CN112404417A - Full-automatic intelligent casting unit for aluminum piston of diesel engine - Google Patents

Abstract

The invention relates to a full-automatic intelligent casting unit for an aluminum piston of a diesel engine, which comprises a casting host, an automatic pouring system, a pouring seventh shaft structure, a ring-inlaid heating aluminizing robot system, a filter screen system, a blank casting quenching and waste product detecting mechanism, a rapid cooling system, a matched hydraulic system, a pneumatic system, a lubricating system, a protection system, an electrical control system and a die. The invention realizes the full automation of the casting process of the aluminum piston blank of the diesel engine and greatly improves the production efficiency.

Description

Full-automatic intelligent casting unit for aluminum piston of diesel engine

Technical Field

The invention relates to the technical field of machining of mechanical equipment, in particular to a full-automatic intelligent casting unit for an aluminum piston of a diesel engine.

Background

In view of the current situation that labor cost pressure and labor recruitment difficulty are increasing, the automation level of domestic aluminum piston casting enterprises is increasing in recent years, and a considerable part of enterprises have realized automatic actions such as automatic pouring of manipulators/robots, manipulator grabbing of blanks and the like, and have a primary effect on reducing labor intensity, improving efficiency and realizing automation (see fig. 1).

However, in the whole aluminum piston casting process, it is not enough to realize the above automation actions, and there are also processes such as ring-inlaid aluminizing, molten aluminum skimming, ring-inlaid placement, filter screen placement and the like which are difficult to realize automation, and most enterprises still operate manually in these processes, and thus, the full automation of the aluminum piston casting process cannot be realized.

The condition that the monitoring of the domestic aluminum piston casting enterprises on the casting process technological parameters (such as mold temperature, mold water flow and pressure, aluminum water temperature, casting quenching water temperature and the like) generally exists without monitoring or in place, and the product produced under the condition is doped with waste products which do not meet the technological parameters, and the waste products are internal casting defect waste products and cannot be found by a detection means, so that the probability of generating serious product quality accident risks is increased.

Disclosure of Invention

Aiming at the problems of low automation degree, high labor intensity of workers and high casting quality risk in the prior art, the invention provides a full-automatic intelligent casting unit for an aluminum piston of a diesel engine, and the casting unit can realize full automation and reduce the casting quality risk.

The invention is realized by the following technical scheme:

the full-automatic intelligent casting unit for the aluminum piston of the diesel engine comprises a casting host, an automatic pouring system, a ring-inlaid heating aluminizing robot system, a filter screen system, a blank casting quenching and waste product detecting mechanism, a quick cooling system, a matched hydraulic system, a pneumatic system, a lubricating system, a protection system, an electrical control system and a die.

Further, the casting host computer includes the lathe bed and the workstation that verts, the workstation that verts is installed on the lathe bed, it is fixed with big slip table on the workstation to vert, the center core mechanism is installed under the workstation that verts on the bottom surface, the workstation upper surface that verts has external mold mechanism, top mould mechanism and limit core structure, top mould structure spanes external mold structrual installation on the workstation that verts, it verts the hydro-cylinder to be connected with under the workstation to vert.

Further preferably, limit core structural installation is on the workstation that verts, including inside core and outside core, outside core links to each other with outside core slider, inside core links to each other with inside core slider, outside core slider passes through outside core slider connecting rod and links to each other with first limit core hydro-cylinder, inside core slider is stirred the connecting piece through the right angle and is linked to each other with second limit core hydro-cylinder, the below of second limit core hydro-cylinder is equipped with the stopper.

Further preferably, the outer mold mechanism comprises an outer mold oil cylinder support, an inner side outer mold sliding table and an outer side outer mold sliding table are installed on the large sliding table, outer molds are installed on the inner side outer mold sliding table and the outer side outer mold sliding table, an outer mold oil cylinder is installed on the outer mold oil cylinder support, the outer mold oil cylinder is connected with the inner side outer mold sliding table and the outer side outer mold sliding table through outer mold guide rods, the outer mold guide rods are fixed on the outer mold guide rod support, and the outer mold guide rod support is installed on the large sliding table.

Further preferably, the top die structure comprises a top die upper guide frame and a top die lower guide frame, the top die upper guide frame and the top die lower guide frame are fixedly installed on a tilting workbench, top die oil cylinder supports are installed on the top die upper guide frame and the top die lower guide frame, a top die oil cylinder is fixed to the upper portion of the top die mechanism through the top die oil cylinder supports, top die horizontal supports are arranged between the top die oil cylinder supports, the top die horizontal supports are connected with the top die oil cylinder and the top die upper guide rod, a top die horizontal cylinder is installed on one side of the top die horizontal supports, the top die horizontal cylinder is connected with a top die front support through the top die horizontal guide rod, a top die pull rod is installed below the top die front support, and a top die is installed on the lower portion of the top die pull rod.

Further preferably, well core mechanism includes well core hydro-cylinder mounting panel, well core hydro-cylinder mounting panel is fixed in the workstation bottom of verting, well core hydro-cylinder is fixed below well core hydro-cylinder mounting panel and is linked to each other with well core bracket, even there is the bracket round pin axle between the well core bracket, well core bracket installs on well core bracket mounting panel, be equipped with well core guide bar on well core bracket mounting panel and the well core hydro-cylinder mounting panel, the well core bracket mounting panel of telling installs the travel switch lance, be equipped with the travel switch ram on the travel switch lance, the opposite side of travel switch ram is equipped with the travel switch support, install travel switch on the travel switch support. And a piston rod of the central core oil cylinder is fixed at the bottom of the central core bracket mounting plate through a locking nut.

Further, the automatic pouring system and the pouring seventh axis structure comprise a pouring seventh axis structure and a pouring ABB robot, the pouring seventh axis structure is installed on the pouring ABB robot, and the pouring ABB robot is fixed on the robot base. The pouring seventh shaft structure comprises a motor reducer case, a transmission shaft shell and a gear case, the transmission shaft shell is connected with the motor reducer case and the gear case, a seventh shaft motor is installed in the motor reducer case and directly connected with a seventh shaft reducer, the motor and reducer combination is connected with a first transmission gear through a coupler, a second transmission gear is arranged in the gear case, the first transmission gear and the second transmission gear are meshed with a rack, the second transmission gear is fixed on the ladle transmission shaft, a ladle mounting plate is arranged on the ladle transmission shaft, and a ladle is installed on the ladle mounting plate. The motor and the reducer are combined and driven by a gear and a rack, so that the casting ladle can be driven to turn back and forth, and the actions of blank casting and aluminum liquid taking are completed.

Furthermore, the ring-inlaying heating aluminizing robot system comprises a ring-inlaying heating mechanism, a ring-inlaying aluminizing mechanism and a ring-inlaying pick-up robot system.

Further preferred, ring inlaying heating mechanism includes ring inlaying heating mechanism base, be equipped with the ring inlaying workstation on the ring inlaying heating mechanism base, be fixed with the ring inlaying heater on the ring inlaying workstation, install the ring inlaying guide post in the ring inlaying heater, be equipped with the ring inlaying delivery board below the ring inlaying workstation, be equipped with the fluting on the ring inlaying delivery board, the fluting is located the ring inlaying heater under, the lower part of ring inlaying delivery board is equipped with linear guide, ring inlaying delivery board and linear guide sliding connection, be equipped with the promotion cylinder between the linear guide, the promotion cylinder passes through the cylinder connecting block and links to each other with the ring inlaying delivery board, be equipped with the ring inlaying slide between the support pillar, when the ring inlaying delivery board is released, the ring inlaying slide is located the grooved below of ring inlaying delivery board.

Further preferably, an aluminum skin scraper blade fixing frame is arranged on one side of the base of the ring inlaying heating mechanism, and an aluminum skin scraper blade is arranged on the aluminum skin scraper blade fixing frame.

Further, ring mechanism base is oozed including to inlay aluminizing mechanism, be equipped with the linear motion unit mounting panel on the ring mechanism base oozes, locate first linear motion unit and second linear motion unit on the linear motion unit mounting panel, linear motion unit mounting panel sliding connection is on horizontal linear guide, the linear motion unit mounting panel links to each other with the horizontal migration cylinder, first linear motion unit and second linear motion unit sliding connection have the couple support, the bottom on the couple support is connected with the ring couple.

Further preferably, a vibrator is fixed to the hook support.

Further, an inlaying ring picking robot system comprises a robot base, an inlaying ring picking robot and an ABB robot are installed on the robot base, the inlaying ring picking robot and the ABB robot are connected with a clamping jaw mounting plate through connecting blocks, and an inlaying ring clamping jaw and an aluminum skin scraper blade clamping jaw are installed on the clamping jaw mounting plate.

Furthermore, the filter screen system comprises an automatic part taking hand, a filter screen clamping jaw mechanism and a filter screen automatic shearing mechanism.

Further preferably, the automatic filter screen shearing mechanism comprises a filter screen shearing and fixing support, a filter screen storage box, a filter screen conveying mechanism and a filter screen cutter, the middle part of the filter screen shearing and fixing bracket is provided with a filter screen storage box, the top of the filter screen storage box is provided with a filter screen outlet, the upper part of the filter screen storage box is provided with a filter screen conveying mechanism which comprises an installation plate, the mounting plate is provided with a directional guide rail and a filter screen input groove, the filter screen input groove is upwards provided with a conveying cylinder, the conveying cylinder is upwards provided with a filter screen clamping conveying block, a conveying clamping cylinder is fixed on the filter screen clamping conveying block, the filter screen clamping conveying block is upwards provided with a shearing clamping block which is provided with a shearing clamping cylinder, the shearing clamping cylinder is upwards provided with a shearing cylinder, and a filter screen cutter is arranged inside the shearing cylinder. The filter screen conveying mechanism drives the filter screen to move, after a certain length is exposed, the filter screen is fixed by the clamping blocks, and the cutter performs shearing action to complete automatic shearing of the filter screen.

Further preferred, get a hand and filter screen clamping jaw mechanism automatically and include the robot base, install ABB industrial robot on the robot base, ABB industrial robot passes through the connecting rod and links to each other with the clamping jaw mounting panel, install on the clamping jaw mounting panel and get filter screen under the cylinder, the clamping jaw mounting panel has blank clamping jaw and filter screen clamping jaw, the blank clamping jaw links to each other with blank clamping jaw cylinder, the filter screen clamping jaw links to each other with filter screen clamping jaw cylinder. The combined mechanism of the blank clamping jaw and the filter screen clamping jaw is fixed on a robot, after piston casting is completed, a mold is opened, the robot drives the blank clamping jaw to clamp and place a piston blank into a casting quenching tank, then the piston blank is moved to the position above the automatic filter screen shearing mechanism, the filter screen clamping jaw clamps and clamps a sheared filter screen, and the sheared filter screen is placed into a piston mold of the host machine.

Further, the blank is cast and is quenched and waste product is examined mechanism includes water tank fixed bolster and bin fixed bolster, it casts the quenching case to be equipped with the blank on the water tank fixed bolster the blank is cast the quenching case and is linked to each other with the slide upper end, the slide end links to each other with the blank bin of bin fixed bolster, one side that the quenching case was cast to the blank is equipped with blank propelling movement cylinder, be connected with the slider on the piston rod of blank propelling movement cylinder, be fixed with the blank push pedal on the slider, the slider slides along the guide bar, be equipped with the waste product mouth in the middle of the slide, slide one side is equipped with the waste product and opens and shuts the cylinder, the waste product opens and shuts the cylinder and passes through the baffle connecting rod and links to each other with waste product mouth baffle, waste product mouth baffle lid. And a waste slideway is arranged below the waste port, and the bottom of the waste slideway is connected with a waste vehicle.

Furthermore, the rapid cooling system comprises a water cooling machine, a cooling cabinet, a flowmeter and a cooling pipeline. The cooling system of every host computer includes 16 ways of cluster water, and the water-cooling machine is responsible for providing high-pressure cooling water for cooling system, and the flowmeter is installed in the cooling cabinet, is responsible for controlling the flow of each way cooling water, and the cooling water passes through cooling line entering mould, makes the blank cool off fast.

The invention has the beneficial effects that: the invention realizes the full automation of the casting process of the aluminum piston blank of the diesel engine and greatly improves the production efficiency; the automatic production mode reduces the number of operators operating 2 devices from 2 to 1 for inspecting a plurality of devices, and reduces the labor intensity of the operators to the maximum extent; the waste detection, identification and isolation system of the casting unit monitors the process parameters of the whole casting process, so that blanks which cannot meet the requirements of the process parameters are identified and isolated, the casting quality high risk state is greatly reduced, and the defect-free rate of delivered products is improved.

Drawings

FIG. 1 is a schematic layout of a prior art aluminum piston casting system of the present invention;

FIG. 2 is a schematic layout of the fully automated aluminum piston casting system of the present invention;

FIG. 3 is a schematic structural view of a foundry machine host of the present invention;

FIG. 4 is a schematic structural diagram of an outer mold mechanism of a main machine of a casting machine in the invention;

FIG. 5 is a schematic structural diagram of a top die mechanism of a main frame of a casting machine according to the present invention;

FIG. 6 is a schematic structural view of a core mechanism of a main frame of a casting machine according to the present invention;

FIG. 7 is a front view of the insert heating mechanism of the present invention;

FIG. 8 is a side view of the insert heating mechanism of the present invention;

FIG. 9 is a front view of the insert ring aluminizing system of the present invention;

FIG. 10 is a side view of the insert aluminizing system of the present invention;

FIG. 11 is a schematic structural view of an insert picking robot system according to the present invention;

FIG. 12 is a schematic diagram of the construction of the automatic casting system of the present invention;

FIG. 13 is a front view of a cast seventh axial structure of the present invention;

FIG. 14 is a cross-sectional view of a cast seventh axial structure of the present invention;

FIG. 15 is a schematic structural view of a cast iron extraction and screen system of the present invention;

FIG. 16 is a front view of the automatic cutting structure of the filter net according to the present invention;

FIG. 17 is a side view of the automatic cutting structure of the filter screen of the present invention;

FIG. 18 is a front view of the blank casting and scrap detection system of the present invention;

FIG. 19 is a top view of the blank casting and scrap detection system of the present invention;

FIG. 20 is a schematic structural diagram of a blank casting quenching and waste product detecting system and a workpiece taking casting quenching and lower filter screen ABB robot in a filter screen system according to the present invention;

FIG. 21 is a process flow diagram of an automatic cycle process for piston casting of the present invention;

FIG. 22 is a schematic structural view of a side core mechanism of a main frame of a casting machine according to the present invention;

shown in the figure:

1. a lathe bed, 2, a tilting workbench, 3, an outer die mechanism, 4, a top die mechanism, 5, a central core mechanism, 6, a tilting cylinder, 7, an outer die cylinder, 8, an outer die cylinder bracket, 9, an outer die guide rod, 10, an outer die guide rod bracket, 11, a large sliding table, 12, an inner outer die sliding table, 13, an outer die sliding table, 14, a first side core cylinder, 15, a first travel switch, 16, a top die upper and lower guide frame, 17, a top die horizontal cylinder, 18, a top die horizontal guide rod connecting plate, 19, a top die horizontal bracket, 20, a top die cylinder bracket, 21, a top die cylinder, 22, a proximity switch bracket, 23, a top die horizontal guide rod, 24, a top die front bracket, 25, a top die pull rod, 26, a top die upper and lower guide rod, 27, a central core bracket, 28, a central core bracket mounting plate, 29, a central core guide rod, 30, a central core cylinder mounting plate, 31, a central core cylinder, 32. bracket pin shaft, 33, locknut, 34, travel switch striker, 35, second travel switch, 36, insert guide post, 37, insert heater, 38, linear guide, 39, aluminum skin scraper, 40, insert heating mechanism base, 41, cylinder connecting block, 42, push-out cylinder, 43, insert output plate, 44, insert slideway, 45, first linear motion unit, 46, second linear motion unit, 47, horizontal linear guide, 48, ring infiltration mechanism base, 49, horizontal moving cylinder, 50, linear motion unit mounting plate, 51, vibrator, 52, hook bracket, 53, insert hook, 54, aluminizing furnace, 55, insert taking piece and placing ABB robot, 56, connecting block, 57, clamping jaw mounting plate, 58, insert clamping jaw, 59, aluminum skin scraper clamping jaw, 60, first robot base, 61, casting seventh shaft mechanism, 62, ABB robot, 63. a second robot base, 64, a motor, a speed reducer case, 65, a seventh shaft connecting rod, 66, a gear box, 67, a ladle, 68, an aluminum liquid probe, 69, a motor, a speed reducer combination, 70, a coupler, 71, a first transmission gear, 72, a rack, 73, a second transmission gear, 74, a ladle transmission shaft, 75, a ladle mounting plate, 76, a piece taking, casting and quenching and lower filter screen ABB robot, 77, a blank casting and quenching water tank and a slideway, 78, a waste vehicle, 79, a filter screen automatic shearing mechanism, 80, a filter screen cutter, 81, a filter screen clamping and conveying block, 82, a filter screen storage tank, 83, a filter screen shearing and fixing support, 84, a shearing cylinder, 85, a shearing and clamping cylinder, 86, a conveying and clamping cylinder, 87, a conveying cylinder, 88, a filter screen input groove, 89, a blank pushing cylinder, 90, a water tank fixing support, 91, a sliding block, 92 and a guide rod, 93. the device comprises a waste opening and closing cylinder, 94, a slide way, 95, a blank storage box, 96, a storage box fixing support, 97, a blank casting quenching water box, 98, a waste marking spray gun, 99, a blank push plate, 100, a waste opening baffle, 101, a baffle connecting rod, 102, a third robot base, 103, a connecting rod, 104, a filter screen taking upper cylinder, 105, a filter screen clamping jaw cylinder, 106, a filter screen clamping jaw, 107, a blank clamping jaw cylinder, 108, a blank clamping jaw, 109, a side core structure, 110, a side core sliding block connecting rod, 111, an outer side core sliding block, 112, an outer side core, 113, an inner side core sliding block, 114, a right-angle connecting piece, 115, a second side core oil cylinder, 116, a limiting block, 117 and an inner side core.

Detailed Description

In order to clearly illustrate the technical features of the present solution, the present solution is explained below by way of specific embodiments.

Referring to fig. 2, the full-automatic intelligent casting unit for the aluminum piston of the diesel engine comprises a casting host, an automatic pouring system, a ring insert heating aluminizing robot system, a filter screen system, a blank casting quenching and waste product detecting mechanism, a rapid cooling system, a hydraulic system, a pneumatic system, a lubricating system, a protection system, an electrical control system and a die which are matched with each other.

Referring to fig. 3, the casting host computer includes the lathe bed and the workstation that verts, the workstation that verts is located the lathe bed, install well core mechanism 5 under the workstation that verts on the bottom surface, the workstation upper surface that verts has external mold mechanism and a mould mechanism, the mould structure that pushes up stretches over external mold structrual installation on the workstation that verts, it is connected with the hydro-cylinder 6 that verts to vert under the workstation.

Referring to fig. 4, outer die mechanism is including installing big slip table 11 and outer mould hydro-cylinder support 8 on the workstation that verts, install inboard outer mould slip table 12 and outside outer mould slip table 13 on the big slip table 11, install the external mold on inboard outer mould slip table 12 and the outside outer mould slip table 13, install outer mould hydro-cylinder 7 on the outer mould hydro-cylinder support 8, outer mould hydro-cylinder 7 links to each other with inboard outer mould slip table 12 and outside outer mould slip table 13 through outer mould guide bar 9, outer mould guide bar 9 is fixed on outer mould guide bar support 10, outer mould guide bar support 10 is installed on big slip table 11, be equipped with first travel switch 15 in the outer die mechanism.

The working principle of the outer die mechanism is as follows: the outer mold oil cylinder 7 is connected with the outer mold sliding table through an outer mold guide rod 9 to drive the inner outer mold sliding table 12 and the outer mold sliding table 13 to reciprocate on the large sliding table 11 to complete mold opening and closing actions of the mold, and the outer mold guide rod support 10 provides a supporting and guiding function for the outer mold guide rod 9.

Referring to fig. 5, the top die structure comprises a top die upper guide frame 16 and a top die lower guide frame 16, the top die upper guide frame 16 and the top die lower guide frame 16 are fixedly installed on a tilting workbench, top die oil cylinder supports 20 are installed on the top die upper guide frame 16 and the top die lower guide frame 16, a top die oil cylinder 21 is fixed on the upper portion of a top die mechanism through the top die oil cylinder supports 20, top die horizontal supports 19 are arranged between the top die oil cylinder supports 20, the top die horizontal supports 19 are connected with the top die oil cylinder 21 and top die upper guide rods 26, a top die horizontal air cylinder 17 is installed on one side of the top die horizontal support 19, the top die horizontal air cylinder 17 is connected with a top die front support 24 through top die horizontal guide rods 23, the top die horizontal guide rods 23 are fixed on a top die horizontal guide rod connecting plate 18, a top die pull rod 25 is installed below the top die front support 24, and a top die is installed. And a proximity switch is arranged on the top die mechanism and is fixed on a proximity switch bracket 22.

The working principle of the top die mechanism is as follows: the top die horizontal support 19 is connected with a top die oil cylinder 21 and a top die upper and lower guide rod 26, and the top die oil cylinder 21 drives the top die horizontal support 19 to move up and down. The top die front bracket 24 is connected with a top die horizontal guide rod 23 and is driven by a top die horizontal cylinder 17 to reciprocate in the horizontal direction. The lower part of the top die pull rod 25 is provided with a top die, and the top die can move up and down, left and right along with the top die front bracket 24 to complete the die opening and closing action of the top die.

Referring to fig. 6, well core mechanism 5 includes well core cylinder mounting panel 30, well core cylinder mounting panel 30 is fixed in the workstation bottom of verting, well core cylinder 31 is fixed and is linked to each other with well core bracket 27 below well core cylinder mounting panel 30, even there is bracket round pin axle 32 between well core bracket 27, well core bracket 27 is installed on well core bracket mounting panel 28, be equipped with well core guide bar 29 on well core bracket mounting panel 28 and the well core cylinder mounting panel 30, well core bracket mounting panel 28 of telling installs travel switch lance 34, be equipped with the travel switch ram on the travel switch ram 34, the opposite face of travel switch ram 34 is equipped with the travel switch support, install second travel switch 35 on the travel switch support. The piston rod of the central core oil cylinder 31 is fixed at the bottom of the central core bracket mounting plate 28 through a locking nut 33.

The working principle of the central core mechanism 5 is as follows: the central core oil cylinder 31 drives the central core bracket 27 to move up and down along a guide mechanism consisting of the central core bracket mounting plate 28, the central core oil cylinder mounting plate 30 and the central core guide rod 29, and the travel switch impact rod 34 moves up and down along with the central core bracket mounting plate 28 and contacts with the travel switch bracket to trigger an in-place signal.

Referring to fig. 22, limit core structure (109) is installed on the workstation that verts, including inside core 117 and outside core 112, outside core 112 links to each other with outside core slider 111, inside core 117 links to each other with inside core slider 113, outside core slider 111 links to each other with first limit core hydro-cylinder 14 through outside core slider connecting rod (110), inside core slider 113 links to each other with second limit core hydro-cylinder 115 through right angle toggle connecting piece 114, the below of second limit core hydro-cylinder 115 is equipped with stopper 116.

The working principle of the side core mechanism is as follows: the first side core cylinder 14 moves left and right to drive the outer side core slide block 111 and the outer side core to move left and right, the second side core cylinder 115 moves up and down to drive the right-angle toggle connecting piece 114 to toggle so as to drive the inner side core slide block 113 and the inner side core 117 to move left and right, and then the inner and outer side cores 112 are approached and kept away.

Referring to fig. 12-14, the automatic pouring system and pouring seventh axis structure includes a pouring seventh axis structure mounted on a pouring ABB robot 62 and a pouring ABB robot 62, the pouring ABB robot 62 being fixed to a second robot base 63. The pouring seventh shaft structure comprises a motor reducer case, a transmission shaft shell and a gear case 66, the transmission shaft shell is connected with the motor reducer case and the gear case 66, a seventh shaft motor is installed in the motor reducer case and directly connected with a seventh shaft reducer, the motor and reducer combination 69 is connected with a first transmission gear 71 through a coupler 70, a second transmission gear 71 is arranged in the gear case 66, the first transmission gear 71 and the second transmission gear 71 are meshed with a rack 72, the second transmission gear 71 is fixed on a ladle transmission shaft 74, a ladle mounting plate 75 is arranged on the ladle transmission shaft 74, and a ladle 67 is mounted on the ladle mounting plate 75. And a liquid probe 68 is arranged on the pouring seventh shaft structure. The motor and the reducer combination are driven by the gear rack 72, so that the casting ladle 67 can be driven to turn back and forth, and the actions of blank casting and aluminum liquid taking are completed.

The working principle of the pouring seventh shaft structure is as follows: the seventh shaft motor transmits mechanical energy to the right-angle gear box 66 through the seventh shaft speed reducer and the transmission rod, the right-angle gear box 66 is connected with the ladle 67, and the ladle 67 is driven to rotate to complete the actions of scooping up the molten aluminum and pouring the molten aluminum into the mold when the seventh shaft motor rotates. The whole pouring seventh shaft structure reaches the molten aluminum holding furnace and the pouring cup of the casting main machine die under the driving of the ABB six-shaft industrial robot.

Referring to fig. 7 and 8, the insert ring heating aluminizing robot system comprises an insert ring heating mechanism, an insert ring aluminizing mechanism and an insert ring picking robot system. Inlay circle heating mechanism including inlaying circle heating mechanism base 40, be equipped with the inlay circle workstation on the inlay circle heating mechanism base 40, be fixed with inlay circle heater 37 on the inlay circle workstation, install inlay circle guide post 36 in the inlay circle heater 37, be equipped with inlay circle output plate 43 below the inlay circle workstation, be equipped with the fluting on the inlay circle output plate 43, the fluting is located inlay circle heater 37 under, the lower part of inlay circle output plate 43 is equipped with linear guide 38, inlay circle output plate 43 and linear guide 38 sliding connection, be equipped with the promotion cylinder between the linear guide 38, the promotion cylinder passes through cylinder connecting block 41 and links to each other with inlay circle output plate 43, be equipped with inlay circle slide 44 between the support pillar, when inlaying circle output plate 43 and being released, inlay circle slide 44 and be located the grooved below of inlay circle output plate 43. An aluminum sheet scraper 39 fixing frame is arranged on one side of the ring embedding heating mechanism base 40, and an aluminum sheet scraper 39 is arranged on the aluminum sheet scraper 39 fixing frame.

The working principle of the ring inlaying heating mechanism is as follows: the insert heater 37 is fixed to the insert table, and can set the heating temperature and automatically control the heating temperature. The insert is heated by placing the insert guide post 36 inside the insert heater 37. The heated insert falls into the slot on the insert output plate 43, and the insert output plate 43 is pushed by the push cylinder to output the insert to wait for the insert robot to take the insert.

Referring to fig. 9 and 10, the insert ring aluminizing mechanism comprises an insert ring mechanism base 48, a linear motion unit mounting plate 50 is arranged on the insert ring mechanism base 48, a first linear motion unit 45 and a second linear motion unit 46 are arranged on the linear motion unit mounting plate 50, the linear motion unit mounting plate 50 is connected to a horizontal linear guide rail 47 in a sliding mode, the linear motion unit mounting plate 50 is connected with a horizontal moving cylinder 49, the first linear motion unit 45 and the second linear motion unit 46 are connected with a hook support 52 in a sliding mode, and an insert ring hook 53 is connected to the bottom of the hook support 52. A vibrator 51 is fixed to the hanger bracket 52.

The working principle of the ring-inserting aluminizing mechanism is as follows: the horizontal moving cylinder 49 pushes the first linear moving unit 45 and the second linear moving unit 46 to move outwards, so that the insert ring is arranged on the upper part of the aluminum liquid with the oxide skin scraped off, and the first linear moving unit 45 and the second linear moving unit 46 drive the insert ring to move downwards, so that the insert ring is completely immersed in the aluminum liquid in the aluminizing furnace 54. Then the vibrator 51 starts to vibrate to make the insert ring vibrate in the aluminum liquid so as to meet the requirements of the insert ring aluminizing process. After the aluminizing is finished, the aluminum liquid is exposed out of the insert ring, and the insert ring is taken away by the insert ring taking robot and placed into the mold.

Referring to fig. 11, the ring-inlaying and piece-taking robot system comprises a first robot base 60, wherein a ring-inlaying and piece-taking and ABB-placing robot 55 is mounted on the first robot base 60, the ring-inlaying and piece-placing ABB-placing robot 55 is connected with a clamping jaw mounting plate 57 through a connecting block 56, and an inlaying clamping jaw 58 and an aluminum skin scraper clamping jaw 59 are mounted on the clamping jaw mounting plate 57.

The working principle of the ring inlaying and piece taking robot system is as follows: the ring-inlaying taking and placing ABB robot 55 clamps the inlaying ring by fingers through the inlaying ring clamping jaws 58 for transferring, clamps the inlaying ring pushed out by the inlaying ring heating mechanism by the inlaying ring clamping jaws 58, and then places the inlaying ring on a hook in the aluminizing mechanism; in the ring-inlaying aluminizing mechanism, a hook is fixed on two linear motion unit mounting plates 50, the two linear motion units respectively drive two inlaying rings to move downwards so that the inlaying rings are immersed in molten aluminum, and after ring-inlaying aluminizing is completed, a robot clamps the inlaying rings and puts the inlaying rings into a piston mold of a host machine. The scraper blade clamping jaw clamps the aluminum sheet scraper 39 through the clamping jaw fingers to scrape off oxide skin on the upper surface of the aluminum liquid in the insert ring aluminizing furnace 54, so that the oxide skin is prevented from being adhered to the surface of the insert ring in the process of putting the insert ring into the aluminum liquid, and the requirements of the insert ring aluminizing process are met.

Referring to fig. 15-17, the filter screen system includes an automatic pick-up hand and filter screen clamping jaw 106 mechanism and a filter screen automatic shearing mechanism 79. The automatic filter screen shearing mechanism 79 comprises a filter screen shearing fixing support 83, a filter screen storage box 82, a filter screen conveying mechanism and a filter screen cutter 80, the middle of the filter screen shearing fixing support 83 is provided with the filter screen storage box 82, the top of the filter screen storage box 82 is provided with a filter screen outlet, the upper part of the filter screen storage box 82 is provided with the filter screen conveying mechanism, the filter screen conveying mechanism comprises a mounting plate, the mounting plate is provided with a directional guide rail and a filter screen input groove 88, the filter screen input groove 88 is upwards provided with a conveying cylinder 87, the conveying cylinder 87 is upwards provided with a filter screen clamping conveying block 81, the filter screen clamping conveying block 81 is fixed with a conveying clamping cylinder 86, the filter screen clamping conveying block 81 is upwards provided with a shearing clamping block, the shearing clamping cylinder 85 is arranged on the shearing clamping block, and the shearing clamping cylinder 85 is upwards, the inside of the shearing cylinder 84 is provided with a filter screen cutter 80. The filter screen conveying mechanism drives the filter screen to move, after a certain length is exposed, the filter screen is fixed by the clamping blocks, and the cutter performs shearing action to complete automatic shearing of the filter screen.

Wherein the filter screen lapping is placed in the filter screen storage box, the filter screen passes through filter screen input groove 88 from the exit on filter screen storage box 82 upper portion and gets into filter screen shearing part, it is tight to press from both sides by filter screen clamp transport block 81, carry cylinder 87 to drive the filter screen through the filter screen and carry and press from both sides tight piece rebound, the output filter screen, after the filter screen exposes the certain length in top, filter screen shearing clamping cylinder 85 drives and presss from both sides tight piece clamp tight filter screen, filter screen clamping jaw 106 mechanism moves to the filter screen top afterwards, press from both sides tight filter screen, filter screen cutter 80 passes through the cylinder and drives the shearing filter screen, accomplish the transport and the shearing process of.

See 20, automatic get a hand and filter screen clamping jaw 106 mechanism includes third robot base 102, install on the third robot base 102 and get a cast and quench and filter screen ABB robot 76 down, get a cast and quench and filter screen ABB robot 76 down and link to each other with clamping jaw mounting panel 57 through connecting rod 103, install on the clamping jaw mounting panel 57 and get filter screen under and go up cylinder 104, clamping jaw mounting panel 57 has blank clamping jaw (108) and filter screen clamping jaw 106, blank clamping jaw (108) link to each other with blank clamping jaw cylinder 107, filter screen clamping jaw 106 links to each other with filter screen clamping jaw cylinder 105. The combined mechanism of the blank clamping jaw (108) and the filter screen clamping jaw 106 is fixed on a robot, after piston casting is completed, a mold is opened, the robot drives the blank clamping jaw (108) to clamp a piston blank and place the piston blank into a casting quenching tank, then the piston blank is moved to the position above the automatic filter screen shearing mechanism 79, and the filter screen clamping jaw 106 clamps a sheared filter screen and places the filter screen into a piston mold of a host machine.

Referring to fig. 18 to 19, the blank casting quenching and reject detecting mechanism includes a water tank fixing bracket 90 and a storage tank fixing bracket 96, a blank casting quenching water tank 97 is arranged on the water tank fixing bracket 90, the blank casting quenching water tank 97 is connected with the upper end of the slideway 94, the tail end of the slide way 94 is connected with a blank storage box 95 of a storage box fixing bracket 96, one side of the blank cast quenching water box 97 is provided with a blank pushing cylinder 89, a piston rod of the blank pushing cylinder 89 is connected with a slide block 91, a blank push plate 99 is fixed on the slide block 91, the slide block 91 slides along the guide rod 92, a waste product port is arranged in the middle of the slide way 94, a waste product opening and closing cylinder is arranged on one side of the slide way 94, the waste opening and closing cylinder is connected with a waste opening baffle 100 through a baffle connecting rod 101, the waste opening baffle 100 covers the waste opening, and a waste marking spray gun 98 is arranged on one side of the slide way 94. A waste slide way is arranged below the waste opening, and the bottom of the waste slide way is connected with a waste vehicle 78.

The working principle of the blank casting quenching and waste product detecting mechanism is as follows: a filter screen robot in the filter screen system utilizes a workpiece taking clamping jaw to clamp a blank to carry out cast quenching in a cast quenching water tank, the blank is placed on the upper plane of a slide way 94 after a certain time, and then a blank pushing cylinder 89 drives a slide block 91 and a blank pushing plate 99 to push the blank forwards so that the blank slides into a blank storage box 95 at the tail end of the slide way 94 from the upper end of the slide way 94. Various technological parameters in the blank casting process are set in the casting unit system, such as the temperature and the flow of cooling water of a mold, cooling time, insert ring preheating temperature, insert ring aluminizing time, blank casting and quenching time and the like. The waste product detecting system can count various process parameters in the production process of each blank and analyze and compare the process parameters with set parameters, if unqualified products exist, the detecting system can give a signal to the waste product marking spray gun 98, the unqualified blanks are sprayed with pigment for marking, meanwhile, the waste product opening and closing air cylinder 93 obtains a signal to drive the waste product opening baffle 100 to be opened, the waste products are pushed into the slide way 94 and then fall into the waste product vehicle 78, and the detection of the waste products is completed.

The rapid cooling system comprises a water cooler, a cooling cabinet, a flowmeter and a cooling pipeline. The cooling system of every host computer includes 16 ways of cluster water, and the water-cooling machine is responsible for providing high-pressure cooling water for cooling system, and the flowmeter is installed in the cooling cabinet, is responsible for controlling the flow of each way cooling water, and the cooling water passes through cooling line entering mould, makes the blank cool off fast.

A process flow for preparing the aluminum piston of the diesel engine by using the full-automatic intelligent casting unit is shown in fig. 21, wherein the cyclic process takes a mold closing state as an initial state.

Of course, the above description is not limited to the above examples, and the undescribed technical features of the present invention can be implemented by or using the prior art, and will not be described herein again; the above embodiments and drawings are only for illustrating the technical solutions of the present invention and not for limiting the present invention, and the present invention has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that changes, modifications, additions or substitutions within the spirit and scope of the present invention may be made by those skilled in the art without departing from the spirit of the present invention, and shall also fall within the scope of the claims of the present invention.

Claims (10)

1. Full-automatic intelligent casting unit of diesel engine aluminium piston, its characterized in that: the automatic casting machine comprises a casting host machine, an automatic casting system, a seventh pouring shaft structure, an insert ring heating aluminizing robot system, a filter screen system, a blank casting and quenching and waste product detecting mechanism, a quick cooling system, a hydraulic system, a pneumatic system, a lubricating system, a protection system, an electrical control system and a die which are matched with each other.

2. The full-automatic intelligent casting unit for the aluminum piston of the diesel engine as recited in claim 1, wherein: the casting host computer includes lathe bed (1) and workstation (2) verts, workstation (2) verts is located lathe bed (1), install well core mechanism (5) on the bottom surface under workstation (2) verts, surface mounting has external mold mechanism (3) and top mould mechanism (4) on workstation (2) verts, the top mould structure spanes the external mold structrual installation on workstation (2) verts, it is connected with hydro-cylinder (6) verts to vert workstation (2) down.

3. The full-automatic intelligent casting unit for the aluminum piston of the diesel engine as recited in claim 2, wherein:

the outer die mechanism (3) comprises a large sliding table (11) and an outer die oil cylinder support (8) which are arranged on a tilting workbench (2), wherein an inner side outer die sliding table (12) and an outer side outer die sliding table (13) are arranged on the large sliding table (11), outer dies are arranged on the inner side outer die sliding table (12) and the outer side outer die sliding table (13), an outer die oil cylinder (7) is arranged on the outer die oil cylinder support (8), the outer die oil cylinder (7) is connected with the inner side outer die sliding table (12) and the outer side outer die sliding table (13) through an outer die guide rod (9), the outer die guide rod (9) is fixed on the outer die guide rod support (10), the outer die guide rod support (10) is arranged on the large sliding table (11), and a first travel switch (14) is arranged on the outer die mechanism;

the side core structure (109) is installed on the tilting workbench (2) and comprises an inner side core (117) and an outer side core (112), the outer side core (112) is connected with an outer side core sliding block (111), the inner side core (117) is connected with an inner side core sliding block (113), the outer side core sliding block (111) is connected with a first side core oil cylinder (14) through an outer side core sliding block connecting rod (110), the inner side core sliding block (113) is connected with a second side core oil cylinder (115) through a right-angle toggle connecting piece (114), and a limiting block (116) is arranged below the second side core oil cylinder (115);

the top die structure comprises a top die upper guide frame and a top die lower guide frame (16), the top die upper guide frame and the top die lower guide frame (16) are fixedly installed on a tilting workbench (2), a top die oil cylinder support (20) is installed on the top die upper guide frame and the top die lower guide frame (16), a top die oil cylinder (21) is fixed on the upper portion of a top die mechanism (4) through the top die oil cylinder support (20), a top die horizontal support (19) is arranged between the top die oil cylinder supports (20), the top die horizontal support (19) is connected with the top die oil cylinder (21) and a top die upper guide rod and a top die lower guide rod (26), a top die horizontal cylinder (17) is installed on one side of the top die horizontal support (19), the top die horizontal cylinder (17) is connected with a top die front support (24) through a top die horizontal guide rod (23), the top die horizontal guide rod (23) is fixed on the top die horizontal guide rod (18), and a top die pull rod (25) is installed below the top die front support, the lower part of the top die pull rod (25) is provided with a top die;

a proximity switch is arranged on the top die mechanism (4), and the proximity switch is fixed on a proximity switch bracket (22);

well core mechanism (5) are including well core hydro-cylinder mounting panel (30), well core hydro-cylinder mounting panel (30) are fixed in tilting workstation (2) bottom, well core hydro-cylinder (31) are fixed and are linked to each other with well core bracket (27) below well core hydro-cylinder mounting panel (30), even there is bracket round pin axle (32) between well core bracket (27), well core bracket (27) are installed on well core bracket mounting panel (28), be equipped with well core guide bar (29) on well core bracket mounting panel (28) and well core hydro-cylinder mounting panel (30), the well core bracket mounting panel of telling (28) install travel switch striker bar (34), be equipped with travel switch striker bar on travel switch striker bar (34), the opposite side of travel switch striker bar (34) is equipped with the travel switch support, install second travel switch (35) on the travel switch support, the piston rod of well core hydro-cylinder (31) passes through lock nut (33) to be fixed at well core bracket mounting panel (28) A bottom portion.

4. The full-automatic intelligent casting unit for the aluminum piston of the diesel engine as recited in claim 1, wherein: the automatic pouring system and pouring seventh axis structure includes a pouring seventh axis structure and a pouring ABB robot (62).

5. The full-automatic intelligent diesel engine aluminum piston casting unit according to claim 4, characterized in that: the pouring seventh shaft structure is arranged on a pouring ABB robot (62), the pouring ABB robot (62) is fixed on a second robot base (63), the pouring seventh shaft structure comprises a motor, a speed reducer case (64), a transmission shaft shell and a gear box (66), the transmission shaft shell is connected with the motor speed reducer case and the gear box (66), a seventh shaft motor is arranged in the motor and the speed reducer case (64), the seventh shaft motor is directly connected with a seventh shaft speed reducer, the motor and speed reducer combination (69) is connected with a first transmission gear (71) through a coupler (70), a second transmission gear (73) is arranged in the gear box (66), the first transmission gear (71) and the second transmission gear (73) are meshed with a rack (72), the second transmission gear (73) is fixed on a pouring ladle transmission shaft (74), and a pouring ladle mounting plate (75) is arranged on the pouring ladle transmission shaft (74), a ladle (67) is arranged on the ladle mounting plate (75).

6. The full-automatic intelligent casting unit for the aluminum piston of the diesel engine as recited in claim 1, wherein: the ring-inlaying heating aluminizing robot system comprises a ring-inlaying heating mechanism, a ring-inlaying aluminizing mechanism and a ring-inlaying pick-up robot system.

7. The full-automatic intelligent diesel engine aluminum piston casting unit of claim 6, wherein:

the ring inlaying heating mechanism comprises a ring inlaying heating mechanism base (40), a ring inlaying workbench is arranged on the ring inlaying heating mechanism base (40), a ring inlaying heater (37) is fixed on the ring inlaying workbench, a ring inlaying guide post (36) is installed in the ring inlaying heater (37), a ring inlaying output plate (43) is arranged below the ring inlaying workbench, a groove is formed in the ring inlaying output plate (43), the groove is located under the ring inlaying heater (37), a linear guide rail (38) is arranged at the lower portion of the ring inlaying output plate (43), the ring inlaying output plate (43) is in sliding connection with the linear guide rail (38), a pushing cylinder is arranged between the linear guide rails (38), the pushing cylinder is connected with the ring inlaying output plate (43) through cylinder connecting blocks (56) and (41), a ring inlaying slide way (44) is arranged between support pillars, and the ring inlaying output plate (43) is pushed out, the ring inlaying slideway (44) is positioned below the slot of the ring inlaying output plate (43);

an aluminum skin scraper blade (39) fixing frame is arranged on one side of the ring embedding heating mechanism base (40), and an aluminum skin scraper blade (39) is arranged on the aluminum skin scraper blade (39) fixing frame;

the ring-inlaying aluminizing mechanism comprises a ring-infiltrating mechanism base (48), wherein a linear motion unit mounting plate (50) is arranged on the ring-infiltrating mechanism base (48), a first linear motion unit (45) and a second linear motion unit (46) are arranged on the linear motion unit mounting plate (50), the linear motion unit mounting plate (50) is connected to a horizontal linear guide rail (47) in a sliding mode, the linear motion unit mounting plate (50) is connected with a horizontal moving cylinder (49), the first linear motion unit (45) and the second linear motion unit (46) are connected with a hook support (52) in a sliding mode, a ring-inlaying hook (53) is connected to the bottom of the hook support (52), and a vibrator (51) is fixed on the hook support (52);

the ring inlaying and pick-up robot system comprises a first robot base (60), an inlaying ring is mounted on the first robot base (60) and pick up and place an ABB robot (55), the inlaying ring is picked up and the ABB robot (55) is placed and is connected with a clamping jaw mounting plate (57) through a connecting block (56), and an inlaying ring clamping jaw (58) and an aluminum skin scraper clamping jaw (59) are mounted on the clamping jaw mounting plate (57).

8. The full-automatic intelligent casting unit for the aluminum piston of the diesel engine as recited in claim 1, wherein: the filter screen system comprises an automatic part taking hand, a filter screen clamping jaw (106) mechanism and a filter screen automatic shearing mechanism (79).

9. The full-automatic intelligent casting unit for the aluminum piston of the diesel engine as recited in claim 1, wherein: the automatic filter screen shearing mechanism (79) comprises a filter screen shearing fixing support (83), a filter screen storage box (82), a filter screen conveying mechanism and a filter screen cutter (80), wherein the middle of the filter screen shearing fixing support (83) is provided with the filter screen storage box (82), the top of the filter screen storage box (82) is provided with a filter screen outlet, the upper part of the filter screen storage box (82) is provided with the filter screen conveying mechanism, the filter screen conveying mechanism comprises a mounting plate, the mounting plate is provided with a directional guide rail and a filter screen input groove (88), the filter screen input groove (88) is upwards provided with a conveying cylinder (87), the conveying cylinder (87) is upwards provided with a filter screen clamping conveying block (81), the filter screen clamping conveying block (81) is fixed with a conveying clamping cylinder (86), and the filter screen clamping conveying block (81) is upwards provided with a shearing clamping, a shearing clamping cylinder (85) is arranged on the shearing clamping block, a shearing cylinder (84) is arranged above the shearing clamping cylinder (85), and a filter screen cutter (80) is arranged inside the shearing cylinder (84);

automatic get a hand and filter screen clamping jaw (106) mechanism and include third robot base (102), install on third robot base (102) and get a cast and quench and filter screen ABB robot (76) down, get a cast and quench and filter screen ABB robot (76) link to each other with clamping jaw mounting panel (57) down through connecting rod (103), install on clamping jaw mounting panel (57) and get filter screen cylinder (104) from top to bottom, clamping jaw mounting panel (57) have blank clamping jaw (108) and filter screen clamping jaw (106), blank clamping jaw (108) link to each other with blank clamping jaw cylinder (107), filter screen clamping jaw (106) link to each other with filter screen clamping jaw cylinder (105).

10. The full-automatic intelligent casting unit for the aluminum piston of the diesel engine as recited in claim 1, wherein: the blank casting quenching and waste product detecting mechanism comprises a water tank fixing support (90) and a storage box fixing support (96), a blank casting quenching tank (97) is arranged on the water tank fixing support (90), the blank casting quenching tank (97) is connected with the upper end of a slide (94), the tail end of the slide (94) is connected with a blank storage box (95) of the storage box fixing support (96), one side of the blank casting quenching tank (97) is provided with a blank pushing cylinder (89), a piston rod of the blank pushing cylinder (89) is connected with a slide block (91), a blank push plate (99) is fixed on the slide block (91), the slide block (91) slides along a guide rod (92), a waste product opening is arranged in the middle of the slide (94), one side of the slide (94) is provided with a waste product opening and closing cylinder, and the waste product opening and closing cylinder is connected with a waste product opening and closing baffle (100) through a baffle connecting, the waste opening baffle (100) covers above the waste opening, a waste marking spray gun (98) is arranged on one side of the slide way (94), a waste slide way (94) is arranged below the waste opening, and the bottom of the waste slide way (94) is connected with a waste vehicle (78).

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