DE102005055877B4 - Separation of cast body and mold by selective unpacking - Google Patents

Abstract

A method of automatically separately unpacking a casting, in particular as a casting tube or a casting mold from a molding box stack, in which method
(a) in a first step
the molding box stack is opened from a top box and a bottom box placed on a transport pallet (P) with a cast piece lying therein by removing the top box;
(b) in a second step
an automatic transfer of the casting (G) with a small amount of enveloping thermally stressed molding sand and with inner core sand in a cooling shell (20) by turning the opened residual molding box stack together with the cooling shell (20), and from the turned remainder -Formkastenstapel the casting falls with the small amount of enveloping thermally stressed molding sand and with the inner core sand in the cooling shell (20), which stands below it when the casting falls down;
(c) and in at least one further step
from the remainder of the stack of mold boxes, the lower box is removed and placed in an ejector of the ...

Description

The invention relates to a method for automatic separate unpacking of a cast body, esp. A Gusstraube and a mold from a foundry molding box stack. Also affected is a device of individual automatic devices for automatic separate unpacking of Gusstraube and mold from a foundry molding box stack. The molding box stack includes
a top box and
a placed on a transport pallet lower box with it lying
Casting, especially a casting mold or cast iron tube.

On an automatic molding plant are required for casting Sand molds made. Here, the two molding boxes for upper and Lower part over the with model plates for put a cylinder head or a cylinder crankcase stocked model carrier. The molding sand is filled in the two molding boxes and compacted by pressing. The molding sand takes on the contour of the models. Before the casting or adding the cores are inserted into the lower mold half, the two mold halves assembled and transported the closed mold to the automatic casting machine.

At the Cast the sand molds are filled with the required amount of liquid iron. This is e.g. above an electronically controlled plug of the casting machine ensured.

After this the castings have cooled to a required unpacking temperature, The sand bale with the Gusstraube is knocked out of the molding box. The Gusstraube is separated from the sand bale and the subsequent process steps Tapping and cleaning supplied.

In a casting production in an automatic box-shaped molding plant DE 23 15 725 A1 the cast-off mold package - consisting of upper box, lower box, clay-bound sand mold and inner Gusstraube - moved into a demolding station, and lifted the top box, moving the lower box and unpacked by turning the lower box with the form this on a Rüttelrost solely by gravity. The separation of the Gusstraube from the sand mold takes place on the Rüttelrost, whereby the molding and core sand slips through the grate grid. The Gusstraube or the casting remain on the Rüttelrost and are by shaking or according to the proposal of the aforementioned DE 23 15 725 A1 transported away from a carriage with pivoting grate bars, with a transfer to a refrigerated container (there 22).

Other earlier used methods for separating cast body and mold used gripper systems, those in the open Grab the lower case and remove a respective Gusstraube. A disadvantage of this method is that for each (different styled) casting and even different for each one to take out trained Gusstraube a special gripper constellation necessary is.

Suggestions for the selective treatment of foundry old sands are the DE 41 21 765 C2 (Georg Fischer) and the DE 40 40 573 A1 (Georg Fischer) and the DE 198 10 273 A1 (Mazda). The former document has a four-stage treatment process in which, inter alia, a separation between large and small grains of the foundry used to be regenerated sand is made, and the smaller grains are thermally treated, see. there example column 4, lines 8 to 31. In the second-mentioned document, the regenerate is also separated and fed to two separate circuits. In a regeneration stage, there 6, branched off residual dust is quantitatively replaced by core sand, which is supplied to the system. From the molding plant sand is collected under the Auspackrost, which is given to the treatment plant, but not separated according to what types of sand from the sand mold arise, but generally old sand is defined as the sum of the molded, already used sand. Differently works here the regeneration of the sand according to the third mentioned writing (Mazda), which after the disassembly of the form, step S3 already pays attention, which kind of sand is separated and a separate collecting of the sand of an outer shell section of a wet casting mold and the sand in the inner shell portion of the wet casting mold makes, see. there claim 1 and column 3, line 44 et seq. The there named two types of sand of fatigued sand A and the remaining vital molding sand B is achieved by a vibrating conveyor, which separates the particles of fatigued sand molds from the lumps of the vital molding sand and thereby separated Förderbahnen are fed, which are named there with 18.19. Finally, that is EP 1 260 288 A1 (Sintokogio) to take a way of breaking up the sand mold, which is described primarily in the paragraphs [17] and [18]. In a separate chamber, the sand mold is subjected to a strong sinking pressure, so that the part of the sand mold, which is less affected by the heat of the casting process, can be blasted off or broken off, and then make a separate further treatment of the sand. Here is the separation of the sand in the remaining residual form (after removal of the casting grape).

To damage by shaking too In order to avoid or to influence the solidification and cooling of the cast body, delicate casting bodies, the cast iron tube and the molding material from the molding box should be unpacked separately during manufacture, whereby the lower and upper box must first be opened. The object of the invention is to realize the selective unpacking by a shape-independent removal of the Gusstraube from the open mold box.

According to the invention Task by a technical device Structure and a process sequence according to the invention realized as in the claims 1, 2 or 4 circumscribed.

Surprised This also improves the selectivity when selecting the thermal differently stressed sand parts of the mold.

Thereby reduces the expenditure on equipment. Grippers will not work anymore adapted to a respective cast body needed.

The Environmental impact decreases during the process step of removing the cast body the mold. Affected are reduced emissions, dust loads and waste heat.

• • Die Formschichten, die relativ entfernt von der Gussoberfläche sind, sind thermisch wenig oder kaum beansprucht. Der Formstoff behält dadurch nahezu vollständig seine Eigenschaften und wird mit wenig Aufwand zur erneuten Formherstellung wiederaufbereitet.
• • Der Formstoff in der Nähe der Gusstraube und die die Hohlräume des Gusskörpers bildenden Kerne sind thermisch stark beansprucht: – Der tongebundene Formstoff – bestehend aus Formgrundstoff (meistens Quarzsand), Ton (meistens Bentonit), Zusätze (meistens kohlenstoffhaltige Zusätze) und Wasser – verliert durch die Gießhitze den größten Teil seines Wassergehaltes. Durch die thermische Beanspruchung verliert auch der Ton vollständig oder teilweise seine Bindefähigkeit und die Zusätze verbrennen vollständig oder teilweise. – Die Sandkerne – bestehend aus Formgrundstoff (meistens Quarzsand) und Binder (meistens organischer Natur) – zerfallen nahe zu vollständig.

Further advantages of the selective unpacking result from the possibility of separating the thermally differently stressed mold parts into two separate used sand streams and to further process them selectively.

• • The mold layers, which are relatively remote from the casting surface, are thermally little or hardly stressed. As a result, the molding material almost completely retains its properties and is reprocessed with little effort for re-molding.
• • The molding material in the vicinity of the Gusstraube and the cores of the casting forming cores are thermally stressed: - The clay-bound molding material - consisting of mold base material (mostly quartz sand), clay (usually bentonite), additives (mostly carbonaceous additives) and water - loses through the casting heat most of its water content. Due to the thermal stress and the clay loses all or part of its ability to bind and the additives burn completely or partially. - The sand cores - consisting of mold base material (mostly quartz sand) and binder (mostly organic nature) - decay close to complete.

This thermally stressed used sand requires much more energy for one Preparation for clay-bound molding material than the remaining molding sand a poured mold. He is but due to its thermal (Pre) treatment much easier to process reclaimed, then reused as a new sand substitute in core production to be.

The Invention based on embodiments explained and supplemented with the aid of the drawing. In In the following description of examples, concepts are rewritten.

1 is an example of a device for a cooling shell for a molding box stack (crossfeed).

2 is a turner in another step of the workflow.

3 is the turner in yet another step of the workflow with 180 ° turn.

4a is a bumper above the inverter in yet another step of the workflow.

4b is a lowering of the cooling shell in yet another step of the workflow.

5 is the turner in a further step of the procedure with removal of the bumper.

6 is the turner in a further step of the workflow when filling with the next "set" (box stack of sub-box and pallet).

7-1 to 7-10 are individual steps in the workflow with a longitudinal feed of the cooling shell 21 ,

• 1) Das Formpaket, bestehend aus Oberkasten, Unterkasten 1, Sandform und innen liegender Gusstraube als Beispiel eines Gusskörpers, befindet sich auf einer Palette und wird mittels dieser Palette vom Gießbereich in den Kühlbereich der Formanlage transportiert.
• 2) Am Ende eines ersten Kühlabschnittes wird der Oberkasten abgenommen. Beim Öffnen des Formkastenstapels und Abnehmen des Oberkastens verbleibt der thermisch wenig beanspruchte verdichtete Formsand im Oberkasten. Beim Abnehmen findet eine Sandtrennung entlang der durch die Gießhitze verursachten Kondensationszone statt. Der Oberkasten wird konventionell wegtransportiert und in einer konventionellen Ausstoßvorrichtung vom Formstoff durch Ausdrücken befreit. Damit beginnt am Ende des ersten Kühlabschnittes der Vorgang des selektiven Auspackens des Rest-Formkastenstapels als Set.
• 3) Der verbliebene Kastenstapel, bestehend aus Palette und Unterkasten mit innen liegender Gusstraube, durchläuft OPTIONAL eine Stechvorrichtung. Der auf dem Unterkasten umliegende Sand wird mit der von oben beweglichen Stechvorrichtung freigestochen. Durch das Freistechen werden gezielt weitere thermisch wenig beanspruchte Formpartien selektiert.
• 4) Der verbliebene Kastenstapel wird OPTIONAL in eine Wendevorrichtung eingeführt. Zunächst fährt ein beweglicher Niederhalter zum Niederhalten der Gusstraube herunter. Danach wird der Kastenstapel für kurze Zeit vor- und zurückgewendet und der freigestochene Sand auf eine Rinne ausgekippt.
• 5) Der nach Schritt 2 verbliebene Kastenstapel, bestehend aus Palette und Unterkasten mit innen liegender Gusstraube, wird nach Ziffer 2, 3 oder 4 in einen zweiten Kühlabschnitt transportiert. Hier wird die Gusstraube mit einer geringen Menge von umhüllendem Formsand und mit innen liegendem Kernsand vom Unterkasten in eine Kühlschale überführt, dann mit der Kühlschale weiter gefördert und gekühlt. Anschließend wird der Gusskörper von thermisch stark beanspruchtem Sand konventionell gereinigt.
• 6) Der Unterkasten mit dem in ihm verbliebenen thermisch wenig beanspruchten verdichteten Formsand wird konventionell weitertransportiert und in einer konventionellen Ausstoßvorrichtung vom Formsand durch Ausdrücken befreit. Damit endet der Vorgang des selektiven Auspackens bei diesem Beispiel.

Examples of a first procedure are:

• 1) The mold package, consisting of upper box, lower box 1 , Sand mold and internal Gusstraube as an example of a cast body, located on a pallet and is transported by means of this range from the casting area in the cooling area of the molding plant.
• 2) At the end of a first cooling section, the top box is removed. When opening the mold box stack and removing the top box, the thermally less stressed compacted sand remains in the top box. When removing a sand separation takes place along the caused by the casting heat condensation zone. The upper box is conventionally transported away and freed from the molding material by pressing in a conventional ejector. Thus begins at the end of the first cooling section of the process of selectively unpacking the rest of the mold box stack as a set.
• 3) The remaining stack of boxes, consisting of Pallet and lower box with inner Gusstraube, OPTIONAL goes through a lancing device. The sand surrounding the lower box is pierced with the lancing device, which is movable from above. The freestyle specifically selects more thermally less stressed form parts.
• 4) The remaining stack of boxes is inserted OPTIONAL in a turning device. First, a movable hold-down moves down to hold down the Gusstraube. Thereafter, the stack of piles is turned back and forth for a short time and dumped the sand liberated on a gutter.
• 5) The remaining after step 2 stack of boxes, consisting of pallet and lower box with inner Gusstraube is transported to paragraph 2, 3 or 4 in a second cooling section. Here, the Gusstraube is transferred with a small amount of enveloping molding sand and with inner core sand from the lower box in a cooling shell, then further promoted and cooled with the cooling shell. Subsequently, the casting of thermally stressed sand is conventionally cleaned.
• 6) The lower box with the thermally less stressed compacted molding sand remaining in it is conventionally transported on and released from the molding sand in a conventional ejection device by expressions. This ends the process of selective unpacking in this example.

LOSE WEIGHT

TRANSFER OF CAST BODY

version 1

Crossfeed of the cooling trays

• 7) An empty cooling bowl 20 is removed by means of a translator from a branch line and applied to the upwardly open bottom box with the bottom up, such as 1 shows.
• 8) The cooling shell has previously gone through a turning device and possibly remaining Sand from the previous process has been spilled.
• 9) The stack of pallet, lower box with cast body and inverted clamped cooling shell is turned into a special turning device 30 hazards. The cooling shell 20 is fixed or clamped on the lower case as below 2 ,
• 10) In the turning device 30 the entire stack is rotated 180 °. This is the cooling shell 20 now below and the sub-box 1 with pallet P is up, as after 3 ,
• 11) Above the turning device 30 OPTIONAL is a push device 10 accommodated. This shock device consists of long rods. The long rods of the pushing device push through openings in the pallet P and the predrilled holes in the sand mold the Gusstraube (the casting G) in the cooling shell 20 like after 4a (Comparison left / right field).
• 12) The Gusstraube with inner core sand and little adhering foundry sand falls into the cooling shell with minimal drop height 20 , Especially with heavy cast screws is a shock device after 10 not necessary, because the Gusstraube G falls into the cooling bowl by its own weight.
• 13) The cooling shell is de-clamped and a lifting device H below the Wenders lowers the now correct position cooling shell, as after 4b ,
• 14) The bumper 10 gets up from the access level of the Wenders 30 removed and the turner with the lower box and pallet turned back by 180 °, as shown 5 (right picture).
• 15) In the following box thrust of the sub-box is further promoted with the remaining in it thermally stressed molding sand and the turning device 30 filled with the next set as after 6 ,
• 16) Below is the cooling shell transported away and placed laterally or longitudinally in any form in a cooling tray conveyor.

Variant 2

Longitudinal feed of cooling trays

• 17) After removing the top box (corresponding to Point 2) and after the optional freestyle (corresponding to point 3) and dump of loose sand (according to point 4) becomes the remaining stack of boxes, consisting of pallet and lower case with inner cast iron tube, in a second cooling section transferred (corresponding to Point 5).
• 18) Under the second cooling section, a cooling-cup transport path runs parallel, cf. 7-1 , The transport of the cooling shells 21 takes place as the box stack by means of conventional pushers.
• 19) The stack of boxes is turned into a turning device by box push 31 introduced. In the upper part of the Wenders is an empty cooling shell 2 positioned and fixed with the floor up. In the lower part of the Wenders a short lifting device h is integrated. A second, higher lifting device H is located below the turner and at the height of the cooling-plate web, cf. 7-1 ,
• 20) After the box push the remaining stack of boxes from pallet and lower box by means of the integrated lifting device in the inverter h to cooling tray 21 lifted, cf. 7-2 ,
• 21) The stack of pallet, lower box with cast iron tube and cooling bowl is turned by 180 °, cf. 7-3 ,
• 22) The Gusstraube with inner core sand and little adhesive Form sand falls with minimal drop height in the cooling bowl. Especially with heavy cast screws is a corresponding point 11 described shock device not required because the Gusstraube by its own weight in the cooling shell falls.
• 23) The lifting device H below the Wenders takes over the now correctly positioned cooling shell with the Gusstraube, cf. 7-4 ,
• 24) The cooling shell 21 with the filled Gusstraube is lowered by means of the lifting device on the cooling tray track, see. 7-5 ,
• 25) In the cooling tray track, the transport thrust takes place. This will make the full cooling shell through an empty cooling shell 21a replaced, cf. 7-6 ,
• 26) The lifting device H below the reverser moves up again, takes over the new empty cooling shell and lifts it into the turner 31 high, where the empty cooling shell is fixed, cf. 7-7 ,
• 27) The lifting device H below the inverter is lowered back to the height of the cooling tray track, see. 7-8 ,
• 28) The turner with the stack of pallet, empty lower box and empty cooling shell is turned back by 180 °, cf. 7-9 ,
• 29) The box stack of pallet and lower box (without Gusstraube) is lowered by means of integrated in the inverter turning device to the height of the cooling section, see. 7-10 ,
• 30) In the cooling section, the transport thrust for the molding boxes (lower box with pallet) takes place. As a result, the lower box is replaced with the remaining in it thermally little strained molding sand of the next full sub-box and the process for transferring the Gusstraube from the lower box into the cooling shell ( 21a it will 21 ) can start again, cf. 7-1 ,

Claims (4)

A method of automatically separately unpacking a casting, in particular as a casting tube or mold from a molding box stack, in which method (a) in a first step, the forming box stack of top box and bottom box placed on a transport pallet (P) with cast piece therein by removal of the top box is opened; (B) in a second step, an automatic transfer of the casting (G) with a small amount of enveloping thermally stressed molding sand and with inner core sand in a cooling shell ( 20 ) by turning the opened residual molding box stack together with the cooling shell ( 20 ) takes place, and from the turned residual molding box stack the casting with the small amount of enveloping thermally stressed molding sand and with the inner core sand in the cooling shell ( 20 ), which is below it, when the casting falls down; (C) and is removed in at least one further step from the remainder of the mold box stack of the lower box and is released in a discharge device of the remaining little-stressed molding sand by pressing. An apparatus of individual automatic devices for unpacking a cast tube and mold from a foundry box stack, means being provided which (a) open the box stack of top box and bottom box on a transport pallet (P) with cast piece located therein by removing the top box ; (B) an automatic transfer of the casting (G) with a small amount of enveloping thermally stressed molding sand and with inner core sand in a cooling shell ( 20 ) by turning the opened residual molding box stack together with the cooling shell ( 20 ), and from the turned residual mold box stack the casting with the small amount of enveloping thermally stressed molding sand and with the inner core sand in the cooling shell ( 20 ), which is below it, when the casting falls down; (c) further comprising: • a translating device placed the previously everted empty cooling shell on the remainder of the mold box stack as a sub-box; • a pusher the stack of pallet, lower box with cast iron tube and inverted cooling shell in a turning device ( 30 ) introduced; A clamping device the everted empty cooling shell ( 20 ) fixed to the opened rest-mold-box pile; The turning device rotates the clamped stack according to feature (b) by 180 ° and thereby the casting tube with a small amount of enveloping thermally stressed molding sand and with inner core sand from the lower box in the cooling shell ( 20 ) falls; • one under the turning device ( 30 ) positioned lifting device (H) the cooling shell ( 20 ) and lowers to a lying below the mold box stack section cooling shell section; • the individual automatic devices execute their sequence of movements in such a coordinated way that - after each box push, a new cooling shell ( 20 ) is placed on a new remainder box stack from which the top box was previously removed; - All molding boxes moved by one position who - returns each device after performing their sequence of movements in the starting position and performs a new sequence of movements for the next stack of boxes. Apparatus according to claim 2, wherein the pusher comprises the stack of pallet, lower box with cast iron tube and everted cooling shell ( 20 ) into the special turning device ( 30 ) and at the same time discharges the previous remaining mold box stack already emptied of the Gusstraube. An apparatus of individual automatic devices for unpacking a cast tube and mold from a foundry box stack, means being provided which (a) open the box stack of top box and bottom box on a transport pallet (P) with cast piece located therein by removing the top box ; (B) an automatic transfer of the casting (G) with a small amount of enveloping thermally stressed molding sand and with inner core sand in a cooling shell ( 21 ) by turning the opened residual molding box stack together with the cooling shell ( 21 ), and from the turned residual mold box stack the casting with the small amount of enveloping thermally stressed molding sand and with the inner core sand in the cooling shell ( 21 ), which is below it, when the casting falls down; (c) further comprising • a pusher, the pallet, lower box with cast iron tube, into a turning device ( 31 ) and at the same time removed the previous box already emptied of the Gusstraube; A lifting device (h) in the turning device ( 31 ) positioned, everted and empty cooling shell ( 21 ) lowered and fixed relatively on the lower box; The turning device ( 31 ) rotates the stack according to (b) by 180 ° and thereby the Gusstraube with a small amount of enveloping thermally stressed molding sand and with inner core sand from the lower box into the cooling shell ( 21 ) falls; A lifting device (H) positioned below the turner takes over the full cooling pan and lowers it to a cooling-cup route running under the mold-box stacking line; A further thrust device in the cooling-shell section the full cooling shell located in the region of the lowered lifting device ( 21 ) and at the same time introduces a new empty cooling tray into this position; • the new, empty cooling tray by raising the lifting device in the turner ( 31 ) is positioned; • the individual automatic devices execute their sequence of movements in such a coordinated manner that - after each box push a new opened stack of boxes in the turner ( 31 ) is introduced, wherein the opened box stack consists of lower box with mold and pallet, with removed top box; - Move the lower boxes with the pallets by one position; - Each device after returning its movement sequence returns to its original position to perform a new sequence of movements for the next stack of boxes.