CN113927018A - Electrostatic spraying casting forming system and using method - Google Patents
Electrostatic spraying casting forming system and using method Download PDFInfo
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- CN113927018A CN113927018A CN202111219015.3A CN202111219015A CN113927018A CN 113927018 A CN113927018 A CN 113927018A CN 202111219015 A CN202111219015 A CN 202111219015A CN 113927018 A CN113927018 A CN 113927018A
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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
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C23/00—Tools; Devices not mentioned before for moulding
- B22C23/02—Devices for coating moulds or cores
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
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Abstract
The invention relates to an electrostatic spraying casting forming system which comprises a casting machine, a cooling machine, a casting transfer mechanical arm, a crucible heat preservation furnace, a hydraulic working station, an electrostatic dust recovery device, a tailing collecting station, a main control working station, an operation control working platform and a protective side wall, wherein the protective side wall forms a working cavity, the casting machine, the casting transfer mechanical arm, the crucible heat preservation furnace and the tailing collecting station are positioned in the working cavity and are respectively and electrically connected with the main control working station and the operation control working platform, and the main control working station, the operation control working platform and the cooling machine are positioned outside the working cavity. The using method comprises two steps of equipment assembly, casting operation and the like. On one hand, the invention improves the automation and intellectualization of low-pressure and gravity casting operation, and effectively realizes the centralized collection and treatment of dust, waste liquid, waste and solid waste generated in the casting process; on the other hand, the efficiency and the precision of the spraying operation of the release agent and the spraying quality between the release agent and the surface of the forming die are effectively improved.
Description
Technical Field
The invention relates to a casting molding system for electrostatic spraying and a using method thereof, belonging to the technical field of low-pressure casting.
Background
In the low-pressure casting processing operation at present, although the used low-pressure casting equipment can meet the requirements of the processing operation, such as 'a copper alloy low-pressure casting system with a mold spraying function' with the patent application number of '202110360786.8', and 'a copper alloy low-pressure casting system with a mold spraying function' with the patent application number of '201922164587.0', on one hand, the devices need to be additionally provided with a plurality of auxiliary devices which are independently operated, such as a cooling device, a mold release agent spraying device, a mold release agent cleaning device, a molten metal transferring device and the like, thereby causing the normative running layout of each device during the current low-pressure casting operation and lacking the capability of unification, coordination and synchronous running among the devices, meanwhile, the automation degree and the modularization degree of operation among equipment are greatly influenced during low-pressure casting operation, so that the production efficiency and the quality of the low-pressure casting operation are seriously influenced; on the other hand, when the current low-pressure casting equipment runs, effective and professional equipment is often lacked during spraying and cleaning of the release agent, so that the spraying precision and the spraying efficiency during spraying operation of the release agent and the adhesive force between the sprayed release agent and a forming mold are relatively poor, and the working efficiency of casting and the surface quality of a casting are seriously influenced; on the other hand, the cleaning efficiency and the cleaning quality of the mold surface release agent are relatively poor after the casting is finished, so that the casting quality, particularly the surface of a casting and the continuous casting efficiency of the mold are greatly adversely affected.
Therefore, in order to improve the working efficiency and quality of the low-pressure casting and forming operation, a new low-pressure casting device and a new casting process are urgently needed to be developed to meet the actual use requirement.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention provides a casting and forming system for electrostatic spraying and a using method thereof.
A casting forming system for electrostatic spraying comprises a casting machine, a cooler, a casting transfer mechanical arm, a crucible holding furnace, a hydraulic workstation, an electrostatic dust recovery device, a tailing collecting station, a main control workstation, an operation control workbench, a protective side wall and an operation door, wherein the protective side walls are a plurality of operation cavities which are vertically distributed with a horizontal plane and are sequentially connected end to form a closed annular structure in cross section, the casting machine, the casting transfer mechanical arm, the crucible holding furnace and the tailing collecting station are all positioned in the operation cavities and are respectively and electrically connected with the main control workstation and the operation control workbench, the main control workstation, the operation control workbench and the cooler are positioned outside the operation cavities and are connected with the outer surface of the protective side wall, the operation control workbench is respectively and electrically connected with the cooler and the main control workstation, the crucible holding furnace and the casting machine are symmetrically distributed on two sides of the center line of the operation cavities, the casting transfer mechanical arms are positioned on two sides of the center line of the crucible holding furnace, Between the casting machines, a hydraulic working station and a tailing collecting station are positioned on two sides of the axis of an operation cavity and are communicated with the casting machines through supply pipelines, an electrostatic dust recovery device covers the upper end surface of the casting machines and is communicated with the tailing collecting station through the supply pipelines, 1-2 operation doors are arranged on the corresponding protection side wall of the operation cavity, and the operation doors are in sliding connection with the protection side wall.
Further, the casting transfer mechanical arm comprises a base, a storage rack, a transfer crucible, an operation mechanical arm, a horizontal driving mechanism, an electrostatic spraying gun, a high-pressure jet flow nozzle, a jet flow fan, a solid release agent storage tank, a feeding pump and a driving circuit, wherein the base is connected with the ground plane of the operation cavity, the upper end face of the base is hinged with the operation mechanical arm through a three-dimensional turntable mechanism, the axis of the operation mechanical arm forms an included angle of 0-180 degrees with the ground plane, the front end face of the operation mechanical arm is hinged with the storage rack through the three-dimensional turntable mechanism, the storage rack is of a frame structure with a rectangular cross section, the upper end face of the storage rack forms an included angle of 0-180 degrees with the ground plane, the upper end face of the storage rack is provided with at least one storage cavity which is vertically distributed with the upper end face of the storage rack, the transfer crucible is embedded in the storage cavity and coaxially distributed with the storage cavity, and the upper end face of the storage rack is additionally provided with a horizontal driving mechanism which is distributed in parallel with the axis of the transfer crucible, horizontal drive mechanism is connected through slider and at least one electrostatic spraying rifle and at least one high-pressure efflux spout in addition, electrostatic spraying rifle, high-pressure efflux spout axis intersect with the transportation crucible axis, and the nodical position in transportation crucible top, the electrostatic spraying rifle is in addition through feed pump and solid release agent storage jar intercommunication, high-pressure efflux spout and jet fan communicate each other, jet fan, solid release agent storage jar, feed pump and drive circuit all with pedestal connection, just operation arm, horizontal drive mechanism, electrostatic spraying rifle, jet fan, feed pump all with drive circuit electrical connection to through drive circuit and control operation panel electrical connection.
Furthermore, the slide block is hinged with the electrostatic spraying gun and the high-pressure jet nozzle through a turntable mechanism, and in addition, the electrostatic spraying gun and the high-pressure jet nozzle are respectively provided with an in-place detection sensor.
Further, the electrostatic dust recovery device comprises a protection cavity, a negative pressure fan, a backflow air port and pm2.5 sensors, wherein the protection cavity is of a cavity structure with an axial section in a shape like the Chinese character 'Jiong', the protection cavity is coated above the casting machine and coaxially distributed with the casting machine, an operation port is arranged at the position, corresponding to the casting transfer mechanical arm, of the side surface of the protection cavity, the backflow air port and the pm2.5 sensors are both positioned in the protection cavity, at least two backflow air ports are uniformly distributed around the axis of the protection cavity and are connected with the inner surface of the side wall of the protection cavity, the axis of the backflow air port is intersected with the axis of the protection cavity and form a range of 30-90 degrees, the pm2.5 sensors are embedded in the top of the protection cavity and coaxially distributed with the protection cavity, each backflow air port comprises a flow guide port, a bearing keel, an electrode needle and an insulating cushion block, the flow guide port is of a hollow tubular structure with an isosceles trapezoid axial section, and the rear end face of the backflow air port is communicated with the negative pressure fan through a drainage tube, the electrode needle latter half inlay in the water conservancy diversion mouth and with the coaxial distribution of water conservancy diversion mouth, the terminal surface surpasss water conservancy diversion mouth front end off-plate 0-10 millimeter before the electrode needle, and the rear end passes through insulating cushion and connects and coaxial distribution, and insulating cushion is connected with water conservancy diversion mouth medial surface through bearing fossil fragments, it is the toper frame construction with water conservancy diversion mouth coaxial distribution to bear fossil fragments, and its vertex of a cone is located and is close to water conservancy diversion mouth rear end face position department, and is 1/3 to the water conservancy diversion mouth degree of depth with water conservancy diversion mouth rear end face interval, negative pressure fan is connected with protection chamber lateral surface to through honeycomb duct and tails collecting station intercommunication, the static needle of negative pressure fan pm2.5 sensor and return air inlet all with control operation panel electrical connection.
Further, the tails collecting station include frame, waste liquid recovery jar, sack cleaner, backwash pump, backward flow fan, wherein the frame is the frame construction that axial cross-section is the rectangle, waste liquid recovery jar, sack cleaner all at least one to inlay in the frame, and each waste liquid recovery jar, sack cleaner connect in parallel each other, the waste liquid recovery jar passes through backwash pump and supply line intercommunication to communicate with the casting machine through supply line, the sack cleaner passes through backwash fan and supply line intercommunication to communicate with electrostatic dust recovery unit through supply line, the sack cleaner passes through backward flow fan and at least one waste liquid recovery jar communicating pipe in addition, waste liquid recovery jar, sack cleaner, backwash pump, backward flow fan all with master control workstation, control operation panel electrical connection.
Further, master control workstation, control operation panel all include automatically controlled cabinet and circuit system, and circuit system all inlays in automatically controlled cabinet, wherein master control workstation's circuit system includes power supply circuit, power regulating circuit, voltage regulation rectifier circuit, based on programmable controller drive circuit, just based on programmable controller drive circuit on the basis respectively with power supply circuit, power regulating circuit, voltage regulation rectifier circuit and control operation panel's circuit system electrical connection, control operation panel's circuit system is based on arbitrary one in FPGA chip, the DSP chip controls circuit system, control circuit system establishes in addition based on button, display, potentiometre and the arbitrary one of multisection switch or several kinds of shared control interface, control the interface and inlay in the lateral surface of controlling operation panel automatically controlled cabinet.
Furthermore, the electric control cabinet of the operation and control operation platform is in sliding connection with the protective side wall through a guide sliding rail, the guide sliding rail is parallel to the ground plane, a towline groove is formed in the guide sliding rail, the towline groove and the guide sliding rail are coaxially distributed, and wires connected between the main control workstation and the operation and control operation platform are embedded in the towline groove.
A method of using an electrostatically sprayed foundry molding system comprising the steps of:
s1, assembling equipment, namely, assembling a casting machine, a cooler, a casting transfer mechanical arm, a crucible holding furnace, an electrostatic dust recovery device, a hydraulic work station, a tailing collecting station, a main control work station, an operation control work table, a protective side wall and an operation door, establishing electrical connection between the main control work station and an external power supply system, establishing data connection between the operation control work table and an external remote control system, and recording an operation control program for casting operation into the operation control work table for caching; on the other hand, according to the requirement of casting operation, molten metal liquid to be cast is filled into a crucible heat-preserving furnace for heat preservation and standby, and meanwhile, corresponding release agents are respectively filled into each release agent storage tank of the electrostatic dust recovery device for standby, so that the prefabrication of the equipment can be completed;
s2, casting operation, after the step S1 is completed, firstly, the casting transfer mechanical arm carries out electrostatic spraying of a release agent meeting the requirement of the casting operation on the inner surface of a forming die of a casting machine according to the use casting requirement, a release agent layer is formed on the inner surface of the forming die, then the casting transfer mechanical arm is driven to operate according to the recorded casting program, a proper amount of molten metal is taken out from a crucible heat preservation furnace through a transfer crucible according to the use requirement by the casting transfer mechanical arm, the molten metal is transferred into the casting machine and is cast by the casting machine, after the workpiece is formed, the workpiece is demoulded and taken out, then the release agent on the surface of the forming die sprayed on the surface of the forming die is cleaned by high-pressure airflow through a high-pressure jet nozzle of the casting transfer mechanical arm, and the release agent is sprayed on the surface of the forming die again after the cleaning operation is completed, the repeated casting and molding operation is realized, and meanwhile, when the mold release agent is sprayed and cleaned and the casting and molding operation is carried out, on one hand, the tailing collection station is used for intensively recycling the waste liquid generated during the operation of the casting machine; on the other hand, the solid release agent in the spraying cleaning operation is recovered by the tailing collecting station and the return air inlet of the electrostatic dust recovery device, so that the pollution of the casting molding operation is eliminated.
Further, in the steps S1 and S2, the release agent is a powder release agent, specifically including but not limited to boron nitride powder, graphite powder, gypsum powder, talc powder, mica powder, clay powder, and white clay powder.
Further, in the step S2, when the release agent is sprayed, on one hand, the electrostatic current value is adjusted to adjust the thickness and the adhesion force of the release agent adhering to the molding die; on the other hand, the purpose of adjusting the adhesion force between the release agent and the forming die is achieved by adjusting the particle size of the release agent.
On one hand, the invention effectively realizes the centralized arrangement and organic combination of the low-pressure casting system, the tailing purification system, the release agent spraying system and the molten metal caching and transferring equipment, greatly improves the integration and modularization degree of the low-pressure casting operation system, and effectively improves the automation and intellectualization of the low-pressure casting operation, thereby achieving the purpose of improving the working efficiency of the low-pressure casting operation, effectively realizing the centralized collection and treatment of waste liquid, waste and solid waste generated in the casting process, and reducing the pollution of the casting operation to the environment; on the other hand, when low-pressure casting operation is carried out, the solid powder release agent and electrostatic spraying construction equipment and process are adopted, the solid powder release agent with the precision adsorption positioning is utilized to protect the die, the air permeability and the lubricity between the die and a workpiece are effectively improved, the efficiency and the precision of the release agent spraying operation and the spraying quality between the release agent and the surface of a forming die are greatly improved, the aim of improving the recycling casting operation efficiency of the forming die for casting and improving the repeated utilization rate of the die, the product demoulding efficiency and the surface quality of a demoulded product is fulfilled, and meanwhile, the cooling sequence of the product can be adjusted by using the heat conductivity coefficient of the solid powder release agent, the stability of the cooling sequence is improved, so that the casting forming quality of the workpiece is further improved.
Drawings
The invention is described in detail below with reference to the drawings and the detailed description;
FIG. 1 is a schematic diagram of the system of the present invention;
FIG. 2 is a schematic structural view of an electrostatic dust recycling apparatus;
FIG. 3 is a schematic view of a casting transfer robot;
FIG. 4 is a schematic view of a partial connection structure of the operation platform and the guide rail;
FIG. 5 is a schematic view of a tailings collection station;
FIG. 6 is a schematic flow chart of the method of the present invention.
Detailed Description
In order to facilitate the implementation of the technical means, creation features, achievement of the purpose and the efficacy of the invention, the invention is further described below with reference to specific embodiments.
As shown in FIGS. 1-5, an electrostatic spraying casting forming system comprises a casting machine 1, a cooling machine 2, a casting transfer mechanical arm 3, a crucible holding furnace 4, a hydraulic workstation 6, an electrostatic dust recovery device 5, a tailing collecting station 7, a main control workstation 8, an operation control workbench 9, a protective side wall 10 and an operation door 11, wherein a plurality of protective side walls 10 are vertically distributed with a horizontal plane and are sequentially connected end to form an operation cavity 12 with a closed annular cross section, the casting machine 1, the casting transfer mechanical arm 3, the crucible holding furnace 4 and the tailing collecting station 7 are all positioned in the operation cavity 12 and are respectively electrically connected with the main control workstation 8 and the operation control workstation 9, the main control workstation 8, the operation control workstation 9 and the cooling machine 2 are positioned outside the operation cavity 12 and are connected with the outer surface of the protective side wall 10, and the operation control workstation 9 is respectively and electrically connected with the cooling machine 2 and the main control workstation 8, crucible heat preservation furnace 4, casting machine 1 symmetric distribution are in operation chamber 12 central line both sides, casting is transported mechanical arm 3 and is located between crucible heat preservation furnace 4, casting machine 1, hydraulic pressure workstation 6, tails collection station 7 is located operation chamber 12 axis both sides, and communicate through supply tube 13 way with casting machine 1 within a definite time, static dust recovery unit 5 cladding is outside casting machine 1 up end, in addition communicate with tails collection station 7 through supply tube 13 way, establish 1-2 operation doors on the protective side wall 11 that operation chamber 12 corresponds, and operation door 11 and protective side wall 10 sliding connection.
It is emphasized that the casting transfer mechanical arm 3 comprises a base 31, a storage rack 32, a transfer crucible 33, an operation mechanical arm 34, a horizontal driving mechanism 35, an electrostatic spraying gun 36, a high-pressure jet nozzle 37, a jet fan 306, a solid release agent storage tank 38, a feeding pump 39 and a driving circuit 30, wherein the base 31 is connected with the ground plane of the operation cavity 12, the upper end surface of the base is hinged with the operation mechanical arm 34 through a three-dimensional turntable mechanism 301, the axis of the operation mechanical arm 34 forms an included angle of 0-180 degrees with the ground plane, the front end surface of the operation mechanical arm 34 is hinged with the storage rack 32 through the three-dimensional turntable mechanism 301, the storage rack 32 is a frame structure with a rectangular cross section, the upper end surface of the storage rack 32 forms an included angle of 0-180 degrees with the ground plane, the upper end surface of the storage rack 32 is provided with at least one storage cavity 302 vertically distributed with the upper end surface of the storage rack 32, the transfer crucible 33 is embedded in the storage cavity 302 and coaxially distributed with the storage cavity 302, the upper end surface of the shelf 32 is further provided with a horizontal driving mechanism 35 which is distributed in parallel with the axis of the transfer crucible 33, the horizontal driving mechanism 35 is further connected with at least one electrostatic spraying gun 36 and at least one high-pressure jet nozzle 37 through a slide block 303, the axes of the electrostatic spraying gun 36 and the high-pressure jet nozzle 37 are intersected with the axis of the transfer crucible 33, and the intersection point is located at a position between the bottom and the top of the transfer crucible 33, the electrostatic coating gun 36 is further communicated with a solid release agent storage tank 38 through a feed pump 39, the high-pressure jet nozzle 37 is communicated with the jet fan 306, the solid release agent storage tank 38, the feeding pump 39 and the driving circuit 30 are all connected with the base 31, and the operation mechanical arm 34, the horizontal driving mechanism 35, the electrostatic coating gun 36, the jet fan 306 and the supply pump 39 are electrically connected with the driving circuit 30 and are electrically connected with the operation and control platform 9 through the driving circuit 30.
Preferably, the slide block 303 is hinged to the electrostatic spraying gun 36 and the high-pressure jet nozzle 37 through a turntable mechanism 304, an in-place detection sensor 305 is further arranged on each of the electrostatic spraying gun 36 and the high-pressure jet nozzle 37, and the turntable mechanism 304 and the in-place detection sensor 305 are electrically connected to the operation and control console 9.
Further optimally, the horizontal driving mechanism is any one of a 35-bit linear motor, a screw rod mechanism and a gear rack mechanism; the driving circuit 30 is a circuit system based on any one of an FPGA chip and a programmable controller.
In this embodiment, the electrostatic dust recycling device 5 includes a protection cavity 51, a negative pressure fan 52, a return air port 53, and a pm2.5 sensor 54, where the protection cavity 51 is a cavity structure with an axial cross-section shaped like "Jiong", covers the casting machine and is distributed coaxially with the casting machine 1, an operation port 55 is provided at a position on a side surface of the protection cavity corresponding to the casting transfer mechanical arm 3, the return air ports 53 and the pm2.5 sensor 54 are both located in the protection cavity 51, at least two return air ports 53 are uniformly distributed around an axis of the protection cavity 51 and connected with an inner surface of a side wall of the protection cavity 51, an axis of the return air port 53 intersects with an axis of the protection cavity 51 and is 30 to 90 degrees, the pm2.5 sensor 54 is embedded in a top of the protection cavity 51 and is distributed coaxially with the protection cavity 51, the return air port 53 includes a flow guide port 531, a bearing keel 532, an electrode needle 533 and an insulating pad 534, the flow guide port 531 is a hollow tubular structure with an axial cross-shaped like an isosceles trapezoid, the rear end face of the electrode needle 533 is embedded in the flow guide port 531 and coaxially distributed with the flow guide port 531, the front end face of the electrode needle 533 exceeds the front end face of the flow guide port 531 by 0-10 mm, the rear end face of the electrode needle 533 is connected and coaxially distributed through the insulating cushion block 531, the insulating cushion block 534 is connected with the inner side face of the flow guide port 531 through the bearing keel 532, the bearing keel 532 is a conical frame structure coaxially distributed with the flow guide port 531, the conical top of the bearing keel is located at a position close to the rear end face of the flow guide port 531, the distance between the conical top of the bearing keel and the rear end face of the flow guide port 531 is 0-1/3 of the depth of the flow guide port 531, the negative pressure fan 52 is connected with the outer side face of the protective cavity 51 and is communicated with the tail material collecting station 7 through the flow guide pipe, and the negative pressure fan 52, the pm2.5 sensor 54 and the static needle 533 of the return air port 53 are electrically connected with the control operation platform 9.
In this embodiment, the tailing collecting station 7 includes a frame 71, a waste liquid recovery tank 72, a bag-type dust collector 73, a reflux pump 74 and a reflux fan 75, wherein the frame 71 has a frame structure with a rectangular axial cross section, at least one of the waste liquid recovery tank 72 and the bag-type dust collector 73 is embedded in the frame 71, the waste liquid recovery tank 72 and the bag-type dust collector 73 are connected in parallel, the waste liquid recovery tank 72 is communicated with the supply pipeline 12 through the reflux pump 74 and is communicated with the casting machine 1 through the supply pipeline 12, the bag-type dust collector 73 is communicated with the supply pipeline 12 through the reflux fan 75 and is communicated with the electrostatic dust recovery device 5 through the supply pipeline 12, the bag-type dust collector 73 is further communicated with the at least one waste liquid recovery tank 72 through the reflux fan 75, and the waste liquid recovery tank 72, the bag-type dust collector 73, the reflux pump 74 and the reflux fan 75 are all communicated with the main control workstation 8, and the reflux fan 75, The console 9 is electrically connected.
During cleaning of the release agent and the residual metal residues after casting, a low-pressure environment is generated at a return air port by using a return fan, the release agent suspended in a protective cavity and the residual metal residues after casting are collected and purified in a centralized manner, and meanwhile, the release agent and the residual metal residues after casting can be actively adsorbed and collected by an electric field effect generated by electrode needles in the return air ports, so that the collection and purification operation efficiency of the release agent and the residual metal residues after casting is improved.
In this embodiment, the main control workstation 8 and the operation and control console 9 both include an electric control cabinet and a circuit system, and the circuit system is embedded in the electric control cabinet, wherein the circuit system of the master control workstation 8 comprises a power supply circuit, a power regulating circuit, a voltage regulating and rectifying circuit and a drive circuit based on a programmable controller, and the drive circuit based on the programmable controller is respectively electrically connected with the power supply circuit, the power regulating circuit, the voltage regulating and rectifying circuit and the circuit system of the operation and control workbench, the circuit system of the operation and control operation platform 9 is an operation and control circuit system based on any one of an FPGA chip and a DSP chip, the control circuit system is additionally provided with a control interface shared by any one or more of a button, a display, a potentiometer and a multi-section switch, and the control interface is embedded in the outer side surface of the electric control cabinet of the control operation platform.
In addition, the electric control cabinet of the operation and control operation platform 9 is slidably connected with the protective side wall 10 through a guide slide rail 14, the guide slide rail 14 is parallel to the ground plane, a towline slot 15 is arranged in the guide slide rail 14, the towline slot 15 and the guide slide rail 14 are coaxially distributed, and wires connected between the main control work station 8 and the operation and control operation platform 9 are embedded in the towline slot 15.
As shown in fig. 6, a method for using an electrostatic spray casting system includes the following steps:
s1, assembling equipment, namely, assembling a casting machine, a cooler, a casting transfer mechanical arm, a crucible holding furnace, an electrostatic dust recovery device, a hydraulic work station, a tailing collecting station, a main control work station, an operation control work table, a protective side wall and an operation door, establishing electrical connection between the main control work station and an external power supply system, establishing data connection between the operation control work table and an external remote control system, and recording an operation control program for casting operation into the operation control work table for caching; on the other hand, according to the requirement of casting operation, molten metal liquid to be cast is filled into a crucible heat-preserving furnace for heat preservation and standby, and meanwhile, corresponding release agents are respectively filled into each release agent storage tank of the electrostatic dust recovery device for standby, so that the prefabrication of the equipment can be completed;
s2, casting operation, after the step S1 is completed, firstly, the casting transfer mechanical arm carries out electrostatic spraying of a release agent meeting the requirement of the casting operation on the inner surface of a forming die of a casting machine according to the use casting requirement, a release agent layer is formed on the inner surface of the forming die, then the casting transfer mechanical arm is driven to operate according to the recorded casting program, a proper amount of molten metal is taken out from a crucible heat preservation furnace through a transfer crucible according to the use requirement by the casting transfer mechanical arm, the molten metal is transferred into the casting machine and is cast by the casting machine, after the workpiece is formed, the workpiece is demoulded and taken out, then the release agent on the surface of the forming die sprayed on the surface of the forming die is cleaned by high-pressure airflow through a high-pressure jet nozzle of the casting transfer mechanical arm, and the release agent is sprayed on the surface of the forming die again after the cleaning operation is completed, the repeated casting and molding operation is realized, and meanwhile, when the mold release agent is sprayed and cleaned and the casting and molding operation is carried out, on one hand, the tailing collection station is used for intensively recycling the waste liquid generated during the operation of the casting machine; on the other hand, the solid release agent in the spraying cleaning operation is recovered by the tailing collecting station and the return air inlet of the electrostatic dust recovery device, so that the pollution of the casting molding operation is eliminated.
In this embodiment, in the steps S1 and S2, the release agent is a powder release agent, which specifically includes, but is not limited to, boron nitride powder, graphite powder, gypsum powder, talc powder, mica powder, clay powder, and white clay powder.
Meanwhile, in the step S2, when the release agent spraying operation is performed, on one hand, the thickness and the adhesion acting force of the release agent adhering to the forming mold are adjusted by adjusting the electrostatic current value; on the other hand, the purpose of adjusting the adhesion force between the release agent and the forming die is achieved by adjusting the particle size of the release agent. Wherein:
in the spraying operation, the larger the electrostatic current value is, the larger the thickness of the release agent adhered to the surface of the forming die is, and the larger the adhesive force of the release agent is;
in the spray coating operation, the smaller the particle size of the release agent, the larger the adhesion force between the release agent and the molding die.
Further, in the release agent spraying work, among the release agents used;
boron nitride powder; the lubricant is similar to graphite in property, has good lubricity, and is an excellent high-temperature solid lubricant; the alloy can resist high temperature of 2000 ℃, has strong neutron absorption capacity and stable chemical property, and is chemically inert to almost all molten metals;
graphite powder: the melting point is 3850 +/-50 ℃, the boiling point is 4250 ℃, the thermal expansion coefficient is very small, the thermal conductivity coefficient is reduced along with the temperature rise, and graphite becomes a heat insulator even at extremely high temperature. The strength of the graphite is enhanced along with the increase of the temperature, the strength of the graphite is doubled at 2000 ℃, the lubricating property depends on the size of graphite flakes, the larger the flakes are, the smaller the friction coefficient is, the better the lubricating property is, the graphite has good chemical stability at normal temperature, can resist acid, alkali and organic solvent corrosion, can withstand the drastic change of the temperature without being damaged when used at normal temperature, and the volume change of the graphite is not large and cracks can not be generated when the temperature is suddenly changed, so that the surface quality of a casting can be effectively improved and enhanced while the demolding property is enhanced;
talc powder: the coating has the characteristics of lubricity, fire resistance, acid resistance, insulativity, high melting point, chemical inertness, good covering power and low friction factor, can make the surface of the coating smooth and soft, can effectively improve the demoulding performance and can also effectively improve and enhance the surface quality of a casting;
mica powder: the coating has the characteristics of insulativity, high temperature resistance, acid and alkali resistance, corrosion resistance, strong adhesive force, good toughness and good sliding property, and can effectively improve the surface quality of a casting while effectively improving the demolding performance;
gypsum powder: the heat preservation performance is good, the heat conductivity is low, the coating performance is excellent, and the surface of the cavity is smooth and clean. The roughness grade of the manufactured product can reach Ra1.6um.
When the electrostatic nozzle is used for spraying the release agent on the surface of the forming die, when the electrostatic effect is used for spraying, a guide magnetic field is applied to the negatively charged release agent particles sprayed from the electrostatic nozzle through a guide needle arranged outside each electrostatic nozzle and a driving electromagnet positioned in a conductive needle, and the adhesion force between the running direction machine of the sprayed negatively charged release agent particles and the surface of the forming die is adjusted through the Lorentz force between the charges and the magnetic field, so that the aim of improving the spraying efficiency, the precision and the quality of the release agent is fulfilled.
On one hand, the invention effectively realizes the centralized arrangement and organic combination of the low-pressure casting system, the tailing purification system, the release agent spraying system and the molten metal caching and transferring equipment, greatly improves the integration and modularization degree of the low-pressure casting operation system, and effectively improves the automation and intellectualization of the low-pressure casting operation, thereby achieving the purpose of improving the working efficiency of the low-pressure casting operation, effectively realizing the centralized collection and treatment of waste liquid, waste and solid waste generated in the casting process, and reducing the pollution of the casting operation to the environment; on the other hand, when the low-pressure casting operation is carried out, the efficiency and the precision of the spraying operation of the release agent and the spraying quality between the release agent and the surface of the forming die are effectively improved, the recycling casting operation efficiency of the forming die for casting is improved, the convenience of separation of the die from a workpiece after die opening is improved through high die recycling rate and the release agent, and the purposes of improving the working efficiency of the casting operation and the quality of a casting are achieved.
Meanwhile, the cooling sequence of the product can be adjusted by using the heat conductivity coefficient of the solid powder release agent, and the stability of the cooling sequence is improved, so that the casting forming quality of the workpiece is further improved.
The foregoing shows and describes the general principles and broad features of the present invention and advantages thereof. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (10)
1. An electrostatic spraying's casting molding system which characterized in that: the electrostatic spraying casting forming system comprises a casting machine, a cooling machine, a casting transfer mechanical arm, a crucible holding furnace, a hydraulic working station, an electrostatic dust recovery device, a tailing collecting station, a main control working station, an operation control working platform, a protective side wall and an operation door, wherein the protective side walls are a plurality of and are vertically distributed with a horizontal plane and are sequentially connected end to form an operation cavity with a cross section in a closed annular structure, the casting machine, the casting transfer mechanical arm, the crucible holding furnace and the tailing collecting station are all positioned in the operation cavity and are respectively and electrically connected with the main control working station and the operation control working platform, the main control working station, the operation control working platform and the cooling machine are positioned outside the operation cavity and are connected with the outer surface of the protective side wall, the operation control working platform is respectively and electrically connected with the cooling machine and the main control working station, the crucible holding furnace and the casting machine are symmetrically distributed on two sides of the center line of the operation cavity, the casting transfer mechanical arm is positioned between the crucible holding furnace and the casting machine, the hydraulic working station and the tailing collecting station are positioned on two sides of the axis of the operation cavity and are communicated with the casting machine through a supply pipeline, the electrostatic dust recovery device covers the upper end surface of the casting machine and is communicated with the tailing collecting station through the supply pipeline, 1-2 operation doors are arranged on the protection side wall corresponding to the operation cavity, and the operation doors are in sliding connection with the protection side wall.
2. The electrostatic spray foundry molding system of claim 1, wherein: the casting transfer mechanical arm comprises a base, a storage rack, a transfer crucible, an operation mechanical arm, a horizontal driving mechanism, an electrostatic spraying gun, a high-pressure jet nozzle, a jet fan, a solid release agent storage tank, a feed pump and a driving circuit, wherein the base is connected with the ground plane of an operation cavity, the upper end surface of the base is hinged with the operation mechanical arm through a three-dimensional turntable mechanism, the axis of the operation mechanical arm forms an included angle of 0-180 degrees with the ground plane, the front end surface of the operation mechanical arm is hinged with the storage rack through the three-dimensional turntable mechanism, the storage rack is of a frame structure with a rectangular cross section, the upper end surface of the storage rack forms an included angle of 0-180 degrees with the ground plane, the upper end surface of the storage rack is provided with at least one storage cavity which is vertically distributed with the upper end surface of the storage rack, the transfer crucible is embedded in the storage cavity and coaxially distributed with the storage cavity, and the upper end surface of the storage rack is additionally provided with a horizontal driving mechanism which is distributed in parallel with the axis of the transfer crucible, horizontal drive mechanism is connected through slider and at least one electrostatic spraying rifle and at least one high-pressure efflux spout in addition, electrostatic spraying rifle, high-pressure efflux spout axis intersect with the transportation crucible axis, and the nodical position in transportation crucible top, the electrostatic spraying rifle is in addition through feed pump and solid release agent storage jar intercommunication, high-pressure efflux spout and jet fan communicate each other, jet fan, solid release agent storage jar, feed pump and drive circuit all with pedestal connection, just operation arm, horizontal drive mechanism, electrostatic spraying rifle, jet fan, feed pump all with drive circuit electrical connection to through drive circuit and control operation panel electrical connection.
3. The electrostatic spray foundry molding system of claim 2, wherein: the slide block is hinged with the electrostatic spraying gun and the high-pressure jet nozzle through a turntable mechanism, and the electrostatic spraying gun and the high-pressure jet nozzle are respectively provided with an in-place detection sensor.
4. The electrostatic spray foundry molding system of claim 1, wherein: the electrostatic dust recovery device comprises a protection cavity, a negative pressure fan, a return air port and pm2.5 sensors, wherein the protection cavity is of a cavity structure with an axial section in the shape of Jiong and is coated above the casting machine and coaxially distributed with the casting machine, an operation port is arranged at the position, corresponding to the casting transfer mechanical arm, of the side surface of the protection cavity, the return air port and the pm2.5 sensors are both positioned in the protection cavity, at least two return air ports are uniformly distributed around the axis of the protection cavity and are connected with the inner surface of the side wall of the protection cavity, the axis of the return air port is intersected with the axis of the protection cavity and is 30-90 degrees, the pm2.5 sensors are embedded in the top of the protection cavity and are coaxially distributed with the protection cavity, each return air port comprises a flow guide port, a bearing keel, an electrode needle and an insulating cushion block, the flow guide port is of a hollow tubular structure with an isosceles trapezoid axial section, and the rear end surface of the flow port is communicated with the negative pressure fan through a drainage tube, the electrode needle latter half inlay in the water conservancy diversion mouth and with the coaxial distribution of water conservancy diversion mouth, the terminal surface surpasss water conservancy diversion mouth front end off-plate 0-10 millimeter before the electrode needle, and the rear end passes through insulating cushion and connects and coaxial distribution, and insulating cushion is connected with water conservancy diversion mouth medial surface through bearing fossil fragments, it is the toper frame construction with water conservancy diversion mouth coaxial distribution to bear fossil fragments, and its vertex of a cone is located and is close to water conservancy diversion mouth rear end face position department, and is 1/3 to the water conservancy diversion mouth degree of depth with water conservancy diversion mouth rear end face interval, negative pressure fan is connected with protection chamber lateral surface to through honeycomb duct and tails collecting station intercommunication, the static needle of negative pressure fan pm2.5 sensor and return air inlet all with control operation panel electrical connection.
5. The electrostatic spray foundry molding system of claim 1, wherein: the tailings collection station comprises a frame, a waste liquid recovery tank, a bag-type dust collector, a reflux pump and a reflux fan, wherein the frame is of a frame structure with a rectangular axial cross section, the waste liquid recovery tank and the bag-type dust collector are at least one and embedded in the frame, the waste liquid recovery tanks and the bag-type dust collectors are connected in parallel, the waste liquid recovery tank is communicated with a supply pipeline through the reflux pump and the supply pipeline and communicated with a casting machine through the supply pipeline, the bag-type dust collector is communicated with the supply pipeline through the reflux fan and the supply pipeline and communicated with an electrostatic dust recovery device through the supply pipeline, the bag-type dust collector is additionally communicated with at least one waste liquid recovery tank through the reflux fan, and the waste liquid recovery tank, the bag-type dust collector, the reflux pump and the reflux fan are all electrically connected with a master control workstation and an operation console.
6. The electrostatic spray foundry molding system of claim 1, wherein: the main control workstation, control the operation panel all include automatically controlled cabinet and circuit system, and circuit system all inlays in automatically controlled cabinet, wherein the circuit system of main control workstation includes power supply circuit, power regulating circuit, voltage regulation rectifier circuit, based on programmable controller drive circuit as the basis, just based on programmable controller drive circuit on the basis respectively with power supply circuit, power regulating circuit, voltage regulation rectifier circuit and control the circuit system electrical connection of operation panel, the circuit system of controlling the operation panel is based on arbitrary one in FPGA chip, the DSP chip controls circuit system, control circuit system establishes in addition based on button, display, potentiometre and the arbitrary one of multisection switch or several kinds of control interface that share, control the interface and inlay in the lateral surface of controlling the automatically controlled cabinet of operation panel.
7. The electrostatic spray foundry molding system of claim 1, wherein: the electric control cabinet and the protective side wall of the control operation platform are connected in a sliding mode through guide sliding rails, the guide sliding rails are distributed in parallel with the ground plane, a towline groove is formed in each guide sliding rail, the towline grooves and the guide sliding rails are distributed coaxially, and wires connected between the main control workstation and the control operation platform are embedded in the towline grooves.
8. The use method of the electrostatic spraying casting and forming system is characterized by comprising the following steps:
s1, assembling equipment, namely, assembling a casting machine, a cooler, a casting transfer mechanical arm, a crucible holding furnace, an electrostatic dust recovery device, a hydraulic work station, a tailing collecting station, a main control work station, an operation control work table, a protective side wall and an operation door, establishing electrical connection between the main control work station and an external power supply system, establishing data connection between the operation control work table and an external remote control system, and recording an operation control program for casting operation into the operation control work table for caching; on the other hand, according to the requirement of the casting industry, molten metal liquid for casting is filled into a crucible heat-preserving furnace for heat preservation and standby, and meanwhile, corresponding release agents are respectively filled into each release agent storage tank of the electrostatic dust recovery device for standby, so that the prefabrication of the equipment can be completed;
s2, casting operation, after the step S1 is completed, firstly, the casting transfer mechanical arm carries out electrostatic spraying of a release agent meeting the requirement of the casting operation on the inner surface of a forming die of a casting machine according to the use casting requirement, a release agent layer is formed on the inner surface of the forming die, then the casting transfer mechanical arm is driven to operate according to the recorded casting program, a proper amount of molten metal is taken out from a crucible heat preservation furnace through a transfer crucible according to the use requirement by the casting transfer mechanical arm, the molten metal is transferred into the casting machine and is cast by the casting machine, after the workpiece is formed, the workpiece is demoulded and taken out, then the release agent on the surface of the forming die sprayed on the surface of the forming die is cleaned by high-pressure airflow through a high-pressure jet nozzle of the casting transfer mechanical arm, and the release agent is sprayed on the surface of the forming die again after the cleaning operation is completed, the repeated casting and molding operation is realized, and meanwhile, when the mold release agent is sprayed and cleaned and the casting and molding operation is carried out, on one hand, the tailing collection station is used for intensively recycling the waste liquid generated during the operation of the casting machine; on the other hand, the solid release agent in the spraying cleaning operation is recovered by the tailing collecting station and the return air inlet of the electrostatic dust recovery device, so that the pollution of the casting molding operation is eliminated.
9. The method of using an electrostatically sprayed foundry molding system in accordance with claim 8, wherein: in the steps S1 and S2, the release agent is a powder release agent, specifically including but not limited to boron nitride powder, graphite powder, gypsum powder, talc powder, mica powder, clay powder, and white clay powder.
10. The method of using an electrostatically sprayed foundry molding system in accordance with claim 8, wherein: in the step S2, when the release agent is sprayed, on one hand, the thickness and the adhesion force of the release agent adhering to the molding die are adjusted by adjusting the electrostatic current value; on the other hand, the purpose of adjusting the adhesion force between the release agent and the forming die is achieved by adjusting the particle size of the release agent.
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