CN113523265A - Intelligent smelting system and operation method thereof - Google Patents
Intelligent smelting system and operation method thereof Download PDFInfo
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- CN113523265A CN113523265A CN202010314350.0A CN202010314350A CN113523265A CN 113523265 A CN113523265 A CN 113523265A CN 202010314350 A CN202010314350 A CN 202010314350A CN 113523265 A CN113523265 A CN 113523265A
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- 238000000034 method Methods 0.000 title claims abstract description 47
- 238000003723 Smelting Methods 0.000 title claims abstract description 25
- 238000005266 casting Methods 0.000 claims abstract description 85
- 230000007246 mechanism Effects 0.000 claims abstract description 55
- 238000003825 pressing Methods 0.000 claims abstract description 46
- 230000008569 process Effects 0.000 claims abstract description 28
- 238000005422 blasting Methods 0.000 claims abstract description 23
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 58
- 239000002893 slag Substances 0.000 claims description 50
- 229910052742 iron Inorganic materials 0.000 claims description 29
- 239000004576 sand Substances 0.000 claims description 18
- 239000007788 liquid Substances 0.000 claims description 14
- 230000033001 locomotion Effects 0.000 claims description 12
- 238000001816 cooling Methods 0.000 claims description 9
- 238000010079 rubber tapping Methods 0.000 claims description 9
- 238000005303 weighing Methods 0.000 claims description 8
- 238000012546 transfer Methods 0.000 claims description 7
- 230000007306 turnover Effects 0.000 claims description 6
- 238000010009 beating Methods 0.000 claims description 4
- 230000003287 optical effect Effects 0.000 claims description 4
- 230000000007 visual effect Effects 0.000 claims description 4
- 238000012423 maintenance Methods 0.000 claims description 3
- 238000001514 detection method Methods 0.000 claims 1
- 239000000463 material Substances 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 18
- 238000011017 operating method Methods 0.000 abstract description 3
- 230000009467 reduction Effects 0.000 abstract description 3
- 230000006872 improvement Effects 0.000 abstract description 2
- 238000004904 shortening Methods 0.000 abstract description 2
- 238000011161 development Methods 0.000 description 6
- 230000018109 developmental process Effects 0.000 description 6
- 239000000428 dust Substances 0.000 description 6
- 238000010586 diagram Methods 0.000 description 3
- 241000196324 Embryophyta Species 0.000 description 2
- 244000035744 Hura crepitans Species 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 238000004140 cleaning Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 238000005007 materials handling Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000000779 smoke Substances 0.000 description 2
- 238000010146 3D printing Methods 0.000 description 1
- 229920001342 Bakelite® Polymers 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 239000004637 bakelite Substances 0.000 description 1
- 238000010923 batch production Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000003028 elevating effect Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000012805 post-processing Methods 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 230000008929 regeneration Effects 0.000 description 1
- 238000011069 regeneration method Methods 0.000 description 1
- 239000013049 sediment Substances 0.000 description 1
- 239000011265 semifinished product Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D47/00—Casting plants
- B22D47/02—Casting plants for both moulding and casting
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Abstract
The invention discloses an intelligent smelting system and an operating method thereof, and relates to the technical field of casting. The automatic casting machine comprises AGV transferring equipment, automatic casting equipment, automatic box pressing equipment, a spheroidizing ladle, automatic box turning equipment, casting head removing equipment, shakeout equipment, shot blasting equipment and accumulating equipment, wherein the automatic casting equipment internally comprises a barrel-shaped casting ladle, a tilting mechanism, a transverse moving mechanism, a lifting mechanism, a casting vehicle body, a track system, a control and operation system, a safety system and a cable device, and the automatic box pressing equipment internally comprises an upright post, a cross beam, a lifting mechanism, a box pressing mechanism, a transverse moving mechanism and a lifting and transverse moving driving mechanism. The invention can realize the reduction of the number of production equipment and the shortening of the process route by compactly arranging the production areas and reasonably arranging the equipment, thereby meeting the requirements of efficiency improvement, cost reduction and green production.
Description
Technical Field
The invention relates to the technical field of casting, in particular to an intelligent smelting system and an operating method thereof.
Background
With the continuous development of the machine manufacturing industry, the casting industry for obtaining blanks, semi-finished products and finished products has entered a rapid development period. The method has the advantages of being green, efficient, energy-saving, environment-friendly, safe and the like, and becomes the future development direction of casting enterprises, and the key processes of smelting, pouring and boxing cleaning are used as casting production. It must also meet the above-mentioned requirements of the development of the foundry industry.
The production of large-scale casting enterprises is generally provided with an automatic production line, and the large-scale batch production can be realized, and the small-scale trial production can also be realized. The smelting and pouring process is realized by adopting a mode of melting → tapping → heat preservation → transferring → pouring, the whole process needs a person to control a travelling crane to lift the molten iron bag to transfer the molten iron back and forth, and the problems of high-altitude operation, heavy physical labor, poor labor environment, high danger, low efficiency and the like also follow the process. The casting cleaning process comprises four procedures of cooling, boxing, sand treatment and finishing, after the casting of the casting line is solidified, the casting enters a cooling line in a roller way conveying mode, after the casting is cooled, a sand mold is broken through manpower or machinery, the sand mold is taken out of a sand box, the loose sand and shakeout sand are broken and recycled for regeneration, the casting is taken out and shot blasting and dead head removal are carried out, under the condition of mass production, the sand box is conveyed to a knockout bed in a roller way conveying mode to be unpacked, then the casting is hoisted, and the casting is transferred to a shot blasting procedure (all small-batch transportation adopts a hoisting mode). Although the process is high in efficiency, the potential safety hazard is large, the dust emission is serious, and the process is a typical representative process with poor mess of a casting plant.
In summary, the existing smelting process arrangement mode can meet the requirement of production takt, but the traditional mode only selects production equipment according to the characteristics of the casting to meet the requirement of green and efficient development of the casting industry, and the casting capacity, the production mode, the logistics direction, the mode and the like are important factors to be considered.
Disclosure of Invention
The invention aims to provide an intelligent smelting system and an operating method thereof, which have the advantages of environmental protection, no smoke and dust, high efficiency and the like, and solve the problems of high-altitude operation, heavy labor, poor working environment, high risk, low efficiency and the like of the traditional smelting and pouring process that a trolley is controlled by a person to hoist an iron liquid ladle to transfer iron liquid back and forth.
In order to solve the technical problems, the invention provides the following technical scheme: an intelligent smelting operation method comprises the following steps:
s1, smelting: slag receiving plate → stokehole slag raking → slag returning plate → ladle (ladle baking device) → stokehole tapping → spheroidization (spheroidizing station) → retroversion slag raking (slag raking position) → automatic pouring → ladle returning (ladle baking device position)
a. The method comprises the following steps The furnace platforms (the first electric furnace and the second electric furnace), the spheroidizing station, the ladle baking device and the slag removing position are arranged in a straight line, and the opposite side of the casting position is arranged.
b. The method comprises the following steps The furnace platform is arranged opposite to the spheroidizing station, the ladle baking device and the slag removing position, and both sides of the furnace platform can be provided with pouring lines.
S2, transferring: the sand mould and the casting are transferred by using a submerged AGV, and the logistics directions are as follows: core assembling station → stokehole buffer zone → pouring station → cooling zone → box turnover machine → cooling zone (empty tray) → core assembling station (empty tray) → AGV, through modifying software, can change on-the-spot logistics route and direction, can effectively avoid traditional roller way line/RGV transport the high cost (equipment is many, equipment basis cost is high), logistics route can't adjust, the maintenance work load is big scheduling problem. Whole transportation unmanned participation, for the inefficiency of artifical transport, the unknown of fork truck and trailer route, speed, safety, AGV's route and speed of traveling are controllable, and the location is stopped accurately to improve materials handling's efficiency greatly, simultaneously, AGV management system can carry out whole control to the AGV dolly, and the reliability obtains improving. In the high-risk operation space of the smelting workshop, the AGV has perfect safety protection capability, intelligent traffic route management, safety and collision avoidance, multi-level warning, emergency braking, fault reporting and the like, and reduces the risk of manual operation.
S3, pressing a box for pouring: the full-automatic pouring equipment is used and comprises a barrel-shaped pouring ladle, a tilting mechanism, a traversing mechanism, a lifting mechanism, a pouring car body, a track system, a control and operation system, a safety system, a cable device and the like. Has four freedom degrees of motion, namely X (longitudinal movement), Y (transverse movement), Z (lifting) and A (tilting casting and slag skimming). The automatic pouring equipment is Y (transverse movement), Z (lifting) and A (tilting pouring and slag removing) three-axis linkage automatic pouring equipment. The onboard vision recognition system continuously shoots or detects through an intelligent camera or an optical sensor, the diameter of molten iron in the pouring cup is fed back to the PLC system through the industrial Ethernet in real time, and the servo pouring speed is controlled through PID to realize full-cup pouring. The weighing system detects the pouring weight and automatically collects the package, and the visual system and the weighing system are matched to realize automatic pouring. The automatic pouring equipment ensures that the pouring cup is quickly filled (full cup pouring) during pouring in operation, and the liquid level in each box in the pouring process is stable.
S4, pouring work flow:
a. and the automatic pouring equipment receives a pouring instruction of the intelligent unit control system, and runs to a slag skimming station to be connected with a slag skimming hopper.
b. And (4) moving the automatic pouring equipment to an electric furnace station, and manually slagging off the molten iron in the electric furnace.
c. The automatic casting equipment moves to a slag skimming station, namely the slag bucket retracts to the slag skimming roller path.
d. And the automatic casting equipment runs to a ladle-in/out roll line to receive the casting ladle.
e. And the automatic pouring equipment moves to an electric furnace tapping station to receive molten iron.
f. The automatic pouring equipment lifts the tilting mechanism to hang the ladle, the automatic pouring equipment moves to a slag skimming station, the slag hopper moves to the automatic pouring equipment, and the iron liquid in the pouring ladle is manually skived.
g. The automatic pouring equipment moves to a to-be-poured station, the tilting mechanism tilts, the lifting mechanism lifts and the transverse moving mechanism moves transversely, the three shafts are linked to perform automatic pouring, and the pouring is finished and then the next station is poured.
h. And after the iron liquid in the casting ladle is completely poured, the automatic pouring equipment is operated to a residual iron pouring station, and the residual iron liquid (if any) is poured.
i. And the automatic pouring equipment operates to the in-out ladle roller way, the pouring ladle is put back, the next cycle is started, and the pouring data is uploaded to the intelligent unit control system.
S5, box pressing work flow:
a. and the box pressing system receives a box pressing instruction of the intelligent unit system.
b. And according to the box pressing coordinates provided by the intelligent unit system, the box pressing mechanism is pressed down to a specified position and locked.
c. And the box pressing device feeds back a box pressing finishing signal to the intelligent unit.
d. After the pouring of current pouring station finishes, according to the pressure case time instruction that the intelligent cell assigned, the pressure case device maintains the pressure case state, reaches regulation pressure case time after, presses the case device to resume initial position.
e. And the box pressing device feeds back a return instruction to the intelligent unit and uploads box pressing data to the intelligent unit control system.
S6, boxing sand treatment and shot blasting:
a. a box beating and shot blasting process: calling and turning over the box → AGV transferring the core bag to the box turning over/box pushing machine → automatically turning over/pushing the box → picking the casting piece → turning over/box pushing machine returning → turning back the empty tray by the AGV → shot blasting the casting piece → newspaper worker.
b. The work flow of the piece grabbing manipulator is as follows: casting grabbing (shakeout machine) → shot blasting upper part → shot blasting lower part → casting head removing → casting placing tray.
The utility model provides an intelligence system of smelting, includes AGV transfer equipment, automatic pouring equipment, automatic pressure case equipment, balling-up bakelite package, automatic equipment of turning over the case, casting head removal equipment, knockout equipment, shot blasting equipment and long-pending equipment of putting, the inside of automatic pouring equipment includes barrel-shaped pouring ladle, verts the mechanism, sideslip mechanism, hoist mechanism, pouring automobile body, rail system, control and operating system, safety system and cable plant, the inside of automatic pressure case equipment includes stand, crossbeam, elevating system, pressure case mechanism, sideslip mechanism and lift and sideslip actuating mechanism.
Compared with the prior art, the intelligent smelting system and the operation method thereof have the following beneficial effects:
1. the invention enables the devices to be reasonably distributed (figure 1) by compactly distributing the production areas, thereby reducing the number of production devices and shortening the process route, and achieving the requirements of efficiency improvement, cost reduction and green production.
2. The automatic casting device can directly reach the ladle baking station, the tapping station, the slag skimming station, the spheroidizing station and the casting station within the operation range of the automatic casting device, so that the space of a workshop can be effectively utilized, and the molten iron transfer flow is shortened. The pouring process is shortened, the problem of temperature drop of molten iron can be effectively solved, the tapping temperature can be properly reduced, the running power of the electric furnace is reduced, and the ladle drying times and time are reduced, so that the production cost is reduced. Automatic pouring equipment is used for molten iron transferring and pouring, manual operation is reduced, labor intensity is effectively reduced, and operation safety is guaranteed. The stokehole casting process is centralized, which is beneficial to the centralized dust removal treatment of a furnace platform, a slagging-off station and a casting station spheroidizing station, so as to ensure no smoke dissipation in the casting process and meet the environmental protection requirement.
3. The method has the advantages that the dust raising is large in the process of the sand falling procedure, the working environment is poor, and the sand falling procedure is always the place where workers are least willing to work. The arrangement mode enables dust raising points to be concentrated and facilitates dust removal treatment. The manipulator is used for replacing a roller way for conveying or hoisting, the space is saved, an operator can complete a series of processes such as turning over boxes, beating boxes, shot blasting, casting head removing and piece rotating only in a manipulator cab, the state of equipment can be monitored, abnormity can be timely processed when the equipment is found, the labor intensity of workers is greatly reduced, and the operation environment is improved.
Drawings
FIG. 1 is an overall layout of the structure smelting production of the present invention;
FIG. 2 is an overall layout of the pouring area of the structure of the present invention;
FIG. 3 is a horizontal layout of the pouring area of the structure of the present invention;
FIG. 4 is a layout of the opposite side of the pouring area of the structure of the present invention;
FIG. 5 is an overall layout of the structural boxing zone of the present invention;
FIG. 6 is a layout diagram of a post-processing loop of the structure of the present invention;
FIG. 7 is a schematic diagram of a structure for transporting an AGV and a pallet according to the present invention;
FIG. 8 is a schematic view of an automatic casting machine according to the present invention;
FIG. 9 is a schematic view of an automatic box pressing machine according to the present invention;
FIG. 10 is a schematic diagram of the structure of the present invention in a box-turning state.
Detailed Description
Referring to fig. 1-3, the present invention provides a technical solution: an intelligent smelting operation method comprises the following steps:
s1, smelting: slag receiving plate → stokehole slag raking → slag returning plate → ladle (ladle baking device) → stokehole tapping → spheroidization (spheroidizing station) → retroversion slag raking (slag raking position) → automatic pouring → ladle returning (ladle baking device position)
a. The method comprises the following steps The furnace platforms (the first electric furnace and the second electric furnace), the spheroidizing station, the ladle baking device and the slag removing position are arranged in a straight line, and the opposite side of the casting position is arranged.
b. The method comprises the following steps The furnace platform is arranged opposite to the spheroidizing station, the ladle baking device and the slag removing position, and both sides of the furnace platform can be provided with pouring lines.
S2, transferring: the sand mould and the casting are transferred by using a submerged AGV, and the logistics directions are as follows: core assembling station → stokehole buffer zone → pouring station → cooling zone → box turnover machine → cooling zone (empty tray) → core assembling station (empty tray) → AGV, through modifying software, can change on-the-spot logistics route and direction, can effectively avoid traditional roller way line/RGV transport the high cost (equipment is many, equipment basis cost is high), logistics route can't adjust, the maintenance work load is big scheduling problem. Whole transportation unmanned participation, for the inefficiency of artifical transport, the unknown of fork truck and trailer route, speed, safety, AGV's route and speed of traveling are controllable, and the location is stopped accurately to improve materials handling's efficiency greatly, simultaneously, AGV management system can carry out whole control to the AGV dolly, and the reliability obtains improving. In the high-risk operation space of the smelting workshop, the AGV has perfect safety protection capability, intelligent traffic route management, safety and collision avoidance, multi-level warning, emergency braking, fault reporting and the like, and reduces the risk of manual operation.
S3, pressing a box for pouring: the full-automatic pouring equipment is used and comprises a barrel-shaped pouring ladle, a tilting mechanism, a traversing mechanism, a lifting mechanism, a pouring car body, a track system, a control and operation system, a safety system, a cable device and the like. Has four freedom degrees of motion, namely X (longitudinal movement), Y (transverse movement), Z (lifting) and A (tilting casting and slag skimming). The automatic pouring equipment is Y (transverse movement), Z (lifting) and A (tilting pouring and slag removing) three-axis linkage automatic pouring equipment. The onboard vision recognition system continuously shoots or detects through an intelligent camera or an optical sensor, the diameter of molten iron in the pouring cup is fed back to the PLC system through the industrial Ethernet in real time, and the servo pouring speed is controlled through PID to realize full-cup pouring. The weighing system detects the pouring weight and automatically collects the package, and the visual system and the weighing system are matched to realize automatic pouring. The automatic pouring equipment ensures that the pouring cup is quickly filled (full cup pouring) during pouring in operation, and the liquid level in each box in the pouring process is stable.
S4, pouring work flow:
a. and the automatic pouring equipment receives a pouring instruction of the intelligent unit control system, and runs to a slag skimming station to be connected with a slag skimming hopper.
b. And (4) moving the automatic pouring equipment to an electric furnace station, and manually slagging off the molten iron in the electric furnace.
c. The automatic casting equipment moves to a slag skimming station, namely the slag bucket retracts to the slag skimming roller path.
d. And the automatic casting equipment runs to a ladle-in/out roll line to receive the casting ladle.
e. And the automatic pouring equipment moves to an electric furnace tapping station to receive molten iron.
f. The automatic pouring equipment lifts the tilting mechanism to hang the ladle, the automatic pouring equipment moves to a slag skimming station, the slag hopper moves to the automatic pouring equipment, and the iron liquid in the pouring ladle is manually skived.
g. The automatic pouring equipment moves to a to-be-poured station, the tilting mechanism tilts, the lifting mechanism lifts and the transverse moving mechanism moves transversely, the three shafts are linked to perform automatic pouring, and the pouring is finished and then the next station is poured.
h. And after the iron liquid in the casting ladle is completely poured, the automatic pouring equipment is operated to a residual iron pouring station, and the residual iron liquid (if any) is poured.
i. And the automatic pouring equipment operates to the in-out ladle roller way, the pouring ladle is put back, the next cycle is started, and the pouring data is uploaded to the intelligent unit control system.
S5, box pressing work flow:
a. and the box pressing system receives a box pressing instruction of the intelligent unit system.
b. And according to the box pressing coordinates provided by the intelligent unit system, the box pressing mechanism is pressed down to a specified position and locked.
c. And the box pressing device feeds back a box pressing finishing signal to the intelligent unit.
d. After the pouring of current pouring station finishes, according to the pressure case time instruction that the intelligent cell assigned, the pressure case device maintains the pressure case state, reaches regulation pressure case time after, presses the case device to resume initial position.
e. And the box pressing device feeds back a return instruction to the intelligent unit and uploads box pressing data to the intelligent unit control system.
S6, boxing sand treatment and shot blasting:
a. a box beating and shot blasting process: calling and turning over the box → AGV transferring the core bag to the box turning over/box pushing machine → automatically turning over/pushing the box → picking the casting piece → turning over/box pushing machine returning → turning back the empty tray by the AGV → shot blasting the casting piece → newspaper worker.
b. The work flow of the piece grabbing manipulator is as follows: the casting grabbing (shakeout machine) → shot blasting upper part → shot blasting lower part → casting head removing → casting placing tray, wherein in the traditional casting shakeout process, a crown block is generally adopted to cool a core package after pouring, and then the core package is hoisted to a shakeout station from a cooling station to be broken and shakeout. The overhead travelling crane is adopted for hoisting and conveying at high altitude, so that great potential safety hazards exist, certain requirements are imposed on workshop space, operation workers are required to complete the operation in a cooperative mode, the labor cost is high, and the efficiency is low. Along with the continuous development of foundry industry, the degree of automation of foundry goods production is more and more high, and the shakeout process that traditional adoption crane was not practical to 3D printing flaskless molding technique, therefore is the principle of convenient safety, and this process adopts AGV transport dolly and box turnover machine to combine to realize automatic transport turnover to shakeout machine and carry out the shakeout and handle. And (3) for a bare casting sand mold or a pouring box sand mold, conveying the sand mold into a shakeout bed in a box turnover or box pushing mode, shakeout on the shakeout bed, grabbing and overturning the casting by using a grabbing manipulator, pouring scattered sand in the inner cavity of the casting into the shakeout bed, continuing hanging the casting on a lifting hook of a shot blasting machine by using the manipulator, performing shot blasting, and taking the casting to remove a casting head.
The utility model provides an intelligence system of smelting, transport equipment including AGV, automatic pouring equipment, automatic pressure case equipment, the package is baked in the balling, automatic equipment of turning over the case, the dead head is got rid of the equipment, the equipment that shakeouts, throw ball equipment and long-pending equipment of putting, the inside of automatic pouring equipment includes barrel-shaped pouring package, the mechanism that verts, the sideslip mechanism, hoist mechanism, the pouring automobile body, rail system, control and operating system, safety system and cable device, wherein, automatic pouring equipment is Y (sideslip), Z (lift), the automatic pouring equipment of A (verting pouring and taking off the sediment) triaxial linkage. The onboard vision recognition system continuously shoots or detects through an intelligent camera or an optical sensor, the diameter of molten iron in the pouring cup is fed back to the PLC system through the industrial Ethernet in real time, and the servo pouring speed is controlled through PID to realize full-cup pouring. The weighing system detects the pouring weight and automatically collects the package, and the visual system and the weighing system are matched to realize automatic pouring. The automatic pouring equipment ensures that a pouring cup is filled quickly (full cup pouring) during pouring in operation, the liquid level in each box pouring process is stable, and the automatic box pressing equipment comprises a stand column, a cross beam, a lifting mechanism, a box pressing mechanism, a transverse moving mechanism and a lifting and transverse moving driving mechanism. The upright post and the cross beam are made of H-shaped steel, the guide mechanism consists of linear guide rails, the lifting mechanism adopts a ball screw, and the servo motor drives and controls the lifting and the lifting stroke. The transverse moving is composed of a linear guide rail and a connecting support, the transverse moving range is +/-400-650 mm, the distance is 250mm, and the transverse moving mechanism is driven by a servo motor. The contact part of the box pressing mechanism and the sand mould is in floating connection so as to achieve the best pressing effect.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents. The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (2)
1. An intelligent smelting operation method comprises the following steps:
s1, smelting: slag receiving plate → stokehole slag raking → slag returning plate → ladle (ladle baking device) → stokehole tapping → spheroidization (spheroidizing station) → retroversion slag raking (slag raking position) → automatic pouring → ladle returning (ladle baking device position)
: the furnace platforms (the first electric furnace and the second electric furnace), the spheroidizing station, the ladle baking device and the slag removing position are arranged in a straight line shape, and the opposite side of the casting position is arranged;
: the furnace platform is arranged opposite to the spheroidizing station, the ladle baking device and the slag removing position, and both sides of the furnace platform can be provided with casting lines;
s2, transferring: the sand mould and the casting are transferred by using a submerged AGV, and the logistics directions are as follows: the core assembly station → the buffer zone in front of the furnace → the pouring station → the cooling zone → the box turnover machine → the cooling zone (empty tray) → the core assembly station (empty tray) uses the AGV, and the software is modified, so that the on-site logistics route and direction can be changed, and the problems of high cost (more equipment, high equipment foundation cost), incapability of adjusting the logistics route, large maintenance workload and the like caused by the traditional roller line/RGV conveying can be effectively avoided; the whole transfer process is unattended, the running path and speed of the AGV are controllable, and the positioning and stopping are accurate, so that the material transfer efficiency is greatly improved, meanwhile, the AGV management system can monitor the whole process of the AGV, and the reliability is improved; in the high-risk operation space of the smelting workshop, the AGV has perfect safety protection capability, intelligent traffic route management, safety and collision avoidance, multi-level warning, emergency braking, fault reporting and the like, and reduces the risk of manual operation;
s3, pressing a box for pouring: the method comprises the following steps of using full-automatic pouring equipment, wherein the automatic pouring equipment comprises a barrel-shaped pouring ladle, a tilting mechanism, a traversing mechanism, a lifting mechanism, a pouring car body, a track system, a control and operation system, a safety system, a cable device and the like; has four freedom degrees of motion of X (longitudinal movement), Y (transverse movement), Z (lifting) and A (tilting casting and slag skimming); the automatic pouring equipment is Y (transverse movement), Z (lifting) and A (tilting pouring and slag removing) three-axis linkage automatic pouring equipment; the onboard vision recognition system feeds the diameter of the molten iron of the pouring cup back to the PLC system in real time through industrial Ethernet by continuous shooting of an intelligent camera or detection of an optical sensor, and controls the servo pouring speed through PID to realize full-cup pouring; the weighing system detects the pouring weight and automatically collects the package, and the visual system and the weighing system are matched to realize automatic pouring; the automatic pouring equipment ensures that a pouring cup is quickly filled (full cup pouring) during pouring in operation, and the liquid level in each box in the pouring process is stable;
s4, pouring work flow:
the automatic pouring equipment receives a pouring instruction of the intelligent unit control system, and operates to a slag skimming station to be connected with a slag skimming hopper;
the automatic pouring equipment is moved to an electric furnace station, and the molten iron in the electric furnace is manually subjected to slag skimming;
the automatic pouring equipment moves to a slag skimming station, namely the slag bucket returns to the slag skimming raceway;
the automatic casting equipment is operated to a ladle-in/out roll way line to connect with a casting ladle;
the automatic pouring equipment moves to an electric furnace tapping station to receive molten iron;
lifting the tilting mechanism of the automatic pouring equipment to hang the ladle, moving the automatic pouring equipment to a slag skimming station, moving a slag hopper to the automatic pouring equipment, and manually skimming the molten iron in the pouring ladle;
the automatic casting equipment moves to a to-be-cast station, the tilting mechanism tilts, the lifting mechanism lifts and the transverse moving mechanism moves transversely, three shafts are linked to perform automatic casting, and the automatic casting equipment enters the next station for casting after casting is finished;
after the iron liquid in the casting ladle is completely poured, the automatic pouring equipment is operated to a residual iron pouring station, and the residual iron liquid (if any) is poured;
the automatic pouring equipment operates to a ladle inlet and outlet roller way, a pouring ladle is put back, the next cycle is started, and the pouring data of the time is uploaded to an intelligent unit control system;
s5, box pressing work flow:
the box pressing system receives a box pressing instruction of the intelligent unit system;
according to the box pressing coordinates provided by the intelligent unit system, the box pressing mechanism is pressed down to a specified position and locked;
the box pressing device feeds back a box pressing completion signal to the intelligent unit;
after the current pouring station finishes pouring, the box pressing device maintains a box pressing state according to a box pressing time instruction issued by the intelligent unit, and the box pressing device recovers to an initial position after the specified box pressing time is reached;
the box pressing device feeds back a homing completion instruction to the intelligent unit and uploads box pressing data to the intelligent unit control system;
s6, boxing sand treatment and shot blasting:
a box beating and shot blasting process: calling and turning over the box → AGV transferring the core bag to the box turning over/box pushing machine → automatically turning over/pushing the box → capturing the casting → turning over/box pushing machine returning → AGV turning back to the empty tray → casting shot blasting → newspaper worker;
the work flow of the piece grabbing manipulator is as follows: casting grabbing (shakeout machine) → shot blasting upper part → shot blasting lower part → casting head removing → casting placing tray.
2. The intelligent smelting operation process of claim 1, wherein: the intelligent smelting system of the intelligent smelting operation method comprises AGV transfer equipment, automatic pouring equipment, automatic box pressing equipment, a spheroidizing ladle, automatic box turning equipment, casting head removing equipment, shakeout equipment, shot blasting equipment and accumulating equipment, and is characterized in that: the automatic casting equipment comprises a barrel-shaped casting ladle, a tilting mechanism, a transverse moving mechanism, a lifting mechanism, a casting car body, a track system, a control and operation system, a safety system and a cable device, and the automatic box pressing equipment comprises a stand column, a cross beam, a lifting mechanism, a box pressing mechanism, a transverse moving mechanism and a lifting and transverse moving driving mechanism.
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| CN114769576A (en) * | 2022-04-26 | 2022-07-22 | 江苏豪然新材料有限公司 | Large-scale aluminum alloy injection molding flexible and parallel production mode and melt transfer method thereof |
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