number), product serial 2 (product serial number given to the other cast product cast by one mold), good or defective mold, and whether or not the noticed information about the mold is entered Is shown. These pieces of information are displayed in a horizontal row on the display screen of the touch panel 32, and are displayed in the order from the top to the bottom in the order of the molds arranged in the pouring line 30.

The touch panel 32 acquires such information every minute and updates the display when there is an update. Since the operator can recognize the defective mold from these pieces of information, it is possible to prevent the molten metal from being poured into the defective mold. In addition, it is possible to recognize how many molds are poured in a single pouring ladle. In addition, since whether the mold is a non-defective product or a defective product is displayed on the display screen of the touch panel 32 in the order of the molds arranged in the pouring line 30, the operator can easily grasp the defective mold. be able to. Enter the information you noticed for each mold after pouring the melt.

Thus, this casting apparatus inputs whether the mold is a non-defective product or a defective product to the touch panel 12 which is an input device installed in the molding line 10, and is installed in the pouring line 30 based on the input. The automatic pouring device 31 automatically pours only molds that are determined to be good. Further, whether the mold on the pouring line 30 is a non-defective product or a defective product is displayed on the touch panel 32 which is a display device installed in the pouring line 30 based on the input to the touch panel 12. For this reason, the automatic pouring device 31 does not pour the molten metal into the defective mold, and the operator who is in charge of the pouring line 30 uses the automatic pouring apparatus 31 to melt the molten metal because the mold is defective. Recognize that no hot water is poured. Thus, it is possible to prevent the operator from switching the automatic pouring device 31 to manual and pouring the molten metal into a defective mold.

Therefore, the casting equipment of Example 1 can prevent the occurrence of troubles and product defects in the casting process.

The present invention is not limited to the first embodiment described above with reference to the drawings and, for example, the following embodiments are also included in the technical scope of the present invention.
(1) In Example 1, the molten metal of 3t was manufactured in the melting furnace, the hot water was discharged to the treatment ladle 1t at a time, and transferred to the pouring ladle. The capacity is not limited to this.
(2) In Example 1, even when there is a defective mold, the molten metal of 1 t was poured from the melting furnace into the treatment ladle and transferred to the pouring ladle. It is not necessary to discharge the molten metal from the melting furnace to the treatment ladle. In this case, the molten metal remaining in the melting furnace may be added to the molten metal melted in the melting furnace (residual molten metal melting).
(3) In Example 1, the core was stored in the mold, but the core may not be stored in the mold.
(4) Although the three-dimensional warehouse is provided in the first embodiment, the three-dimensional warehouse may not be provided.
(5) The display form of the touch panel is not limited to the form described in the first embodiment.

10 ... Molding line 12 ... Touch panel (input device)
20 ... Melting line 30 ... Pouring line 31 ... Automatic pouring device 32 ... Touch panel (display device)

Claims (3)

A casting facility comprising a molding line for molding a mold, a melting line for producing a molten metal poured into the mold, and a pouring line for pouring the molten metal into the mold,
An input device that is installed in the molding line and inputs whether the mold is a non-defective product or a defective product;
An automatic pouring device that is installed in the pouring line and that automatically pours molten metal only to the mold that is determined to be non-defective, based on an input to the input device;
And a display device that is installed in the pouring line and displays whether the mold on the pouring line is a good product or a defective product based on an input to the input device. Casting equipment. The melting line has a tapping process in which the molten metal melted at one time in a melting furnace is divided into a plurality of times and poured into a ladle.
2. The casting equipment according to claim 1, wherein the display device displays the number of times the molten metal in the ladle is melted at one time in the melting furnace. The casting apparatus according to claim 1 or 2, wherein the display device displays whether the mold is a good product or a defective product in the order in which the mold is arranged in the pouring line.

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