EP1425123A2 - Method for controlling a vacuum valve of a vacuum diecasting device and vacuum diecasting device - Google Patents

Method for controlling a vacuum valve of a vacuum diecasting device and vacuum diecasting device

Info

Publication number
EP1425123A2
EP1425123A2 EP02777076A EP02777076A EP1425123A2 EP 1425123 A2 EP1425123 A2 EP 1425123A2 EP 02777076 A EP02777076 A EP 02777076A EP 02777076 A EP02777076 A EP 02777076A EP 1425123 A2 EP1425123 A2 EP 1425123A2
Authority
EP
European Patent Office
Prior art keywords
casting
piston
vacuum
vacuum valve
predetermined
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP02777076A
Other languages
German (de)
French (fr)
Other versions
EP1425123B1 (en
Inventor
Jürgen Wüst
Klaus Währisch
Dieter Auer
Elisabeth Wenzel
Christophe Bagnoud
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Magna BDW Technologies GmbH
Original Assignee
Magna BDW Technologies GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Magna BDW Technologies GmbH filed Critical Magna BDW Technologies GmbH
Publication of EP1425123A2 publication Critical patent/EP1425123A2/en
Application granted granted Critical
Publication of EP1425123B1 publication Critical patent/EP1425123B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/14—Machines with evacuated die cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/32—Controlling equipment

Definitions

  • the invention relates to a method for controlling a vacuum valve of a vacuum pressure casting device according to the preamble of claim 1.
  • the invention further relates to a vacuum pressure casting device according to the preamble of claim 2.
  • a generic vacuum pressure casting device in which the fill level of liquid metal when it is shot into the casting cavity is detected by a metal contact sensor which emits a signal upon contact with the liquid metal, which is then driven by a linear motor
  • the sealing piston of the vacuum valve is moved in such a way that the vacuum valve is completely closed at the time the metal is filled up accordingly.
  • the known vacuum die-casting device uses a meandering vacuum or ventilation channel in which a plurality of metal contact sensors are arranged, which are connected to a computer which controls the linear motor of the sealing piston in accordance with the signals from the sensors.
  • the invention has for its object to provide a method and an apparatus with which castings of improved quality can be produced.
  • a first solution to this problem is achieved with the method according to claim 1. Because the position of the piston with which the liquid casting material is pressed or shot into the mold cavity is detected according to the invention and the vacuum valve is closed depending on the piston position, it is possible to reliably close the vacuum valve only when the casting material, preferably liquid metal, reaches the vacuum valve. In this way, the casting mold or the casting cavity can be connected to a vacuum source for as long as possible, as a result of which contaminant gases, gases derived from lubricants and separating agents, etc., are sucked off, and a casting which is largely free of pores or inclusions is formed.
  • the claim 3 characterizes the basic structure of a vacuum die-casting device for solving the relevant part of the invention.
  • Claims 4 to 10 are directed to advantageous embodiments of the die casting device according to the invention.
  • the vacuum valve used according to claim 4 advantageously works with a short time delay, so that the closing signal can be generated as late as possible, whereby the closing time is largely independent of any fluctuations occurring during the operation of the casting device.
  • the point in time at which the closing signal has to be generated can currently be calculated from the piston speed.
  • Claims 7 to 9 are directed to advantageous characteristic curves stored in the control device, the operating state of the die casting device being able to be monitored with the features of claim 9. It is achieved with the features of claim 10 that operating fluctuations of the casting device are taken into account when generating the closing signal.
  • the invention is explained below with reference to schematic drawings, for example and with further details.
  • Fig. 1 is a schematic view of a vacuum die casting device
  • a vacuum die casting device contains at least two base bodies 2 and 4, which can be moved towards and away from one another in a manner known per se by means of a drive device (not shown).
  • An associated molded part 6 or 8 is fastened to each base body, with mutually facing surfaces of the molded parts 6 and 8 being formed such that a casting cavity 10 is formed when the base bodies or closed tools are moved towards one another.
  • a cylinder 12 which is open toward the casting cavity 10 and in which a piston 14 is movable and is connected via a shaft 16 to an actuator 17 for driving the piston 14, is used to introduce casting material, preferably liquid metal, into the casting cavity 10.
  • a filling line 18 leads through the wall of the cylinder 12 to fill in the liquid casting material.
  • a level sensor 20 adjoins the casting cavity 10 and generates a signal when it comes into contact with the casting material 22 rising in the casting cavity 10.
  • a vacuum opening 24 adjoins the upper end region of the casting cavity 10 and is connected to a vacuum pump 28 via a vacuum valve 26.
  • the vacuum valve 26 is of a type in which the valve member of the vacuum valve moves with the shortest possible delay into the closed position in which the vacuum valve 26 is closed upon a closing signal.
  • the valve member is actuated, for example, by means of an actuator, for example an electromagnet 30. It can also be carried out hydraulically or in some other suitable manner.
  • the position of the piston 14 or the shaft 16 is detected by a motion sensor 32 along the stroke of the piston 14.
  • the motion sensor 32 can, for example, be a linear sensor be a sensor or an incremental rotation sensor if the linear movement of the piston is converted into a rotary movement by means of appropriate mechanics.
  • the motion sensor 32, the fill level sensor 20 and the magnet of the vacuum valve 26 are connected to an electronic control unit 34 which contains a microprocessor with associated memory devices, a display unit, for example in the form of a display, and operating elements.
  • the actuator 17 which is hydraulic, for example, is advantageously switched from the trigger signal to a higher speed, so that the casting material is injected into the rest of the mold cavity at high speed and under high pressure.
  • Fig. 2 illustrates the situation.
  • the speed of the piston 14 is shown as a function of the distance s traveled. As can be seen, the piston movement begins at a low speed up to the position sj, at which the casting material 22 reaches the fill level sensor 20. The associated position s is stored in the control unit 34. At the same time, the force or, if provided, the speed at which the actuator 17 drives the piston 14 is switched to a high value. It is assumed that the position s 2 of the piston corresponds to the position in which the casting material has the vacuum opening 24 of the vacuum valve 26 reached, that is, the piston position at which the vacuum valve 26 must be closed in order not to be destroyed by the casting material.
  • the piston moves the distance ⁇ s within a predetermined delay time period ⁇ t that the vacuum valve 26 needs to conclude in response to a closing signal.
  • the closing signal for the vacuum valve 26 must then be generated at the point in time at which the piston has the position s 3 . Since the position si of the piston is marked in the control unit 17, the distance s 3 -s 2 or the position s 3 of the piston can be detected precisely with the aid of the motion sensor 32, and the closing signal for the vacuum valve 26 can be generated at this time.
  • FIG. 3 shows a characteristic curve which indicates the time course of the piston position.
  • the delay ⁇ t of the vacuum valve 26 is also shown in FIG. 3.
  • the characteristic curve of FIG. 2 can be generated by differentiating the characteristic curve of FIG. 3.
  • the characteristic of FIG. 2 or FIG. 3 can be recorded directly and the characteristic of FIG. 3 by integrating the characteristic of FIG. 2 or the characteristic of FIG. 2 by differentiating the characteristic of FIG. 3 are generated.
  • the casting cavity can be completely filled when the piston position s 2 is reached (casting material reaches the vacuum opening 24) or, as shown in the figures, can only be largely filled so that the piston has a small additional amount Distance traveled. It goes without saying that the piston can also be controlled in such a way that it is braked in the position s.
  • the target characteristic curve can be continuously visualized, for example on a screen, together with an actual characteristic curve, so that changes in the operation of the die casting device are immediately visible and any errors are recognized at an early stage. Furthermore, in the series production of castings, the characteristic curve which is used to determine s 3 can be updated continuously, for example by the actual characteristic curve of a casting process that occurred immediately behind is used as the characteristic curve for determining s 3 or a characteristic curve averaged from several previous casting processes.
  • the casting cavity can be subjected to vacuum for as long as possible during the casting, so that high-quality vacuum die-cast parts are produced.
  • the pore-free nature of the die-cast parts is further improved in that the final phase of the casting is carried out by the higher piston force under high casting pressure, so that any pores, insofar as the gas contained in them is not sucked out by the vacuum, are reduced in volume.
  • the device according to the invention can be modified and developed in a variety of ways.
  • a plurality of connections to vacuum valves and a plurality of level sensors starting from a casting cavity 10 can be provided in a pressure casting device, the application of the method according to the invention then presupposing that no changes occur in the relations of the fillings of the individual channels lying between the level sensors and the vacuum valves ,
  • the visualization of the characteristic of FIG. 2 is, as can be seen immediately, advantageous because of its good resolution; however, other characteristic curves can also be visualized.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Manipulator (AREA)
  • Compressors, Vaccum Pumps And Other Relevant Systems (AREA)
  • Control Of Fluid Pressure (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

A vacuum die casting apparatus includes a casting cavity ( 10 ), which is evacuatable via a vacuum valve ( 26 ). A liquid casting material is pressable into the casting cavity by a piston ( 14 ) actuated by an actuator ( 17 ). A filling level sensor ( 20 ) detects a predetermined filling level of the casting material in the casting cavity. A control device ( 34 ) is connected to the filling level sensor for controlling the vacuum valve, and a position sensor ( 32 ) is connected to the control device ( 34 ) for detecting movement of the piston ( 14 ). The control device generates a closing signal for the vacuum valve ( 26 ) when the piston, after reaching the position (s<SUB>1</SUB>) at which the filling level sensor ( 20 ) indicates a predetermined filling level of the casting cavity ( 10 ) with casting material has been reached, is displaced in a predetermined manner.

Description

Verfahren zum Steuern eines Vakuumventils einer Vakuumdruck- gießvorrichtung sowie Vakuumdruckgießvorrichtung Method for controlling a vacuum valve of a vacuum pressure casting device and vacuum pressure casting device
Die Erfindung betrifft ein Verfahren zum Steuern eines Vakuumventils einer Vakuumdruckgießvorrichtung gemäß dem Oberbegriff des Anspruchs 1. Die Erfindung betrifft weiter eine Vakuumdruckgießvorrichtung gemäß dem Oberbegriff des Anspruchs 2.The invention relates to a method for controlling a vacuum valve of a vacuum pressure casting device according to the preamble of claim 1. The invention further relates to a vacuum pressure casting device according to the preamble of claim 2.
Aus der DE 200 16 166 Ul ist eine gattungsgemäße Vakuumdruckgießvorrichtung bekannt, bei der der Füllstand von flüssigem Metall beim Einschießen in den Gießhohlraum von einem Metallkontaktsensor erfasst wird, der bei Kontakt mit dem flüssigen Metall ein Signal abgibt, auf das hin ein von einem Linearmotor angetriebener Verschlusskolben des Vakuumventils derart bewegt wird, dass das Vakuumventil zum Zeitpunkt der entsprechenden Auffüllung des Metalls ganz geschlossen ist. In einer Weiterbildung verwendet die bekannte Vakuumdruckgießvorrichtung einen mäanderförmig ausgebildeten Vakuum- bzw. Entlüftungskanal, in dem mehrere Metallkontaktsensoren angeordnet sind, die mit einem Rechner verbunden sind, der den Linearmotor des Verschlusskolbens entsprechend den Signalen der Sensoren steuert.From DE 200 16 166 Ul a generic vacuum pressure casting device is known, in which the fill level of liquid metal when it is shot into the casting cavity is detected by a metal contact sensor which emits a signal upon contact with the liquid metal, which is then driven by a linear motor The sealing piston of the vacuum valve is moved in such a way that the vacuum valve is completely closed at the time the metal is filled up accordingly. In a further development, the known vacuum die-casting device uses a meandering vacuum or ventilation channel in which a plurality of metal contact sensors are arranged, which are connected to a computer which controls the linear motor of the sealing piston in accordance with the signals from the sensors.
Wenn nur ein Metallkontaktsensor vorgesehen ist, können Schwankungen der Geschwindigkeit, mit der das geschmolzene Metall bei der Herstellung der Gussteile gefüllt wird, nicht ausgeglichen werden, so dass gewährleistet sein muss, dass das Vakuumventil auch bei hohen Einfüllgeschwindigkeiten rechtzeitig geschlossen wird, wodurch die Evakuierung vorzeitig beendet werden muss, was die Qualität des Gussteils nachteilig beeinflussen kann. Die Verwendung mehrerer Metallkontaktsensoren ist verhältnismäßig aufwendig.If only one metal contact sensor is provided, fluctuations in the speed at which the molten metal is filled during the production of the castings cannot be compensated for, so it must be ensured that the vacuum valve is closed in good time even at high filling speeds, as a result of which the evacuation is premature must be ended, which can adversely affect the quality of the casting. The use of several metal contact sensors is relatively complex.
Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren und eine Vorrichtung anzugeben, mit der sich Gussteile verbesserter Qualität herstellen lassen.The invention has for its object to provide a method and an apparatus with which castings of improved quality can be produced.
Eine erste Lösung dieser Aufgabe wird mit dem Verfahren gemäß dem Anspruch 1 erzielt. Dadurch, dass erfindungsgemäß die Stellung des Kolbens, mit dem das flüssige Gießmaterial in den Formhohlraum hin angedrückt bzw. eingeschossen wird, erfasst wird, und das Vakuumventil abhängig von der Kolbenstellung geschlossen wird, ist es möglich, das Vakuumventil zuverlässig erst dann zu schließen, wenn das Gießmaterial, vorzugsweise flüssiges Metall, das Vakuumventil erreicht. Auf diese Weise kann die Gießform bzw. der Gießhohlraum so lang wie möglich an eine Unterdruckquelle angeschlossen werden, wodurch Verunreinigungsgase, aus Schmier- und Trennstoffen entstammende Gase, usw., abgesaugt werden, und ein weitgehend von Poren bzw. Einschlüssen freies Gussteil entsteht.A first solution to this problem is achieved with the method according to claim 1. Because the position of the piston with which the liquid casting material is pressed or shot into the mold cavity is detected according to the invention and the vacuum valve is closed depending on the piston position, it is possible to reliably close the vacuum valve only when the casting material, preferably liquid metal, reaches the vacuum valve. In this way, the casting mold or the casting cavity can be connected to a vacuum source for as long as possible, as a result of which contaminant gases, gases derived from lubricants and separating agents, etc., are sucked off, and a casting which is largely free of pores or inclusions is formed.
Mit den Merkmalen des Anspruchs 2 wird die Qualität der hergestellten Vakuumgussteile weiter verbessert.With the features of claim 2, the quality of the vacuum castings produced is further improved.
Der Anspruch 3 kennzeichnet den grundsätzlichen Aufbau einer Vakuumdruckgießvorrichtung zur Lösung des diesbezüglichen Teils der Erfmdungsaufgabe.The claim 3 characterizes the basic structure of a vacuum die-casting device for solving the relevant part of the invention.
Die Ansprüche 4 bis 10 sind auf vorteilhafte Ausführungsformen der erfindungsgemäßen Druckgießvorrichtung gerichtet.Claims 4 to 10 are directed to advantageous embodiments of the die casting device according to the invention.
Das gemäß dem Anspruch 4 eingesetzte Vakuumventil arbeitet vorteilhafterweise mit einer möglichst kurzen zeitlichen Verzögerung, so dass das Schließsignal möglichst spät erzeugt werden kann, wodurch der Schließzeitpunkt weitgehend unabhängig von im Betrieb der Gießvorrichtung auftretenden Schwankungen möglichst spät ist.The vacuum valve used according to claim 4 advantageously works with a short time delay, so that the closing signal can be generated as late as possible, whereby the closing time is largely independent of any fluctuations occurring during the operation of the casting device.
Mit den Merkmalen des Anspruchs 5 ist eine besonders einfache Steuerung der Erzeugung des Schließsignals möglich.A particularly simple control of the generation of the closing signal is possible with the features of claim 5.
Gemäß dem Anspruch 6 kann der Zeitpunkt, zu dem das Schließsignal erzeugt werden muss, aktuell aus der Kolbengeschwindigkeit errechnet werden.According to claim 6, the point in time at which the closing signal has to be generated can currently be calculated from the piston speed.
Die Ansprüche 7 bis 9 sind auf vorteilhafte, im Steuergerät gespeicherte Kennlinien gerichtet, wobei mit den Merkmalen des Anspruchs 9 der Betriebszustand der Druckgießvorrichtung überwacht werden kann. Mit den Merkmalen des Anspruchs 10 wird erreicht, dass Betriebsschwankungen der Gießvorrichtung bei der Erzeugung des Schließsignals berücksichtigt werden. Die Erfindung wird im folgenden anhand schematischer Zeichnungen beispielsweise und mit weiteren Einzelheiten erläutert.Claims 7 to 9 are directed to advantageous characteristic curves stored in the control device, the operating state of the die casting device being able to be monitored with the features of claim 9. It is achieved with the features of claim 10 that operating fluctuations of the casting device are taken into account when generating the closing signal. The invention is explained below with reference to schematic drawings, for example and with further details.
Es stellen dar:They represent:
Fig. 1 eine schematische Ansicht einer Vakuumdruckgießvorrichtung undFig. 1 is a schematic view of a vacuum die casting device and
Fig. 2 und 3 Kurven zur Erläuterung der Funktionsweise der erfindungsgemäßen Vorrichtung.2 and 3 curves to explain the operation of the device according to the invention.
Gemäß Fig. 1 enthält eine Vakuumdruckgießvorrichtung wenigstens zwei Grundkörper 2 und 4, die mittels einer nicht dargestellten Antriebseinrichtung in an sich bekannter Weise aufeinander zu- und voneinander wegbewegbar sind. An jedem Grundkörper ist ein zugehöriges Formteil 6 bzw. 8 befestigt, wobei einander zugewandte Flächen der Formteile 6 und 8 derart ausgebildet sind, dass bei aufeinander zubewegten Grundkörpern bzw. geschlossenem Werkzeug ein Gießhohlraum 10 gebildet ist.1, a vacuum die casting device contains at least two base bodies 2 and 4, which can be moved towards and away from one another in a manner known per se by means of a drive device (not shown). An associated molded part 6 or 8 is fastened to each base body, with mutually facing surfaces of the molded parts 6 and 8 being formed such that a casting cavity 10 is formed when the base bodies or closed tools are moved towards one another.
Zum Einleiten von Gießmaterial, vorzugsweise flüssigem Metall, in den Gießhohlraum 10 dient ein zum Gießhohlraum 10 hin offener Zylinder 12, in dem ein Kolben 14 beweglich ist, der über einen Schaft 16 mit einem Aktor 17 zum Antrieb des Kolbens 14 verbunden ist. Durch die Wand des Zylinders 12 führt eine Einfüllleitung 18 zum Einfüllen des flüssigen Gießmaterials.A cylinder 12, which is open toward the casting cavity 10 and in which a piston 14 is movable and is connected via a shaft 16 to an actuator 17 for driving the piston 14, is used to introduce casting material, preferably liquid metal, into the casting cavity 10. A filling line 18 leads through the wall of the cylinder 12 to fill in the liquid casting material.
An den Gießhohlraum 10 grenzt ein Füllstandssensor 20 an, der bei Berührung mit in dem Gießhohlraum 10 aufsteigendem Gießmaterial 22 ein Signal erzeugt. An den oberen Endbereich des Gießhohlraums 10 grenzt eine Vakuumöffnung 24, die über ein Vakuumventil 26 mit einer Vakuumpumpe 28 verbunden ist. Das Vakuumventil 26 ist von einer Bauart, bei der das Ventilglied des Vakuumventils sich auf ein Schließsignal hin mit möglichst kurzer Verzögerung in die Schließstellung bewegt, in der das Vakuumventil 26 geschlossen ist. Die Betätigung des Ventilglieds geschieht beispielsweise mittels eines Aktors, beispielsweise eines Elektromagneten 30. Sie kann auch hydraulisch oder sonstwie geeignet erfolgen.A level sensor 20 adjoins the casting cavity 10 and generates a signal when it comes into contact with the casting material 22 rising in the casting cavity 10. A vacuum opening 24 adjoins the upper end region of the casting cavity 10 and is connected to a vacuum pump 28 via a vacuum valve 26. The vacuum valve 26 is of a type in which the valve member of the vacuum valve moves with the shortest possible delay into the closed position in which the vacuum valve 26 is closed upon a closing signal. The valve member is actuated, for example, by means of an actuator, for example an electromagnet 30. It can also be carried out hydraulically or in some other suitable manner.
Die Stellung des Kolbens 14 bzw. des Schaftes 16 wird von einem Bewegungssensor 32 längs des Hubs des Kolbens 14 erfasst. Der Bewegungssensor 32 kann beispielsweise ein linearer Sen- sor sein oder ein inkrementeller Drehsensor, wenn die Linearbewegung des Kolbens über eine entsprechende Mechanik in eine Drehbewegung umgewandelt wird.The position of the piston 14 or the shaft 16 is detected by a motion sensor 32 along the stroke of the piston 14. The motion sensor 32 can, for example, be a linear sensor be a sensor or an incremental rotation sensor if the linear movement of the piston is converted into a rotary movement by means of appropriate mechanics.
Der Bewegungssensor 32, der Füllstandssensor 20 und der Magnet des Vakuumventils 26 sind mit einem elektronischen Steuergerät 34 verbunden, das einen Mikroprozessor mit zugehörigen Speichereinrichtungen, eine Anzeigeeinheit, beispielsweise in Form eines Displays, und Bedienelemente enthält.The motion sensor 32, the fill level sensor 20 and the magnet of the vacuum valve 26 are connected to an electronic control unit 34 which contains a microprocessor with associated memory devices, a display unit, for example in the form of a display, and operating elements.
Aufbau und Funktion der geschilderten Komponenten sind an sich bekannt. Im folgenden wird deren Zusammenwirken erläutert:The structure and function of the components described are known per se. Their interaction is explained below:
Es sei angenommen, dass der Kolben 14 gemäß Fig. 1 nach rechts über die Mündung der Einfüllleitung 18 hinaus bewegt ist. Durch die Einfüllleitung 18 kann dann flüssiges Metall in den evakuierten Gießhohlraum 10 eingefüllt werden, wobei der Raum innerhalb des Zylinders 12 links von dem Kolben 14 beispielsweise abhängig von den Volumenverhältnissen zu 20% bis 60% mit flüssigem Gießmaterial gefüllt wird. Der Kolben 14 wird dann nach links über die Mündung der Einfüllleitung 18 hinaus bewegt. Das Vakuumventil 26 ist offen. Die Vakuumpumpe 28 läuft, so dass der Gießhohlraum 10 mit Vakuum beaufschlagt ist. Das Gießmaterial 22 wird in den Gießhohlraum 10 gepresst und erreicht den Füllstandssensor 20.It is assumed that the piston 14 according to FIG. 1 is moved to the right beyond the mouth of the filler line 18. Liquid metal can then be filled into the evacuated casting cavity 10 through the filling line 18, the space inside the cylinder 12 to the left of the piston 14 being filled with liquid casting material to 20% to 60% depending on the volume ratios, for example. The piston 14 is then moved to the left beyond the mouth of the filler line 18. The vacuum valve 26 is open. The vacuum pump 28 runs so that the casting cavity 10 is acted upon by vacuum. The casting material 22 is pressed into the casting cavity 10 and reaches the fill level sensor 20.
Sobald das Gießmaterial 22 den Füllstandssensor 20 erreicht, sendet dieser ein Triggersignal an das Steuergerät 34, woraufhin die von dem Bewegungssensor 32 erfasste Stellung, die der Kolben bei Auslösen des Triggersignals hat, im Steuergerät 34 markiert wird. Vorteilhafterweise wird der Aktor 17, der beispielsweise hydraulisch ist, von dem Triggersignal auf eine größere Geschwindigkeit umgeschaltet, so dass das Gießmaterial in den Rest des Formhohlraums mit hoher Geschwindigkeit unter hohem Druck eingeschossen wird.As soon as the casting material 22 reaches the fill level sensor 20, the latter sends a trigger signal to the control unit 34, whereupon the position detected by the motion sensor 32, which the piston has when the trigger signal is triggered, is marked in the control unit 34. The actuator 17, which is hydraulic, for example, is advantageously switched from the trigger signal to a higher speed, so that the casting material is injected into the rest of the mold cavity at high speed and under high pressure.
Fig. 2 verdeutlicht die Verhältnisse. Dargestellt ist die Geschwindigkeit des Kolbens 14 abhängig von der zurückgelegten Wegstrecke s. Wie ersichtlich, beginnt die Kolbenbewegung mit kleiner Geschwindigkeit bis zur Stellung sj, bei der das Gießmaterial 22 den Füllstandssensor 20 erreicht. Die zugehörige Stellung sι wird im Steuergerät 34 gespeichert. Gleichzeitig wird die Kraft oder, falls vorgesehen, die Geschwindigkeit, mit der der Aktor 17 den Kolben 14 antreibt, auf einen hohen Wert geschaltet. Es sei angenommen, dass die Stellung s2 des Kolbens derjenigen Stellung entspricht, in der das Gießmaterial die Vakuumöffnung 24 des Vakuumventils 26 erreicht, das heißt, diejenige Kolbenstellung ist, bei der das Vakuumventil 26 geschlossen sein muss, um vom Gießmaterial nicht zerstört zu werden. Es sei weiter angenommen, dass sich der Kolben innerhalb einer vorbestimmten Verzögerungszeitdauer Δt, die das Vakuumventil 26 benötigt, um auf ein Schließsignal hin zu schließen, um die Strecke Δs bewegt. Wie aus Fig. 2 unmittelbar ersichtlich, muss das Schließsignal für das Vakuumventil 26 dann zu dem Zeitpunkt erzeugt werden, zu dem der Kolben die Stellung s3 hat. Da im Steuergerät 17 die Stellung si des Kolbens markiert ist, kann mit Hilfe des Bewegungssensors 32 die Strecke s3-s2 bzw. die Stellung s3 des Kolbens genau erfasst werden, und zu diesem Zeitpunkt das Schließsignal für das Vakuumventil 26 erzeugt werden.Fig. 2 illustrates the situation. The speed of the piston 14 is shown as a function of the distance s traveled. As can be seen, the piston movement begins at a low speed up to the position sj, at which the casting material 22 reaches the fill level sensor 20. The associated position s is stored in the control unit 34. At the same time, the force or, if provided, the speed at which the actuator 17 drives the piston 14 is switched to a high value. It is assumed that the position s 2 of the piston corresponds to the position in which the casting material has the vacuum opening 24 of the vacuum valve 26 reached, that is, the piston position at which the vacuum valve 26 must be closed in order not to be destroyed by the casting material. It is further assumed that the piston moves the distance Δs within a predetermined delay time period Δt that the vacuum valve 26 needs to conclude in response to a closing signal. As can be seen directly from FIG. 2, the closing signal for the vacuum valve 26 must then be generated at the point in time at which the piston has the position s 3 . Since the position si of the piston is marked in the control unit 17, the distance s 3 -s 2 or the position s 3 of the piston can be detected precisely with the aid of the motion sensor 32, and the closing signal for the vacuum valve 26 can be generated at this time.
Fig. 3 zeigt eine Kennlinie, die den zeitlichen Verlauf der Kolbenstellung angibt. In Fig. 3 ist zusätzlich die Verzögerung Δt des Vakuumventils 26 eingezeichnet.3 shows a characteristic curve which indicates the time course of the piston position. The delay Δt of the vacuum valve 26 is also shown in FIG. 3.
Es versteht sich, dass die Kennlinie der Fig. 2 durch Differenzierung der Kennlinie der Fig. 3 erzeugt werden kann. Je nach Konstruktion des Bewegungssensors 32 kann die Kennlinie der Fig. 2 oder der Fig. 3 unmittelbar aufgenommen werden und die Kennlinie der Fig. 3 durch Integration der Kennlinie der Fig. 2 oder die Kennlinie der Fig. 2 durch Differenzierung der Kennlinie der Fig. 3 erzeugt werden.It is understood that the characteristic curve of FIG. 2 can be generated by differentiating the characteristic curve of FIG. 3. Depending on the construction of the motion sensor 32, the characteristic of FIG. 2 or FIG. 3 can be recorded directly and the characteristic of FIG. 3 by integrating the characteristic of FIG. 2 or the characteristic of FIG. 2 by differentiating the characteristic of FIG. 3 are generated.
Je nach Konstruktion des Vakuumventils und dessen Anordnung im Gießhohlraum kann der Gießhohlraum bei Erreichen der Kolbenstellung s2 (Gießmaterial erreicht die Vakuumöffnung 24) vollständig gefüllt sein oder, wie in den Figuren dargestellt, erst weitgehend gefüllt sein, so dass der Kolben noch eine geringe zusätzliche Strecke zurücklegt. Es versteht sich, dass der Kolben auch derart gesteuert werden kann, dass er in der Stellung s gebremst wird.Depending on the design of the vacuum valve and its arrangement in the casting cavity, the casting cavity can be completely filled when the piston position s 2 is reached (casting material reaches the vacuum opening 24) or, as shown in the figures, can only be largely filled so that the piston has a small additional amount Distance traveled. It goes without saying that the piston can also be controlled in such a way that it is braked in the position s.
Vorteilhaft ist, die Kennlinie der Fig. 2 als eine Sollkennlinie zu speichern, die einem einwandfreien Zustand der Gießvorrichtung entspricht. Diese Sollkennlihie kann dann zur Ermittlung der Stellung s3 des Kolbens dienen, bei der das Schließsignal für das Vakuumventil erzeugt wird.It is advantageous to save the characteristic curve of FIG. 2 as a nominal characteristic curve which corresponds to a perfect condition of the casting device. This Sollkennlihie can then be used to determine the position s 3 of the piston at which the closing signal for the vacuum valve is generated.
Die Sollkennlinie kann laufend zusammen mit einer Istkennlinie beispielsweise auf einem Bildschirm visualisiert werden, so dass Betriebsänderungen der Druckgießvorrichtung unmittelbar sichtbar sind und eventuelle Fehler frühzeitig erkannt werden. Weiter kann bei der Serienherstellung von Gußteilen die Kennlinie, die zur Ermittlung von s3 verwendet wird, laufend aktualisiert werden, indem beispielsweise die Istkennlinie eines unmittelbar zurückliegenden Gießvorgangs als Kennlinie zur Ermittlung von s3 herangezogen wird oder eine aus mehreren zurückliegenden Gießvorgängen gemittelte Kennlinie.The target characteristic curve can be continuously visualized, for example on a screen, together with an actual characteristic curve, so that changes in the operation of the die casting device are immediately visible and any errors are recognized at an early stage. Furthermore, in the series production of castings, the characteristic curve which is used to determine s 3 can be updated continuously, for example by the actual characteristic curve of a casting process that occurred immediately behind is used as the characteristic curve for determining s 3 or a characteristic curve averaged from several previous casting processes.
Insgesamt wird mit der Erfindung erreicht, dass der Gießhohlraum während des Gießens so lange wie möglich mit Vakuum beaufschlagt werden kann, so dass Vakuumdruckgussteile hoher Qualität hergestellt werden. Die Porenfreiheit der Druckgussteile wird dadurch weiter verbessert, dass die Endphase des Gießens durch die höhere Kolbenkraft unter hohem Gießdruck erfolgt, so dass etwaige Poren, soweit das in ihnen enthaltene Gas nicht durch das Vakuum abgesaugt wird, im Volumen verkleinert werden.Overall, it is achieved with the invention that the casting cavity can be subjected to vacuum for as long as possible during the casting, so that high-quality vacuum die-cast parts are produced. The pore-free nature of the die-cast parts is further improved in that the final phase of the casting is carried out by the higher piston force under high casting pressure, so that any pores, insofar as the gas contained in them is not sucked out by the vacuum, are reduced in volume.
Die erfindungsgemäße Vorrichtung kann in vielfältiger Weise abgeändert und weitergebildet werden.The device according to the invention can be modified and developed in a variety of ways.
Beispielsweise können in einer Druckgießvorrichtung mehrere, von einem Gießhohlraum 10 ausgehende Anschlüsse an Vakuumventile und mehrere Füllstandssensoren vorgesehen sein, wobei die Anwendung des erfindungsgemäßen Verfahrens dann voraussetzt, dass in den Relationen der Füllungen der einzelnen, zwischen den Füllstandssensoren und den Vakuumventilen liegenden Kanälen keine Änderungen eintreten. Die Visualisierung der Kennlinie der Fig. 2 ist, wie unmittelbar ersichtlich, wegen deren guter Auflösung zwar vorteilhaft; es können jedoch auch andere Kennlinien visualisiert werden. Weiter ist es möglich, das Schließsignal nicht unmittelbar dadurch zu erzeugen, dass der Kolben eine vorbestimmte Stellung (s ) in Fig. 2 erreicht, sondern dadurch, dass er eine vorbestimmte Geschwindigkeit hat, usw.. For example, a plurality of connections to vacuum valves and a plurality of level sensors starting from a casting cavity 10 can be provided in a pressure casting device, the application of the method according to the invention then presupposing that no changes occur in the relations of the fillings of the individual channels lying between the level sensors and the vacuum valves , The visualization of the characteristic of FIG. 2 is, as can be seen immediately, advantageous because of its good resolution; however, other characteristic curves can also be visualized. Furthermore, it is possible not to generate the closing signal directly by the piston reaching a predetermined position (s) in FIG. 2, but by having a predetermined speed, etc.
BezugszeichenlisteLIST OF REFERENCE NUMBERS
2 Grundkörper2 basic bodies
4 Grundkörper4 basic bodies
6 Formteil6 molding
8 Formteil8 molded part
0 Gießhohlraum0 casting cavity
2 Zylinder2 cylinders
4 Kolben4 pistons
6 Schaft6 shaft
7 Aktor7 actuator
8 Einfüllleitung 0 Füllstandssensor 22 Gießmaterial 4 Vakuumöffnung 6 Vakuumventil 8 Vakuumpumpe 0 Elektromagnet 2 Bewegungssensor 4 Steuergerät 8 Filling line 0 Level sensor 22 Casting material 4 Vacuum opening 6 Vacuum valve 8 Vacuum pump 0 Electromagnet 2 Motion sensor 4 Control unit

Claims

Patentansprüche claims
1. Verfahren zum Steuern eines Vakuumventils einer Vakuumdruckgießvorrichtung, bei welchem Verfahren flüssiges Gießmaterial (22) von einem Kolben (14) in einen evakuierten Gießhohlraum (10) gedrückt wird, ein vorbestimmter Füllstand des Gießmaterials in dem Gießhohlraum erfasst wird und das in einer Verbindung zwischen einer Vakuumquelle (28) und den Gießhohlraum (10) angeordnete Vakuumventil (26) abhängig von dem Erreichen des Füllstandes derart betätigt wird, dass das Vakuumventil geschlossen ist, wenn das Gießmaterial einen Anschluss des Vakuumventils an den Gießhohlraum erreicht, dadurch gekennzeichnet, dass die Bewegimg des Kolbens (14) erfasst wird, die Stellung markiert wird, die der Kolben hat, wenn das Gießmaterial den vorbestimmten Füllstand erreicht und das Vakuumventil (26) geschlossen wird, wenn sich der Kolben, ausgehend von der markierten Stellung in vorbestimmter Weise weiterbewegt hat.1. A method for controlling a vacuum valve of a vacuum pressure casting device, in which method liquid casting material (22) is pressed by a piston (14) into an evacuated casting cavity (10), a predetermined fill level of the casting material in the casting cavity is detected and this in a connection between a vacuum source (28) and the casting cavity (10) arranged vacuum valve (26) is actuated depending on reaching the fill level such that the vacuum valve is closed when the casting material reaches a connection of the vacuum valve to the casting cavity, characterized in that the movement of the piston (14) is detected, the position is marked which the piston has when the casting material reaches the predetermined fill level and the vacuum valve (26) is closed when the piston has moved further from the marked position in a predetermined manner.
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass die Geschwindigkeit, mit der der Kolben (14) bewegt wird, bei Erreichen des vorbestimmten Füllstandes vergrößert wird.2. The method according to claim 1, characterized in that the speed at which the piston (14) is moved is increased when the predetermined fill level is reached.
3. Vakuumdruckgießvorrichtung, enthaltend einen Gießhohlraum (10), der über ein Vakuumventil (26) evakuierbar ist und in den flüssiges Gießmaterial mittels eines von einem Aktor (17) betätigten Kolbens (14) drückbar ist, einen Füllstandssensor (20) zum Erfassen eines Füllstandes des Gießmaterials in dem Gießhohlraum und ein mit dem Füllstandssensor verbundenes Steuergerät (34) zum Steuern des Vakuumventils, gekennzeichnet durch einen mit dem Steuergerät (34) verbundenen Stellungssensor (32) zum Erfassen der Bewegung des Kolbens (14), wobei das Steuergerät ein Schließsignal für das Vakuumventil (26) erzeugt, wenn der Kolben nach Erreichen der Stellung (si), bei der der Füllstandssensor (20) einen vorbestimmten Füllstand des Gießhohlraums (10) mit Gießmaterial anzeigt, in vorbestimmter Weise verschoben ist.3. Vacuum die-casting device, comprising a casting cavity (10) which can be evacuated via a vacuum valve (26) and which can be pressed into the liquid casting material by means of a piston (14) actuated by an actuator (17), a level sensor (20) for detecting a level of the casting material in the casting cavity and a control device (34) connected to the level sensor for controlling the vacuum valve, characterized by a position sensor (32) connected to the control device (34) for detecting the movement of the piston (14), wherein the control unit generates a closing signal for the vacuum valve (26) when the piston is shifted in a predetermined manner after reaching the position (si), in which the fill level sensor (20) indicates a predetermined fill level of the casting cavity (10) with casting material.
4. Vakuumdruckgießvorrichtung nach Anspruch 3, dadurch gekennzeichnet, dass das Vakuumventil (26) auf ein Schließsignal hin mit einer vorbestimmten zeitlichen Verzögerung von seiner Offenstellung in seine Schließstellung schaltet.4. Vacuum die-casting device according to claim 3, characterized in that the vacuum valve (26) switches from its open position to its closed position upon a closing signal with a predetermined time delay.
5. Vakuumdruckgießvorrichtung nach Anspruch 3, dadurch gekennzeichnet, dass das Steuergerät das Schließsignal für das Vakuumventil (26) erzeugt, wenn der Kolben (14), ausgehend von der dem vorbestimmten Füllstand ensprechenden Stellung (s_) eine vorbestimmte Strecke zurückgelegt hat.5. Vacuum die-casting device according to claim 3, characterized in that the control unit generates the closing signal for the vacuum valve (26) when the piston (14) has traveled a predetermined distance from the position corresponding to the predetermined level (s_).
6. Vakuumdruckgießvorrichtung nach Anspruch 3 oder 4, dadurch gekennzeichnet, dass im Steuergerät (34) die vom Bewegungssensor (32) erfasste Stellung des Kolbens (14) zeitlich differenziert wird und aus der Geschwindigkeit des Kolbens und dessen augenblicklicher Stellung der Zeitpunkt bestimmt wird, zu dem das Schließsignal für das Vakuumventil (26) erzeugt wird.6. Vacuum die-casting device according to claim 3 or 4, characterized in that in the control unit (34) the position of the piston (14) detected by the motion sensor (32) is differentiated in time and the time is determined from the speed of the piston and its instantaneous position which the closing signal for the vacuum valve (26) is generated.
7. Vakuumdruckgießvorrichtung nach einem der Ansprüche 3 bis 6, dadurch gekennzeichnet, dass in dem Steuergerät eine Kennlinie gespeichert ist, die die Kolbengeschwindigkeit abhängig von der Kolbenstellung angibt.7. Vacuum die-casting device according to one of claims 3 to 6, characterized in that a characteristic curve is stored in the control device which indicates the piston speed as a function of the piston position.
8. Vakuumdruckgießvorrichtung nach einem der Ansprüche 3 bis 7, dadurch gekennzeichnet, dass im Steuergerät (34) eine Kennlinie gespeichert ist, die den zeitlichen Verlauf der Kolbenstellung angibt. 8. Vacuum die-casting device according to one of claims 3 to 7, characterized in that a characteristic curve is stored in the control unit (34) which indicates the time course of the piston position.
9. Vakuumdruckgießvorrichtung nach Anspruch 7 oder 8, dadurch gekennzeichnet, dass in dem Steuergerät eine Sollkennlinie gespeichert ist und Abweichungen zwischen einer Ist- und der Sollkennlinie visualisiert werden.9. Vacuum die-casting device according to claim 7 or 8, characterized in that a target characteristic is stored in the control device and deviations between an actual and the target characteristic are visualized.
10. Vakuumgießvorrichtung nach einem der Ansprüche 7 bis 9, dadurch gekennzeichnet, dass die Kennlinie, die zur Bestimmung des Zeitpunktes des Schließsignals verwendet wird, laufend aktualisiert wird. 10. Vacuum casting device according to one of claims 7 to 9, characterized in that the characteristic curve which is used to determine the time of the closing signal is continuously updated.
EP02777076A 2001-09-12 2002-09-12 Method for controlling a vacuum valve of a vacuum diecasting device and vacuum diecasting device Expired - Lifetime EP1425123B1 (en)

Applications Claiming Priority (3)

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DE10144945 2001-09-12
DE10144945A DE10144945B4 (en) 2001-09-12 2001-09-12 A method of controlling a vacuum valve of a vacuum die casting apparatus and vacuum die casting apparatus
PCT/EP2002/010234 WO2003022489A2 (en) 2001-09-12 2002-09-12 Method for controlling a vacuum valve of a vacuum diecasting device and vacuum diecasting device

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WO2003022489A3 (en) 2003-08-07
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ATE299767T1 (en) 2005-08-15
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DE50203691D1 (en) 2005-08-25

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