EP1626830B1 - Production line and method for the continuous production of cast parts from a molten metal, in particular a molten light alloy - Google Patents
Production line and method for the continuous production of cast parts from a molten metal, in particular a molten light alloy Download PDFInfo
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- EP1626830B1 EP1626830B1 EP04820597A EP04820597A EP1626830B1 EP 1626830 B1 EP1626830 B1 EP 1626830B1 EP 04820597 A EP04820597 A EP 04820597A EP 04820597 A EP04820597 A EP 04820597A EP 1626830 B1 EP1626830 B1 EP 1626830B1
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- production line
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D47/00—Casting plants
- B22D47/02—Casting plants for both moulding and casting
Definitions
- the invention relates to a production line for the continuous production of castings from a metallic melt, in particular a light metal melt, with a plurality of functional units, including a Kernsch monitor- and curing unit for the manufacture of casting cores, a mold assembly unit for assembling formed as core packages molds, a Casting unit for pouring the molten metal into the molds, a cooling unit for solidifying the molten metal contained in the mold, a cooling unit for quenching in the sense of a heat treatment and a demolding unit for early destructive removal of the mold from the casting.
- a Kernsch monitor- and curing unit for the manufacture of casting cores
- a mold assembly unit for assembling formed as core packages molds
- a Casting unit for pouring the molten metal into the molds
- a cooling unit for solidifying the molten metal contained in the mold
- a cooling unit for quenching in the sense of a heat treatment
- demolding unit for early destructive removal of the mold from the casting.
- the invention likewise relates to a method for continuously casting castings from a molten metal, in which casting cores are first produced and then a casting mold designed as a core package is built from the casting cores. In this mold, the molten metal is poured. Subsequently, the melt contained in the mold is cooled controlled at least until the casting is solidified to a sufficient dimensional stability. Thereupon can start demolding the casting, which destroys the mold. The heat treatment of the casting is done directly from the casting heat by quenching.
- Production lines and methods of the type mentioned above are usually used in large-scale series production of castings.
- the applicant operates a production line with which motor blocks are cast in large quantities in the manner described in an automated process.
- a number of core shooting machines are linearly linked with each other. The number of core shooting machines necessary for this corresponds to the respectively available tool set for a complete core package of a specific type of engine block.
- the shot and completely hardened cores are removed via removal pallets and successively mounted on a parallel to the core shooter assembly line to a core package.
- cycle times of less than 60 seconds must be maintained with a corresponding level of automation.
- molding material for the production of the cores a molding material mixed from a known organic binder and a likewise conventional molding sand is used in the known production line.
- This molding material is solidified in the so-called "cold-box process", in which by gassing with a reaction gas, the curing of the organic binder is effected.
- the finished cores are mounted to the molds, stored in a storage facility for outgassing and then mechanically clamped together in the casting unit and poured.
- the respective casting mold After pouring the molten metal, the respective casting mold is brought into a solidification position, starting from which, depending on the casting, it passes through a cooling section for a time greater than 15 minutes in the clamped state. After solidification, the molds are loaded on pallets and driven into a heat treatment furnace. In this furnace, the castings (engine blocks) are thermally sanded and solution annealed in a process lasting several hours.
- the organic binder of the casting molds is decomposed at temperatures in the casting just below the solidus temperature of the alloy used, so that the sand mold breaks up into coarse fragments.
- mechanical conveyor and screens and the use of elaborate sand cooler and bunker Kernmacherei is then fed back to fine-grained recycled sand. Due to the lengthy, thermal process, large quantities of sand and long transport routes are necessary.
- the invention provides a modular process chain in which the processing stations core-making, core-package assembly, foundry; Solidification, gutting and quenching for the respective casting are carried out in a continuous process.
- the individual workstations are completed directly consecutively.
- the term "direct” in this context does not mean the shortest spatial distance. Rather, it is essential according to the invention that the individual functional units are run without interruption successively. It finds a production process instead, in which the individual work steps are directly interlinked. Molds and castings are conveyed in a continuous flow through the production line.
- Interim storage or other storage are not present in a production line according to the invention.
- the conveying path over which the casting cores and then the casting molds are initially conveyed be guided so that an optimal workflow is ensured regardless of whether the respective parts on the shortest route to each next workstation be transported.
- the cycle of the production process according to the invention is determined by the time-critical unit of production, namely core shooting. The curing times are distributed to several stations in the core production plant.
- the cores output from the core manufacturing unit are taken over by the mold mounting device and assembled into a core package.
- the respectively present at the transfer cores form a G tellkernsatz, from each of which a core forming the mold can be assembled without special sorting. In this way it is possible to assemble molds fully automatically, without the need for elaborate control devices.
- such highly complex castings particularly engine blocks
- the casting molds are designed as core packages, they can react quickly and flexibly to model changes of the castings to be produced, since the production of the cores takes place in a core manufacturing plant which can be easily reconfigured.
- a particularly preferred embodiment of the invention provides that an inorganic, in particular a water glass-based binder is used as the binder. Binders of this type ensure a high dimensional stability of the cores after curing when exposed to heat. By using an inorganic binder, it is also possible to thin-wall the casting cores, which are exposed to larger specific loads in the core package forming the casting mold. In addition, practical experiments have shown that inorganic bonded molding materials can be easily dissolved in water and have good disintegration properties.
- Core package molds constructed from cores produced using inorganic binders thus not only prove to be robust, but have additional beneficial properties for performing the method of the present invention.
- the resulting in a production line according to the invention core sand volume is reduced, as is cored in a short way after pouring into water and the mold can be designed as a thin-walled core package with the advantages mentioned.
- the parts required for holding and transporting the core package (clamping devices, cooling iron, mold segments, support elements, clamping devices, etc.) can be easily cleaned and reused in circulation.
- the invention is particularly suitable for the production of complex shaped engine blocks of aluminum-based alloys.
- An advantageous embodiment of the invention is characterized in that the core production plant has a core shooting station, a plurality of curing stations and a conveyor that promotes the core tools in circulation from the shooting station, the curing stations to the transfer stations to the mold mounting device and then back to the shooting station.
- the required tools are further promoted by the conveyor unit in the working cycle.
- the infeed and discharge during tool change can be done in time, since only small distances must be covered. Since several curing stations are arranged along the conveying path, the cycle time of the core size and the curing behavior of the binder is largely independent.
- the core production unit has a device for the automated changing of the shot hoods in the shooting station assigned to the individual tools required for the shooting of the cores.
- an automatic tool cleaning is integrated. Core breakage can be automatically removed at a position on the conveyor system.
- the automatic mold assembly in the mold assembly unit can be facilitated by the fact that the finished cores are taken directly to transfer stations on the conveyor system of the core manufacturing plant.
- the mold mounting unit used according to the invention comprises more than one assembly station and a conveying device conveys the mold to be produced in succession to the assembly stations in succession.
- a conveying device conveys the mold to be produced in succession to the assembly stations in succession.
- Each of the assembly stations can perform a specific task and optionally has intermediate storage, core adhesive stations, liner supply, screwing devices, etc.
- the production line comprises a heating device for heating these components to be cast into the casting. It is favorable for the desired continuity of the production process, when the heating device is integrated into the casting unit and the heating takes place in the system cycle.
- the temperature of the components to be infused can be adjusted specifically with little expenditure of energy and can be coordinated with the mold filling and solidification process of the entire casting.
- the incorporation of the casting unit into the working cycle predetermined by the core manufacturing unit can be realized by the casting unit comprising a turntable which takes over the casting mold conveyed from the mold assembly unit to the casting unit at a transfer station from the conveying device connecting the die assembly unit to the casting unit promotes a pivoting movement to a casting station and the mold after the done in the casting station controlled mold filling process with melt further promotes to a transfer station at which it passes the respective mold to the cooling unit leading to conveyor.
- the controlled mold filling can be done by coupling the molds to a known low-pressure casting furnace, gas-pressure-controlled melt transport into the mold cavity, closing the pouring opening and subsequent 180 ° rotation in solidification position (roll-over).
- the rotational movement can be used to control the mold filling process.
- a special advantage of core packages made of inorganic binders are hardly any gases when in contact with the melt, since the binder does not burn.
- local cooling molds can be used to remove heat from the area of holes, storage chairs, accumulations of material, etc. in a targeted manner.
- the solution annealing which can only be carried out with great difficulty in the prior art, can be avoided by quenching the cast pieces starting from a specific temperature.
- the cooling unit has a quenching station for quenching the casting from the casting heat out.
- the gutting of the solidified casting can be done in a conventional manner by liquid jets.
- the demolding unit preferably has a liquid jet device for destroying the casting mold. With such a liquid jet device, the casting cores sitting in the casting can be flushed out.
- the demolding unit can also comprise a liquid-fillable basin into which the casting mold can be inserted.
- a movement device for moving the casting mold immersed in the basin can be assigned to the liquid basin.
- the molded parts caught in the liquid further disintegrate into finely granular molding material and can be easily removed from the liquid tank.
- water is optionally suitable with additives, which may be heated to a certain, the decay of the molding material of the mold additionally supporting temperature.
- a particularly practical embodiment of the invention is characterized in that the cooling unit and the demolding unit are combined to form a combined cooling and demolding unit.
- the single figure shows schematically a production line 1 for the fully automatic production of engine blocks made of an aluminum alloy in a plan view.
- the production line comprises a core production unit 2 for manufacturing casting cores, a mold mounting unit 3 for mounting core molds G, a casting unit 4 for casting aluminum melt into the casting molds G, a cooling unit 5a for solidifying the molten metal contained in the casting mold G, and a demolding unit 5b for destructive removal of the respective casting mold G and a quenching unit 5c of the casting M.
- the core production unit 2 has a core shooting station 6 and a conveying device 7 designed as a conveying path.
- the transport device 7 is divided into four sections 7a, 7b, 7c, 7d, which are arranged at right angles to each other such that they form the side line of a rectangle in plan view.
- the Core tool shells WO are conveyed to the section 7d.
- the core shooting station 6 is positioned in a corner region of the transport device 7, on which the sections 7a and 7d of the transport device abut one another. In the core shooting station 6 casting cores are shot in a conventional manner from an inorganic binder and a quartz sand or synthetic sand mixed molding material.
- the core shooting station 6 is associated with a Schusshaubencic excellentness 8 which provides the gun used in the core shooting station 6 each shot hood tool specific.
- the tools W are positioned in the curing stations A. In the middle of the section 7b, the tool shells WO are lifted and transferred to the conveying path 7e.
- a first assembly robot 11 is associated with the mold assembly unit 3, which takes over from the curing station A and transported over the section 7b cores from the lower tool part WU.
- the first casting cores 11 of the respective casting mold G are assembled by the first assembly robot 11. Subsequently, the casting molds G, which are partially finished in this state, reach the section 14 of the conveyor 12 and are conveyed along the assembly robots 10, 9, adding the respective further casting cores G to the respective casting mold until the mold has been finished when leaving the mold assembly unit 3 is.
- the casting molds G reach the section 15, which guides them to a turntable 16.
- the turntable 16 takes over the respective casting mold G and transports in a 90 ° rotation to a heating station 17 in the inserts to be cast into the engine block to be manufactured (eg liners etc.) or mold parts (eg brass quills for bore area, etc.) are heated inductively.
- the casting mold G is conveyed to the casting station 18 of the casting unit 4. There, the molten aluminum is conveyed into the respective casting mold G. Subsequently, the turntable 16 again conveys the casting mold G filled with melt to a transfer station, at which the casting mold G is transferred to a further conveying device 19 designed as a conveying path.
- the casting mold G which still has its original shape, is transported to a transfer station of the demolding unit 5b via a conveying device 21 which is likewise designed as a conveying path and is arranged at right angles to the conveying path 20 of the cooling unit 5a.
- a G cordformmanipulator (robot) 22 takes the respective mold G and dips it into a pool of water 23rd
- the fragments of the mold G are caught in the water basin 23 and disintegrate, since the inorganic binder dissolves in the water basin 23. This results in fine-grained molding material.
- the molding material is mixed with new inorganic binder again to new molding material and fed back to the core production unit 2.
- the inorganic binder is partially dissolved in the water of the water basin 23.
- the water contained in the binder is also fed to a treatment and returned to the production cycle.
- the casting (engine block) M After removal from the mold, the casting (engine block) M, which is now free from casting core residues, is fed via a conveyor line 25 to a post-processing unit 26 in which it is deburred, sawn and, if necessary, subjected to further finishing operations.
- the tact with which the castings M are ejected from the production line 1 is determined by the tact with which the core production unit 2 supplies the casting cores produced by it to the mold mounting unit 3.
- their treatment in the individual functional units 2-6 of the production line 1 only a small number of casting manipulators (robots) is required due to the direct linking of these units 2-6, the rapid cooling and desanding combined directly with the cooling ,
- the production line according to the invention can produce high quality castings in relatively small quantities in a particularly economical manner with little effort on machines and costs.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Casting Devices For Molds (AREA)
- Continuous Casting (AREA)
- Treatment Of Steel In Its Molten State (AREA)
Abstract
Description
Die Erfindung betrifft eine Fertigungslinie zum im kontinuierlichen Durchlauf erfolgenden Herstellen von Gussteilen aus einer metallischen Schmelze, insbesondere einer Leichtmetallschmelze, mit mehreren Funktionseinheiten, unter denen sich eine Kernschieß- und Aushärteeinheit zum Fertigen von Gießkernen, eine Formmontageeinheit zur Montage von als Kernpakete ausgebildeten Gießformen, eine Gießeinheit zum Abgießen der Metallschmelze in die Gießformen, eine Abkühleinheit zum Erstarren der in der Gießform enthaltenen Metallschmelze, eine Abkühleinheit zum Abschrecken im Sinne einer Wärmebehandlung und eine Entformungseinheit zum frühzeitigen zerstörenden Entfernen der Gießform von dem Gussteil befinden.The invention relates to a production line for the continuous production of castings from a metallic melt, in particular a light metal melt, with a plurality of functional units, including a Kernschieß- and curing unit for the manufacture of casting cores, a mold assembly unit for assembling formed as core packages molds, a Casting unit for pouring the molten metal into the molds, a cooling unit for solidifying the molten metal contained in the mold, a cooling unit for quenching in the sense of a heat treatment and a demolding unit for early destructive removal of the mold from the casting.
Ebenso betrifft die Erfindung ein Verfahren zum im kontinuierlichen Durchlauf erfolgenden Herstellen von Gussteilen aus einer Metallschmelze, bei dem zunächst Gießkerne erzeugt und dann aus den Gießkernen eine als Kernpaket ausgebildete Gießform gebaut wird. In diese Gießform wird die Metallschmelze gegossen. Anschließend wird die in der Gießform enthaltene Schmelze zumindest solange kontrolliert abgekühlt, bis das Gussteil zu einer ausreichenden Formhaltigkeit erstarrt ist. Daraufhin kann die Entformung des Gussteils beginnen, bei der die Gießform zerstört wird. Die Wärmebehandlung des Gussteiles erfolgt direkt aus der Gießhitze durch Abschrecken.The invention likewise relates to a method for continuously casting castings from a molten metal, in which casting cores are first produced and then a casting mold designed as a core package is built from the casting cores. In this mold, the molten metal is poured. Subsequently, the melt contained in the mold is cooled controlled at least until the casting is solidified to a sufficient dimensional stability. Thereupon can start demolding the casting, which destroys the mold. The heat treatment of the casting is done directly from the casting heat by quenching.
Fertigungslinien und Verfahren der voranstehend angegebenen Art werden üblicherweise bei der großtechnischen Serienfertigung von Gussteilen eingesetzt. So betreibt die Anmelderin beispielsweise eine Fertigungslinie, mit der in der beschriebenen Weise in einem automatisierten Ablauf Motorblöcke in großen Stückzahlen gegossen werden. In der bekannten Fertigungslinie ist dazu eine Anzahl von Kernschießmaschinen miteinander linear verkettet. Die Anzahl der dazu notwendigen Kernschießmaschinen entspricht dem jeweils zur Verfügung stehenden Werkzeugsatz für ein komplettes Kernpaket eines bestimmten Motorblocktyps.Production lines and methods of the type mentioned above are usually used in large-scale series production of castings. For example, the applicant operates a production line with which motor blocks are cast in large quantities in the manner described in an automated process. In the known production line, a number of core shooting machines are linearly linked with each other. The number of core shooting machines necessary for this corresponds to the respectively available tool set for a complete core package of a specific type of engine block.
Die geschossenen und fertig ausgehärteten Kerne werden über Entnahmepaletten entnommen und auf einem parallel zu den Kernschießmaschinen aufgestellten Montageband nacheinander zu einem Kernpaket montiert. Um die Wirtschaftlichkeit einer solchen Fertigungslinie zu gewährleisten, müssen Taktzeiten kleiner 60 Sekunden mit einem entsprechen Automatisierungsaufwand eingehalten werden.The shot and completely hardened cores are removed via removal pallets and successively mounted on a parallel to the core shooter assembly line to a core package. To ensure the cost-effectiveness of such a production line, cycle times of less than 60 seconds must be maintained with a corresponding level of automation.
Als Formstoff für die Herstellung der Kerne wird in der bekannten Fertigungslinie ein aus einem bekannten organischen Binder und einem ebenso konventionellen Formsand gemischter Formstoff eingesetzt. Dieser Formstoff wird im so genannten "Cold-Box-Verfahren" verfestigt, bei dem durch Begasung mit einem Reaktionsgas die Aushärtung des organischen Binders bewirkt wird. Die fertigen Gießkerne werden zu den Gießformen montiert, in einem Speicher zum Ausgasen zwischengelagert und anschließend in der Gießeinheit mechanisch zusammengespannt und abgegossen.As molding material for the production of the cores, a molding material mixed from a known organic binder and a likewise conventional molding sand is used in the known production line. This molding material is solidified in the so-called "cold-box process", in which by gassing with a reaction gas, the curing of the organic binder is effected. The finished cores are mounted to the molds, stored in a storage facility for outgassing and then mechanically clamped together in the casting unit and poured.
Nach dem Vergießen der Metallschmelze wird die jeweilige Gießform in eine Erstarrungsposition gebracht von der ausgehend sie gussteilspezifisch in verspanntem Zustand für eine Zeit größer 15 Minuten eine Kühlstrecke durchlaufen. Nach der Erstarrung werden die Gießformen auf Paletten geladen und in einen Wärmebehandlungsofen gefahren. In diesem Ofen werden die Gussteile (Motorblöcke) in einem mehrere Stunden dauernden Prozess thermisch entsandtet und lösungsgeglüht.After pouring the molten metal, the respective casting mold is brought into a solidification position, starting from which, depending on the casting, it passes through a cooling section for a time greater than 15 minutes in the clamped state. After solidification, the molds are loaded on pallets and driven into a heat treatment furnace. In this furnace, the castings (engine blocks) are thermally sanded and solution annealed in a process lasting several hours.
Bei der thermischen Entsandung wird der organische Binder der Gießformen bei Temperaturen im Gussteil knapp unter Solidustemperatur der eingesetzten Legierung zersetzt, so dass die Sandform in grobe Bruchstücke zerfällt. Durch weitere Beheizung, mechanische Fördereinrichtung und Siebe und den Einsatz aufwendiger Sandkühler und Bunker wird der Kernmacherei dann wieder feinkörniger Recycling-Sand zugeführt. Aufgrund des langwierigen, thermischen Prozesses sind große Mengen an Sand und lange Förderwege notwendig.During thermal desanding, the organic binder of the casting molds is decomposed at temperatures in the casting just below the solidus temperature of the alloy used, so that the sand mold breaks up into coarse fragments. By further heating, mechanical conveyor and screens and the use of elaborate sand cooler and bunker Kernmacherei is then fed back to fine-grained recycled sand. Due to the lengthy, thermal process, large quantities of sand and long transport routes are necessary.
Aus der DE 40 16 112 C2 ist ferner eine automatisierte Gießereinanlage bekannt, wobei mehrere Funktionseinheiten vorgesehen sind, die durch Zwischenförderer zu einer Produktionslinie verbunden sind.From DE 40 16 112 C2 an automated foundry plant is also known, wherein a plurality of functional units are provided, which are connected by intermediate conveyor to a production line.
Bekannte Fertigungslinien der voranstehend beschriebenen Art ermöglichen es zwar, Motorblöcke in hohen Stückzahlen kosteneffektiv herzustellen. Dem stehen jedoch betriebliche Nachteile entgegen, die sich insbesondere bemerkbar machen, wenn kleinere Stückzahlen hergestellt werden sollen oder die Modelle der zu gießenden Teile häufig wechseln. So ist ein hoher, durch eine Anzahl von Maschinen und Werkzeugen verursachter technischer Aufwand für die Kernfertigung erforderlich. Die große Anzahl komplexer Maschineneinheiten mit dem Zwang Taktzeiten kleiner 60 Sekunden zu fahren bringt bei einem Werkzeugwechsel, der in Folge eines Modellwechsels erforderlich wird, lange Rüstzeiten und aufwändige Montagearbeiten mit sich, die wiederum Verfügbarkeitsverluste verursachen. Diese Verluste bedingen eine geringe Flexibilität der bekannten Fertigungslinie, da einer schnellen Anpassung an geänderte Betriebbedingungen oder Modelltypen hohe Rüstkosten und bei neuen Produkten zusätzliche Investitionskosten entgegenstehen. Für jedes Produkt müssen alle Einrichtungen auf die Realisierbarkeit einer kurzen Taktzeit ausgelegt werden.Known production lines of the type described above make it possible to produce motor blocks cost-effectively in large quantities. However, this is offset by operational disadvantages, in particular make noticeable if smaller quantities are to be produced or the models of the parts to be cast change frequently. Thus, a high, caused by a number of machines and tools technical effort for the core production is required. The large number of complex machine units with the need to drive cycle times of less than 60 seconds brings with a tool change, which is required as a result of a model change, long set-up times and time-consuming assembly work, which in turn cause loss of availability. These losses require little flexibility of the known production line, since a quick adaptation to changing operating conditions or model types high set-up costs and new investment costs preclude additional investment costs. For each product, all facilities must be designed for the realization of a short cycle time.
Die Verwendung von mit organischem Binder gebundenen Kernen bringt des weiteren das Problem mit sich, dass die zur Erzeugung der Kerne eingesetzten Werkzeuge in regelmäßigen Abständen außerhalb der Kernmacherei gereinigt werden müssen. Auch sind aufwendige Abluftanlagen erforderlich, um die beim Aushärten der Kerne im "Cold-Box-Verfahren" und bei der thermischen Verbrennung auftretenden Gase aufzufangen und zu reinigen. Diese Gase führen zudem zu entsprechenden Belastungen des Personals. Beim Gießprozess können durch gasende Cold-Box Kerne Gussfehler entstehen.The use of organic binder bonded cores also poses the problem that the tools used to make the cores need to be periodically cleaned outside the core making shop. Costly exhaust air systems are also required to catch and clean the gases occurring during curing of the cores in the "cold box process" and during thermal combustion. These gases also lead to corresponding burdens on the staff. In the casting process, gaseous cold box cores may cause casting errors.
Ein weiterer, hohe Betriebskosten mit sich bringender Nachteil der bekannten Fertigungslinien besteht in der Notwendigkeit, zur Wärmebehandlung und Entsandung einen Ofen mit langen Behandlungszeiten einzusetzen, der so hohe Temperaturen liefert, dass der Binder der Gießformen zersetzt wird und gleichzeitig eine Lösungsglühbehandlung durchgeführt wird. Die Flexibilität hinsichtlich einer Variation der Wärmebehandlungsparameter ist durch die Kopplung an die thermische Entsandung stark eingeschränkt.Another, high operating costs associated with the disadvantage of the known production lines is the need to use for heat treatment and desanding a furnace with long treatment times, the like high temperatures provide that the binder of the casting molds is decomposed and at the same time a solution annealing treatment is carried out. The flexibility with regard to a variation of the heat treatment parameters is severely restricted by the coupling to the thermal desanding.
Die rein thermische Entsandung erweist sich bei Sandanhaftungen (Penetration, organische Kondensate) insbesondere bei den inneren Kanälen eines Motorblockes als problematisch.Pure thermal desanding proves to be problematic in the case of sand retention (penetration, organic condensates), especially in the inner channels of an engine block.
Hoher Aufwand für den Sandkreislauf aufgrund hoher Sandtemperaturen, großer Sandmengen, der Notwendigkeit, den Sand auf eine definierte Temperatur herabzukühlen und der sehr große Raumbedarf für den Ofen tragen zusätzlich dazu bei, dass die bekannten Fertigungslinien sich nur dann wirtschaftlich betreiben lassen, wenn über einen langen Produktionszyklus gleiche Motorblöcke in hohen Stückzahlen produziert werden. Dieser Wirtschaftlichkeitsbetrachtung steht gegenüber, dass die Entwicklungszeiten bei der Neukonstruktion von Gussteilen, insbesondere im Bereich der Motorenentwicklung, immer kürzer und dementsprechend die Modelländerungen immer häufiger werden.High costs for the sand cycle due to high sand temperatures, large amounts of sand, the need to cool the sand down to a defined temperature and the very large space required for the furnace also contribute to the fact that the known production lines can only be operated economically, if over a long time Production cycle same engine blocks are produced in large quantities. This cost-effectiveness analysis contrasts with the fact that development times in the redesign of cast parts, in particular in the area of engine development, are becoming ever shorter and accordingly the model changes are becoming more and more frequent.
Ausgehend von dem voranstehend erläuterten Stand der Technik bestand daher die Anforderung, einer Fertigungslinie und ein Verfahren zum Herstellen von Gussteilen aus Leichtmetall, insbesondere Aluminiumbasierten Legierungen, zur Verfügung zu stellen, die eine wirtschaftliche und flexible Produktion von komplex geformten, hochbelastbaren Gussteilen, insbesondere Motorblöcken, ermöglichen.On the basis of the above-described prior art, there was therefore the requirement to provide a production line and a method for producing castings made of light metal, in particular aluminum-based alloys, which enable economical and flexible production of complex-shaped, heavy-duty cast parts, in particular engine blocks, enable.
Diese Aufgabe ist durch eine Fertigungslinie der eingangs angegebenen Art gelöst worden, bei der erfindungsgemäß die jeweils aufeinander folgend durchlaufenden Funktionseinheiten durch jeweils eine Fördereinrichtung direkt miteinander verbunden sind und bei der der Takt, mit der die Fertigungslinie fertige Gussteile ausstößt, bestimmt ist durch den Takt, mit dem die Kernfertigungseinheit die von ihr erzeugten Gießkerne liefert.This object has been achieved by a production line of the type described above, in which according to the invention the successive successive functional units are connected directly to each other by a conveyor and in which the clock at which the production line ejects finished castings, is determined by the clock, with which the core production unit supplies the cores it produces.
In entsprechender Weise ist die voranstehend genannte Aufgabe durch ein Verfahren zum Herstellen von Gießformteilen aus einer Metallschmelze gelöst worden, insbesondere einer Leichtmetallschmelze, bei dem in einem kontinuierlichen Fertigungsablauf folgende Arbeitsschritte durchlaufen werden:
- Schießen von Gießkernen in einem Kernwerkzeug aus einem Formgrundstoff und einem Binder gemischten Formstoff,
- Aushärten der Gießkerne in einem Kernwerkzeug an Stationen der Kernfertigungseinheit,
- Übergabe der Gießkerne an eine Formmontageeinheit,
- Montieren der Gießkerne zu einer als Kernpaket ausgebildeten Gießform,
- Übergabe der Gießform an eine Gießeinheit,
- Gesteuerte Formfüllung (Gießen) von Metallschmelze in die Gießform,
- Drehen der Gießform in Erstarrungsposition,
- Übergabe der mit Metallschmelze gefüllten Gießform an eine Abkühleinheit,
- Erstarren der in der Gießform enthaltenen Metallschmelze,
- Übergabe der Gießform mit dem erstarrten Gussteil an eine Entformungseinheit,
- Entformen des Gussteils unter Zerstörung der Gießform in der Entformungseinheit,
- Abschrecken des Gussteiles aus der Gießhitze,
- Ausgeben der fertigen Gussteils,
- wobei der Takt, mit dem die fertigen Gussteile ausgegeben werden, bestimmt ist durch den Takt, mit dem die Gießkerne geschossen werden,
- Aufbereitung und Rückführung des Formstoffes in die Kernanlage.
- Casting cores in a core mold made of a molding material and a binder mixed molding material,
- Hardening of the cores in a core tool at stations of the core production unit,
- Transfer of the casting cores to a mold assembly unit,
- Mounting the casting cores to form a core package,
- Transfer of the casting mold to a casting unit,
- Controlled mold filling (pouring) of molten metal into the casting mold,
- Turning the casting mold in solidification position,
- Transfer of the molten metal filled casting mold to a cooling unit,
- Solidification of the molten metal contained in the casting mold,
- Transfer of the casting mold with the solidified casting to a demolding unit,
- Demolding of the casting with destruction of the casting mold in the demolding unit,
- Quenching the casting from the casting heat,
- Dispensing the finished casting,
- wherein the rate at which the finished castings are dispensed is determined by the rate at which the cores are shot,
- Preparation and return of the molding material to the core plant.
Die Erfindung stellt eine modulare Prozesskette zur Verfügung, bei der die Bearbeitungsstationen Kernmacherei, Kernpaketmontage, Gießerei; Erstarrung, Entkernung und Abschreckung für das jeweilige Gussteil in einem kontinuierlichen Ablauf durchlaufen werden. Die einzelnen Arbeitsstationen werden dabei direkt aufeinander folgend absolviert. Unter dem Begriff "direkt" wird in diesem Zusammenhang nicht die kürzeste räumliche Entfernung verstanden. Vielmehr ist es gemäß der Erfindung wesentlich, dass die einzelnen Funktionseinheiten unterbrechungsfrei nacheinander durchlaufen werden. Es findet ein Produktionsablauf statt, bei dem die einzelnen Arbeitsschritte unmittelbar miteinander verkettet sind. Gießformen und Gießstücke werden in einem durchgehenden Fluss durch die Fertigungslinie gefördert.The invention provides a modular process chain in which the processing stations core-making, core-package assembly, foundry; Solidification, gutting and quenching for the respective casting are carried out in a continuous process. The individual workstations are completed directly consecutively. The term "direct" in this context does not mean the shortest spatial distance. Rather, it is essential according to the invention that the individual functional units are run without interruption successively. It finds a production process instead, in which the individual work steps are directly interlinked. Molds and castings are conveyed in a continuous flow through the production line.
Zwischenlager oder sonstige Speicher, wie sie beim Stand der Technik noch unvermeidbar sind, sind bei einer erfindungsgemäßen Fertigungslinie nicht vorhanden. Um dies zu erreichen, kann bei einer erfindungsgemäßen Fertigungslinie der Förderweg, über den zunächst die Gießkerne und dann die Gießformen gefördert werden, selbstverständlich so geführt werden, dass ein optimaler Arbeitsablauf unabhängig davon gewährleistet wird, ob die jeweiligen Teile auf kürzestem Wege zur jeweils nächsten Arbeitsstation transportiert werden.Interim storage or other storage, as they are still unavoidable in the prior art, are not present in a production line according to the invention. To achieve this, in a production line according to the invention, the conveying path over which the casting cores and then the casting molds are initially conveyed, of course, be guided so that an optimal workflow is ensured regardless of whether the respective parts on the shortest route to each next workstation be transported.
Mit der erfindungsgemäßen unmittelbaren Aufeinanderfolge der einzelnen Funktionseinheiten ist es möglich, den Prozess der Gussteilherstellung von der Kernmacherei bis zum Entformen des Gussstücks "just in time" als "one piece flow" durchzuführen. D.h., es werden jeweils nur die Gießkerne und Gießformen erzeugt, die aktuell in der Fertigungslinie benötigt werden. Die beim Stand der Technik unvermeidbare Bevorratung von Gießkernen oder Gießformen entfällt.
Um diese "just in time"- Produktion zu gewährleisten, wird der Takt des erfindungsgemäßen Produktionsprozesses durch die zeitkritischste Einheit der Fertigung, nämlich das Kernschießen, bestimmt. Die Aushärtezeiten werden auf mehrere Stationen in der Kernfertigungsanlage verteilt.With the direct succession of the individual functional units according to the invention, it is possible to carry out the process of casting production from the core shop to the demoulding of the casting "just in time" as a "one piece flow". This means that only the casting cores and casting molds that are currently required in the production line are produced. The inevitable in the prior art storage of foundry cores or molds is eliminated.
In order to ensure this "just-in-time" production, the cycle of the production process according to the invention is determined by the time-critical unit of production, namely core shooting. The curing times are distributed to several stations in the core production plant.
Auf diese Weise ist sichergestellt, dass stets eine ausreichende Zahl von Kernen zur Verfügung steht, aus denen dann unterbrechungsfrei Kernpakete als Gießformen montiert werden. Gleichzeitig ist gewährleistet,
dass für die Befüllung der Gießformen wiederum jeweils ausreichende Mengen an Metallschmelze vorhanden sind und dass die Kapazität der Abkühleinheit zur Erstarrung, der Entformungseinheit und der Abschreckeinheit ausreicht, um einerseits jeweils ein hinsichtlich seines Gefüges einwandfreies Gussteil zu erhalten und andererseits den als Abfall jeweils anfallenden Formstoff der Gießform aufzubereiten und der Wiederverwendung zuzuführen.In this way, it is ensured that there is always a sufficient number of cores available, from which core packages are then assembled without interruption as casting molds. At the same time, it is ensured
that in each case sufficient quantities of molten metal are present for the filling of the casting molds and that the capacity of the cooling unit for solidification, the demolding unit and the quenching unit is sufficient to one hand in each case to obtain a perfect casting in terms of its structure and on the other hand as waste each incurred molding material of Prepare mold and return for reuse.
Die von der Kernfertigungseinheit ausgegebenen Kerne werden von der Formmontageeinrichtung übernommen und zu einem Kernpaket zusammengesetzt. Die an der Übergabe jeweils vorhandenen Kerne bilden dabei einen Gießkernsatz, aus dem jeweils ein die Gießform bildendes Kernpaket ohne besonderen Sortieraufwand zusammengestellt werden kann. Auf diese Weise lassen sich vollautomatisch Gießformen montieren, ohne dass es zu aufwändiger Steuerungseinrichtungen bedarf.The cores output from the core manufacturing unit are taken over by the mold mounting device and assembled into a core package. The respectively present at the transfer cores form a Gießkernsatz, from each of which a core forming the mold can be assembled without special sorting. In this way it is possible to assemble molds fully automatically, without the need for elaborate control devices.
Gleichzeitig sind dadurch, dass die einzelnen Einheiten der Fertigungslinie direkt miteinander verkoppelt sind, optimierte Transportwege gesichert, die im Ergebnis zu einer Verkürzung der Gesamtfertigungszeit beitragen.At the same time, as a result of the fact that the individual units of the production line are coupled directly to one another, optimized transport paths are secured, which as a result contribute to a shortening of the overall production time.
Mit der Erfindung lassen sich so komplex geformte, hochbelastbare Gussteile, insbesondre Motorblöcke, wirtschaftlich herstellen, ohne dass es dazu aufwändiger Vorrichtungen und hohem apparativem Aufwand bedarf. Gleichzeitig kann dadurch, dass die Giesformen als Kernpakete ausgebildet sind, schnell und flexibel auf Modelländerungen der herzustellenden Gussteile reagiert werden, da die Herstellung der Kerne in einer auf einfache Weise umgestaltbaren Kernfertigungsanlage erfolgt.With the invention, such highly complex castings, particularly engine blocks, can be produced economically without the need for complex equipment and high expenditure on equipment. At the same time, because the casting molds are designed as core packages, they can react quickly and flexibly to model changes of the castings to be produced, since the production of the cores takes place in a core manufacturing plant which can be easily reconfigured.
Eine besonders bevorzugte Ausgestaltung der Erfindung sieht vor, dass als Binder ein anorganischer, insbesondere ein wässerglasbasierter Binder verwendet wird. Binder dieser Art stellen bei Wärmeexposition eine hohe Formstabilität der Kerne nach dem Härten sicher. Durch Verwendung eines anorganischen Binders ist es so möglich, auch die Gießkerne, die im die Gießform bildenden Kernpaket größeren spezifischen Belastungen ausgesetzt sind dünnwandig auszubilden. Zudem haben praktische Versuche gezeigt, dass anorganische gebundene Formstoffe leicht in Wasser aufgelöst werden können und gute Zerfallseigenschaften aufweisen.A particularly preferred embodiment of the invention provides that an inorganic, in particular a water glass-based binder is used as the binder. Binders of this type ensure a high dimensional stability of the cores after curing when exposed to heat. By using an inorganic binder, it is also possible to thin-wall the casting cores, which are exposed to larger specific loads in the core package forming the casting mold. In addition, practical experiments have shown that inorganic bonded molding materials can be easily dissolved in water and have good disintegration properties.
Kernpaket- Gießformen, die aus unter Verwendung von anorganischen Bindern erzeugten Kernen gebaut sind, erweisen sich somit nicht nur als robust, sondern weisen zusätzliche für die Durchführung des erfindungsgemäßen Verfahrens günstige Eigenschaften auf.Core package molds constructed from cores produced using inorganic binders thus not only prove to be robust, but have additional beneficial properties for performing the method of the present invention.
Insgesamt ist das in einer erfindungsgemäßen Fertigungslinie anfallende Kernsandvolumen vermindert, da auf kurzem Weg nach dem Gießen in Wasser entkernt wird und die Gießform als dünnwandiges Kernpaket mit den genannten Vorteilen ausgebildet sein kann.Overall, the resulting in a production line according to the invention core sand volume is reduced, as is cored in a short way after pouring into water and the mold can be designed as a thin-walled core package with the advantages mentioned.
Die zum Halten und Transportieren des Kernpaketes benötigten Teile (Spannvorrichtungen, Kühleisen, Kokillensegmente, Stützelemente, Spannvorrichtungen etc.) können leicht gereinigt und im Umlauf wieder verwendet werden.The parts required for holding and transporting the core package (clamping devices, cooling iron, mold segments, support elements, clamping devices, etc.) can be easily cleaned and reused in circulation.
Besonders geeignet erweist sich die Erfindung bei der Herstellung von komplex geformten Motorblöcken aus Aluminium- basierten Legierungen.The invention is particularly suitable for the production of complex shaped engine blocks of aluminum-based alloys.
Eine vorteilhafte Ausgestaltung der Erfindung ist dadurch gekennzeichnet, dass die Kernfertigungsanlage eine Kernschiessstation, mehrere Aushärtestationen und eine Fördereinrichtung aufweist, die die Kernwerkzeuge im Umlauf von der Schießstation, den Aushärtestationen zu den Übergabestationen an die Formmontageeinrichtung und dann zurück zur Schießstation fördert.An advantageous embodiment of the invention is characterized in that the core production plant has a core shooting station, a plurality of curing stations and a conveyor that promotes the core tools in circulation from the shooting station, the curing stations to the transfer stations to the mold mounting device and then back to the shooting station.
Bei einer solchen Kernfertigungsanlage werden die benötigten Werkzeuge (Anzahl ist abhängig vom Produkt) von der Fördereinheit im Arbeitstakt weitergefördert. Das Ein- und Abfördern beim Werkzeugwechsel kann im Takt erfolgen, da nur geringe Wege zurückgelegt werden müssen. Da entlang der Förderstrecke mehrere Aushärtestationen angeordnet sind, ist die Taktzeit von Kerngröße und Aushärteverhalten des Binders weitgehend unabhängig.In such a core production plant, the required tools (number depends on the product) are further promoted by the conveyor unit in the working cycle. The infeed and discharge during tool change can be done in time, since only small distances must be covered. Since several curing stations are arranged along the conveying path, the cycle time of the core size and the curing behavior of the binder is largely independent.
Gemäß einer weiteren besonders praxisgerechten, den automatischen Produktionsablauf unterstützenden Ausgestaltung der Erfindung weist die Kernfertigungseinheit eine Einrichtung zum automatisierten Wechseln der für das Schießen der Kerne benötigten den einzelnen Werkzeugen zugeordneten Schusshauben in der Schießstation auf.According to another particularly practical embodiment of the invention, which supports the automatic production process, the core production unit has a device for the automated changing of the shot hoods in the shooting station assigned to the individual tools required for the shooting of the cores.
Außerdem ist eine automatische Werkzeugreinigung integriert. Kernbruch kann automatisch an einer Position an der Förderanlage entnommen werden.In addition, an automatic tool cleaning is integrated. Core breakage can be automatically removed at a position on the conveyor system.
Die automatische Formmontage in der Formmontageeinheit kann dadurch erleichtert werden, dass die fertigen Kerne direkt an Übernahmestationen an der Förderanlage der Kernfertigungsanlage übernommen werden.The automatic mold assembly in the mold assembly unit can be facilitated by the fact that the finished cores are taken directly to transfer stations on the conveyor system of the core manufacturing plant.
Typischerweise umfasst die erfindungsgemäß eingesetzte Formmontageeinheit dabei mehr als eine Montagestation und eine Fördereinrichtung fördert die jeweils zu fertigende Gießform nacheinander folgend zu den Montagestationen. Jede der Montagestationen kann eine spezielle Aufgabe ausführen und verfügt ggf. über Zwischenlager, Kernklebestationen, Linerzuführung, Verschraubungsvorrichtungen etc.Typically, the mold mounting unit used according to the invention comprises more than one assembly station and a conveying device conveys the mold to be produced in succession to the assembly stations in succession. Each of the assembly stations can perform a specific task and optionally has intermediate storage, core adhesive stations, liner supply, screwing devices, etc.
Dies ermöglicht es, relativ einfache, an einen bestimmten Montageablauf angepasste Automaten für den Zusammenbau der Gießformen einzusetzen.This makes it possible to use relatively simple, adapted to a specific assembly process machines for the assembly of the molds.
Sollen zusätzliche Bauelemente in die Metallschmelze eingegossen werden, wie beispielsweise Zylinderverstärkungen (Liner) oder Lagerstuhlverstärkungen, so ist es günstig, wenn die Fertigungslinie eine Erwärmungseinrichtung zum Erwärmen dieser in das Gussteil einzugießenden Bauelemente umfasst. Dabei ist es für die angestrebte Kontinuität des Produktionsablaufes günstig, wenn die Erwärmungseinrichtung in die Gießeinheit integriert ist und die Erwärmung im Anlagentakt stattfindet.If additional components are to be poured into the molten metal, such as cylinder reinforcements (liners) or bearing chair reinforcements, it is advantageous if the production line comprises a heating device for heating these components to be cast into the casting. It is favorable for the desired continuity of the production process, when the heating device is integrated into the casting unit and the heating takes place in the system cycle.
In dem die Erwärmung unmittelbar vor dem gesteuerten Formfüllen (Gießen) erfolgt, ist die Gefahr einer unkontrollierten Abkühlung auf ein Minimum reduziert. Die Temperatur der einzugießenden Bauteile kann bei geringem Energieaufwand gezielt eingestellt und mit dem Formfüll- und Erstarrungsablauf des gesamten Gussteiles abgestimmt werden.In that the heating takes place immediately before the controlled mold filling (casting), the risk of uncontrolled cooling is reduced to a minimum. The temperature of the components to be infused can be adjusted specifically with little expenditure of energy and can be coordinated with the mold filling and solidification process of the entire casting.
Bewerkstelligen lässt sich dies auf einfache Weise insbesondere dann, wenn die Erwärmungseinrichtung induktiv arbeitet.This can be done easily, in particular, when the heating device works inductively.
Die Einbindung der Gießeinheit in den durch die Kernfertigungseinheit vorgegebenen Arbeitstakt kann dadurch realisiert werden, dass die Gießeinheit einen Drehtisch umfasst, der die jeweils von der Formmontageeinheit zur Gießeinheit geförderte Gießform an einer Übergabestation von der die Formmontageeinheit mit der Gießeinheit verbindenden Fördereinrichtung übernimmt, die Gießform in einer Schwenkbewegung zu einer Gießstation fördert und die Gießform nach dem in der Gießstation erfolgten gesteuerten Formfüllvorgang mit Schmelze weiter zu einer Übergabestation fördert, an der sie die jeweilige Gießform an die zur Abkühleinheit führende Fördereinrichtung übergibt.The incorporation of the casting unit into the working cycle predetermined by the core manufacturing unit can be realized by the casting unit comprising a turntable which takes over the casting mold conveyed from the mold assembly unit to the casting unit at a transfer station from the conveying device connecting the die assembly unit to the casting unit promotes a pivoting movement to a casting station and the mold after the done in the casting station controlled mold filling process with melt further promotes to a transfer station at which it passes the respective mold to the cooling unit leading to conveyor.
Die gesteuerte Formfüllung kann durch Ankoppeln der Gießformen an einen bekannten Niederdruckgießofen, gasdruckgeregeltem Schmelzetransport in den Formhohlraum, Verschließen der Eingussöffnung und anschließendem 180°- Drehung in Erstarrungsposition (roll-over) erfolgen. Alternativ kann die Drehbewegung zur Steuerung des Formfüllvorganges genutzt werden.The controlled mold filling can be done by coupling the molds to a known low-pressure casting furnace, gas-pressure-controlled melt transport into the mold cavity, closing the pouring opening and subsequent 180 ° rotation in solidification position (roll-over). Alternatively, the rotational movement can be used to control the mold filling process.
Als besonderer Vorteil entstehen bei Kernpaketen aus anorganischen Bindern kaum Gase beim Kontakt mit Schmelze, da der Binder nicht verbrennt.A special advantage of core packages made of inorganic binders are hardly any gases when in contact with the melt, since the binder does not burn.
Erforderlichenfalls lassen sich lokale Kühlkokillen einsetzten, um Wärme aus dem Bereich von Bohrungen, Lagerstühlen, Materialanhäufungen etc. gezielt abzuführen.If necessary, local cooling molds can be used to remove heat from the area of holes, storage chairs, accumulations of material, etc. in a targeted manner.
Das beim Stand der Technik nur aufwändig durchführbare Lösungsglühen kann dadurch vermieden werden, dass die Gussstücke ausgehend von einer bestimmten Temperatur abgeschreckt werden. Um dies zu ermöglichen, sieht eine weitere Ausgestaltung der Erfindung vor, dass die Abkühleinheit eine Abschreckstation zum Abschrecken des Gussteiles aus der Gießhitze heraus aufweist.The solution annealing, which can only be carried out with great difficulty in the prior art, can be avoided by quenching the cast pieces starting from a specific temperature. To make this possible, one sees Another embodiment of the invention that the cooling unit has a quenching station for quenching the casting from the casting heat out.
Die Entkernung des erstarrten Gussteiles kann in an sich bekannter Weise durch Flüssigkeitsstrahlen erfolgen. Dazu weist die Entformungseinheit bevorzugt eine Flüssigkeitsstrahleinrichtung zum Zerstören der Gießform auf. Mit einer solchen Flüssigkeitsstrahleinrichtung können auch die im Gussteil sitzenden Gießkerne ausgespült werden.The gutting of the solidified casting can be done in a conventional manner by liquid jets. For this purpose, the demolding unit preferably has a liquid jet device for destroying the casting mold. With such a liquid jet device, the casting cores sitting in the casting can be flushed out.
Auch kann die Entformungseinheit ein mit Flüssigkeit befüllbares Becken umfassen, in das die Gießform einsetzbar ist. Indem die Gießform mit dem Gussstück in der Flüssigkeit bewegt wird oder Wasserstrahldüsen im Becken angeordnet sind lässt sich der Zerfall der Gießform beschleunigen. Zu diesem Zweck kann dem Flüssigkeitsbecken eine Bewegungseinrichtung zum Bewegen der in das Becken getauchten Gießform zugeordnet sein. Die in der Flüssigkeit aufgefangenen Gießformteile zerfallen weiter zu fein körnigem Formstoff und lassen sich auf einfache Weise aus dem Flüssigkeitsbecken austragen.The demolding unit can also comprise a liquid-fillable basin into which the casting mold can be inserted. By moving the casting mold with the casting in the liquid or by arranging water jet nozzles in the basin, the disintegration of the casting mold can be accelerated. For this purpose, a movement device for moving the casting mold immersed in the basin can be assigned to the liquid basin. The molded parts caught in the liquid further disintegrate into finely granular molding material and can be easily removed from the liquid tank.
Als Flüssigkeit zum Zerstören der Gießform und Ausspülen des Formstoffes eignet sich insbesondere Wasser ggf. mit Additiven, das auf eine bestimmte, den Zerfall des Formstoffs der Gießform zusätzlich unterstützende Temperatur erwärmt sein kann.As a liquid for destroying the casting mold and rinsing out the molding material, in particular water is optionally suitable with additives, which may be heated to a certain, the decay of the molding material of the mold additionally supporting temperature.
Eine besonders praxisgerechte Ausgestaltung der Erfindung ist dadurch gekennzeichnet, dass die Abkühleinheit und die Entformungseinheit zu einer kombinierten Abkühl- und Entformungseinheit zusammengefasst sind.A particularly practical embodiment of the invention is characterized in that the cooling unit and the demolding unit are combined to form a combined cooling and demolding unit.
Die beim Stand der Technik aufgrund der Verwendung organischer Binder verursachten Probleme lassen sich dadurch beseitigen, dass als Binder des Formstoffs ein anorganischer Binder eingesetzt wird. Derartige aus dem Stand der Technik an sich bekannte Bindersystem lassen sich durch Wärmezufuhr härten, ohne dass dabei die Umwelt oder das Maschinenpersonal belastende Gase austreten.The problems caused by the use of organic binders in the prior art can be eliminated by using an inorganic binder as the binder of the molding material. Such known from the prior art binder system can be cured by heat, without causing the environment or the machine personnel polluting gases.
Nachfolgend wird die Erfindung anhand einer ein Ausführungsbeispiel darstellenden Zeichnung näher erläutert.The invention will be explained in more detail with reference to a drawing illustrating an exemplary embodiment.
Die einzige Figur zeigt schematisch eine Fertigungslinie 1 zum vollautomatischen Herstellen von Motorblöcken aus einer Aluminiumlegierung in einer Draufsicht. Die Fertigungslinie umfasst eine Kernfertigungseinheit 2 zum Fertigen von Gießkernen, eine Formmontageinheit 3 zur Montage von als Kernpakete ausgebildeten Gießformen G, eine Gießeinheit 4 zum Abgießen von Aluminiumschmelze in die Gießformen G, eine Abkühleinheit 5a zum Erstarren der in der Gießform G enthaltenen Metallschmelze und eine Entformungseinheit 5b zum zerstörenden Entfernen der jeweiligen Gießform G sowie eine Abschreckeinheit 5c des Gussteiles M.The single figure shows schematically a production line 1 for the fully automatic production of engine blocks made of an aluminum alloy in a plan view. The production line comprises a core production unit 2 for manufacturing casting cores, a mold mounting unit 3 for mounting core molds G, a casting unit 4 for casting aluminum melt into the casting molds G, a cooling unit 5a for solidifying the molten metal contained in the casting mold G, and a
Die Kernfertigungseinheit 2 weist eine Kernschießstation 6 und eine als Förderstrecke ausgebildete Transporteinrichtung 7 auf. Die Transporteinrichtung 7 ist in vier Teilstrecken 7a,7b, 7c, 7d aufgeteilt, die rechtwinklig zueinander derart angeordnet sind, dass sie in Draufsicht die Seitenlinie eines Rechteckes bilden. Über eine parallel zu den kürzeren Teilstrecken 7a, 7c angeordnete Förderstrecke 7e können die Kernwerkzeugoberteile WO zur Teilstrecke 7d gefördert werden. Die Kernschießstation 6 ist dabei in einem Eckbereich der Transporteinrichtung 7 positioniert, an dem die Teilstücke 7a und 7d der Transporteinrichtung aufeinander stoßen. In der Kernschießstation 6 werden in an sich bekannter Weise aus einem anorganischen Binder und einem Quarzsand oder synthetischen Sand gemischten Formstoff Gießkerne geschossen.The core production unit 2 has a core shooting station 6 and a conveying device 7 designed as a conveying path. The transport device 7 is divided into four sections 7a, 7b, 7c, 7d, which are arranged at right angles to each other such that they form the side line of a rectangle in plan view. About a parallel to the shorter sections 7a, 7c arranged conveyor track 7e, the Core tool shells WO are conveyed to the section 7d. The core shooting station 6 is positioned in a corner region of the transport device 7, on which the sections 7a and 7d of the transport device abut one another. In the core shooting station 6 casting cores are shot in a conventional manner from an inorganic binder and a quartz sand or synthetic sand mixed molding material.
Der Kernschießstation 6 ist eine Schusshaubenwechseleinrichtung 8 zugeordnet, die die in der Kernschießstation 6 jeweils eingesetzte Schusshaube werkzeugspezifisch bereitstellt.The core shooting station 6 is associated with a Schusshaubenwechseleinrichtung 8, which provides the gun used in the core shooting station 6 each shot hood tool specific.
Zum Aushärten der Kerne durch Wärmeexposition und Spülluft werden die Werkzeuge W in die Aushärtestationen A positioniert. In der Mitte des Teilstückes 7b werden die Werkzeugoberteile WO abgehoben und der Förderstrecke 7e übergeben.To harden the cores by heat exposure and purging air, the tools W are positioned in the curing stations A. In the middle of the section 7b, the tool shells WO are lifted and transferred to the conveying path 7e.
Anschließend ist ein erster Montageroboter 11 der Formmontageeinheit 3 zugeordnet, der aus der Aushärtestation A austretende und über das Teilstück 7b transportierte Kerne aus dem Werkzeugunterteil WU übernimmt.Subsequently, a
Weitere dem Übernahmeroboter 11 entsprechende Montageroboter 10 der Formmontageeinheit 3 sind entlang des dem Teilstück 7a gegenüberliegend angeordneten Teilstück 7c der Transporteinrichtung 7 positioniert. Ein letzter Montageroboter 9 der Montageeinheit 3 ist in Förderrichtung F am Anfang es Teilstücks 7b gegenüberliegend angeordneten Teilstück 7d positioniert. An den Teilstücken 7b, 7c, 7d, der Transporteinrichtung 7 sind auf diese Weise Übergabestationen gebildet, an denen die fertigen Gießkerne an die Formmontageeinheit 3 übergeben werden. Die jeweils eine Montagestation bildenden Montageroboter 9-11 der Formmontageeinheit 3 setzten aus den von ihnen jeweils übernommenen Gießkernen als Kernpakete ausgebildete Gießformen G zusammen.
Die Gießformen G werden über eine als Förderstrecke ausgebildete Fördereinrichtung 12 transportiert an den Montagerobotern 9-11 entlang gefördert. Die Fördereinrichtung 12 weist drei linear verlaufende Teilstücke 13,14,15 auf, von denen in Draufsicht das erste Teilstück 13 im rechten Winkel zum zweiten Teilstück 14 und das dritte Teilstück 15 wiederum im rechten Winkel zum zweiten Teilstück 15 angeordnet ist, so dass die Teilstücke 13- 15 in Draufsicht U-förmig angeordnet sind.The casting molds G are conveyed via a conveying
Auf dem ersten Teilstück 13 der Transporteinrichtung 12 werden von dem ersten Montageroboter 11 die ersten Gießkerne der jeweiligen Gießform G zusammengesetzt. Anschließend gelangen die in diesem Zustand teilweise fertig gebauten Gießformen G auf das Teilstück 14 der Fördereinrichtung 12 und werden auf diesem entlang der Montageroboter 10, 9 gefördert die jeweils weitere Gießkerne G zu der jeweiligen Gießform hinzufügen, bis beim Verlassen der Formmontageeinheit 3 die Gießform fertig zusammengestellt ist.On the
Vom Teilstück 14 der Transportvorrichtung 12 gelangen die Gießformen G auf das Teilstück 15, das sie zu einem Drehtisch 16 leitet. Der Drehtisch 16 übernimmt die jeweilige Gießform G und transportiert in einer 90° Drehung zu einer Heizstation 17 in der in den zu fertigenden Motorblock einzugießende Inserts (z.B. Liner etc.) oder Kokillenteile (z.B. Messingpinolen für Bohrungsbereich etc.) induktiv erwärmt werden.From
Durch eine weitere 90°- Drehung des Drehtisch 16 wird die Gießform G zur Gießstation 18 der Gießeinheit 4 gefördert. Dort wird die Aluminiumschmelze in die jeweilige Gießform G befördert. Anschließend fördert der Drehtisch 16 wieder die mit Schmelze gefüllte Gießform G zu einer Übergabestation, an der die Gießform G an eine weitere als Förderstrecke ausgebildete Fördereinrichtung 19 übergeben wird.By a further 90 ° rotation of the
Während der Abkühlung wird die Gießform G über eine gradlinig ausgebildete Förderstrecke 20 der Abkühleinheit 5a weitertransportiert. Am Ende der Förderstrecke 20 ist die Erstarrung der Aluminiumschmelze in der Gießform G soweit abgeschlossen, dass das in ihr gebildete Gussteil M eine feste Form erhalten hat.During the cooling, the casting mold G is transported on via a straight-
Vom Ausgang der Abkühleinheit 5a wird die nach wie vor ihre ursprüngliche Gestalt besitzende Gießform G über eine ebenfalls als Förderstrecke ausgebildete, im rechten Winkel zur Förderstrecke 20 der Abkühleinheit 5a angeordnete Fördereinrichtung 21 zu einer Übernahmestation der Entformungseinheit 5b transportiert. Dort übernimmt ein Gießformmanipulator (Roboter) 22 die jeweilige Gießform G und taucht sie in ein Wasserbecken 23.From the exit of the cooling unit 5a, the casting mold G, which still has its original shape, is transported to a transfer station of the
In dem mit temperierten Wasser gefüllten Wasserbecken 23 wird die Gießform G bewegt, um ihren Zerfall beschleunigt einzuleiten. Zusätzlich kann durch nicht dargestellte Wasserstrahleinrichtungen die Gießform G beschleunigt zerstört und im Inneren des erstarrten Gussteils M liegende Kerne ausgespült werden.In the
Die Bruchstücke der Gießform G werden in dem Wasserbecken 23 aufgefangen und zerfallen, da sich der anorganische Binder in dem Wasserbecken 23 auflöst. Dabei fällt feinkörniger Formgrundstoff an. Der Formgrundstoff wird mit neuem anorganischen Binder wieder zu neuem Formstoff gemischt und wieder der Kernfertigungseinheit 2 zugeführt.The fragments of the mold G are caught in the
Der anorganische Binder dagegen wird teilweise im Wasser des Wasserbeckens 23 gelöst. Das den Binder enthaltene Wasser wird ebenfalls einer Aufbereitung zugeführt und in den Produktionskreislauf zurückgeführt.In contrast, the inorganic binder is partially dissolved in the water of the
Nach dem Entformen wird das nun von Gießkernrückständen freie Gussteil (Motorblock) M über eine Förderstrecke 25 einer Nachbearbeitungseinheit 26 zugeführt, in der es entgratet, gesägt und erforderlichenfalls weiteren Nachbearbeitungsoperationen unterzogen wird.After removal from the mold, the casting (engine block) M, which is now free from casting core residues, is fed via a
Der Takt, mit dem die Gussteile M aus der Fertigungslinie 1 ausgestoßen werden, ist durch den Takt bestimmt, mit dem die Kernfertigungseinheit 2 die von ihr erzeugten Gießkerne an die Formmontageeinheit 3 liefert. Für den Transport der Gussteile, ihre Behandlung in den einzelnen Funktionseinheiten 2-6 der Fertigungslinie 1 wird aufgrund der direkten Verkettung dieser Einheiten 2-6, der schnellen Abkühlung und der mit der Abkühlung direkt kombinierten Entsandung nur eine geringe Zahl von Gussteilmanipulatoren (Robotern) benötigt. Auch dies führt dazu, dass die erfindungsgemäße Fertigungslinie mit geringem Aufwand an Maschinen und Kosten in besonders wirtschaftlicher Weise hochwertige Gussteile in relativ kleinen Stückzahlen produzieren kann.The tact with which the castings M are ejected from the production line 1 is determined by the tact with which the core production unit 2 supplies the casting cores produced by it to the mold mounting unit 3. For the transport of the castings, their treatment in the individual functional units 2-6 of the production line 1, only a small number of casting manipulators (robots) is required due to the direct linking of these units 2-6, the rapid cooling and desanding combined directly with the cooling , This also means that the production line according to the invention can produce high quality castings in relatively small quantities in a particularly economical manner with little effort on machines and costs.
- 11
- Fertigungslinieproduction line
- 22
- KernfertigungseinheitCore production unit
- 33
- FormmontageeinheitMold assembly unit
- 44
- Gießeinheitcasting unit
- 5a5a
- Abkühleinheitcooling unit
- 5b5b
- Entformungseinheitdemoulding
- 5c5c
- Abschreckeinheitquenching unit
- 66
- KernschießstationCore shooting station
- 77
- Transporteinrichtungtransport means
- 7a - 7d7a-7d
- Teilstrecken der TransporteinrichtungPartial sections of the transport device
- 88th
- SchusshaubenwechseleinrichtungShot hood changer
- 9 - 119 - 11
- Montageroboterassembly robots
- 1212
- FördereinrichtungConveyor
- 13 - 1513 - 15
- Teilstücke der Fördereinrichtung 12Pieces of the conveyor 12th
- 1616
- Drehtischturntable
- 1717
- Heizstation (induktiv)Heating station (inductive)
- 1818
- Gießstation der Gießeinheit 4Casting station of the casting unit 4
- 1919
- FördereinrichtungConveyor
- 2020
- Förderstrecke der Abkühleinheit 5aConveyor line of the cooling unit 5a
- 2121
- FördereinrichtungConveyor
- 2222
-
Gießformmanipulator der Entformungseinheit 5bCasting manipulator of
demolding unit 5b - 2323
-
Wasserbecken der Entformungseinheit 5bWater basin of
demolding unit 5b - 2424
- Aufbereitungseinheitconditioning unit
- 2525
- Förderstreckeconveyor line
- 2626
- Nachbearbeitungseinheitpost-processing unit
- FF
- Förderrichtung der Transporteinrichtung 7Conveying direction of the transport device 7
- GG
- Gießformenmolds
- MM
- Gussteilecastings
- WW
- KernwerkzeugeCore Tools
- WOWHERE
- KernwerkzeugoberteilCore tool upper part
- WUWU
- KernwerkzeugunterteilCore tool part
- AA
- Aushärtestationcuring
Claims (23)
- A production line for production of cast parts (M) in a continuous flow-through process from a metallic melt, in particular a light metal melt, having multiple function units, including a core production unit (2) for production of cast cores, a mold assembly unit (3) for assembling casting molds (G) designed as core packages, a casting unit for casting the metal melt in the casting molds (G), a cooling unit (5a) for cooling the metal contained in the casting molds (G) and an unmolding unit (5) for destructive removal of the casting mold (G) from the cast part (M),
characterized in that
the function units (2-5b) that follow one another in passing through the system are directly interconnected by a conveyor device (12, 19), and the cycle with which the production line (1) outputs finished cast parts (M) is determined by the cycle with which the core production unit (T) supplies the cast cores produced by it. - The production line according to Claim 1,
characterized in that
the core production unit (2) has a transfer station for transferring the finished cores to the mold assembly device (3) and has a conveyor device (7) which conveys the core injection molds from the transfer station to a core injection station and then back to the transfer station in rotation. - The production line according to Claim 2,
characterized in that
the conveyor device (7) is designed as a conveyor zone and more than one hardening station is situated along the conveyor zone. - The production line according to any one of the preceding claims,
characterized in that
the core production unit (2) has a device for automated changing of the product-specific core molds required for injection of the cores, the cycle with which the change is accomplished being linked to the cycle with which the core production unit (2) supplies the cast cores produced by it. - The production line according to any one of the preceding claims,
characterized in that
the mold assembly unit (3) includes a transfer station with which it receives the finished cores output by the core production device and includes a conveyor device which conveys the casting molds (G) to be produced one after the other to the assembly stations (9-11). - The production line according to Claim 5,
characterized in that
the mold assembly unit (3) comprises more than one assembly station and the conveyor device (12) conveys the casting molds (G) that are to be produced one after the other to the assembly stations. - The production line according to any one of the preceding claims,
characterized in that
it comprises a heating device for heating components to be embedded in the casting of the cast part (M). - The production line according to Claim 7,
characterized in that
the heating device is integrated into the casting unit (4) and the casting mold (G) that is conveyed passes through the heating device in cycle with the mold elements to be cast that are inserted into it. - The production line according to any one of Claims 7 or 8,
characterized in that
the heating device operates inductively. - The production line according to any one of the preceding claims,
characterized in that
the casting unit (4) includes a rotating table (16) which transfers each casting mold (G) conveyed by the mold assembly unit (3) to the casting unit (4) from the conveyor device connecting the mold assembly unit (3) to the casting unit, this transfer being performed at a transfer station, conveying the casting mold (G) in a pivoting motion to a casting station (18) and rotating the casting mold (G) into the solidification position after controlled filling of the mold with melt in the casting station and conveys it further to a transfer station where it transfers the respective casting mold (G) to the conveyor device (19) leading to the cooling unit (5). - The production line according to any one of the preceding claims,
characterized in that
the cooling unit has a quenching station for quenching the cast part (M) from the heat of casting. - The production line according to any one of the preceding claims,
characterized in that
the unmolding unit (5b) has a jet stream device for destroying the casting mold (G). - The production line according to Claim 12,
characterized in that
the jet stream device is intended for flushing the casting molds out of the cast part. - The production line according to any one of the preceding claims,
characterized in that
the unmolding unit (5b) comprises a basin that can be filled with liquid into which the casting mold can be inserted. - The production line according to Claim 14,
characterized in that
a movement device for moving the casting mold (G) immersed in the basin is provided for the liquid basin. - The production line according to any one of the preceding claims,
characterized in that
the cooling unit (5c) and the unmolding unit (5b) are joined together to form a combined quenching and unmolding unit. - A method for automatic production of casting mold parts (M) from a metal melt, in particular a light metal melt, in which the following working steps are run through in a continuous production process:- creating casting cores in a core production unit (2) from a binder prepared by mixing a mold basic substance and a binder,- transferring the casting cores to a mold assembly unit (3),- assembling the casting cores to form a casting mold (G) designed as a core package,- transferring the casting mold (G) to a casting unit (4),- controlled mold filling (casting) of metal melt into the casting mold (G),- transfer of the casting molds (G) filled with metal melt to a cooling unit (5a),- cooling the metal melt contained in the casting mold (G)- transfer of the casting mold (G) with the cooled cast part (M) to an unmolding unit (5b),- unmolding the cast part (M) with destruction of the casting mold (G) in an unmolding unit (5b),- quenching the cast part from the heat of casting,- output of the cast part (M) produced,- whereby the cycle with which the cast parts (M) produced are output is determined by the cycle with which the casting cores are produced.
- The method according to Claim 17,
characterized in that
the binder of the molding material is an inorganic binder. - The method according to any one of Claims 17 or 18,
characterized in that
the respective transfer comprises transport from one unit (2-5a) to the next following unit (3-5b). - The method according to any one of Claims 17 through 19,
characterized in that
the casting mold (G) is immersed in a basin filled with liquid coolant in the wake of the cooling. - The method according to Claim 20,
characterized in that
a strong relative movement is created between the casting mold (G) and the liquid coolant. - The method according to any one of Claims 17 through 21,
characterized in that
the unmolding of the cast piece (M) is accomplished by means of a liquid through which the binding of the molding material is dissolved. - The method according to Claim 22,
characterized in that
the molding material dissolved by the liquid is collected and sent for workup.
Priority Applications (1)
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PL04820597T PL1626830T3 (en) | 2003-12-19 | 2004-12-17 | Production line and method for the continuous production of cast parts from a molten metal, in particular a molten light alloy |
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DE10360694A DE10360694B3 (en) | 2003-12-19 | 2003-12-19 | Production line and method for the continuous production of castings from a metallic melt, in particular a light metal melt |
PCT/EP2004/014388 WO2005061156A1 (en) | 2003-12-19 | 2004-12-17 | Production line and method for the continuous production of cast parts from a molten metal, in particular a molten light alloy |
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EP1626830B1 true EP1626830B1 (en) | 2006-06-28 |
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US (1) | US7588070B2 (en) |
EP (1) | EP1626830B1 (en) |
JP (1) | JP2007514549A (en) |
CN (1) | CN1822912A (en) |
AT (1) | ATE331582T1 (en) |
AU (1) | AU2004305239A1 (en) |
BR (1) | BRPI0414936A (en) |
CA (1) | CA2528474A1 (en) |
DE (3) | DE20320923U1 (en) |
ES (1) | ES2268667T3 (en) |
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2003
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- 2003-12-19 DE DE10360694A patent/DE10360694B3/en not_active Withdrawn - After Issue
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2004
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- 2004-12-17 DE DE502004000896T patent/DE502004000896D1/en active Active
- 2004-12-17 US US10/562,959 patent/US7588070B2/en not_active Expired - Fee Related
- 2004-12-17 ES ES04820597T patent/ES2268667T3/en active Active
- 2004-12-17 EP EP04820597A patent/EP1626830B1/en active Active
- 2004-12-17 MX MXPA06000096A patent/MXPA06000096A/en active IP Right Grant
- 2004-12-17 RU RU2006104714/02A patent/RU2006104714A/en not_active Application Discontinuation
- 2004-12-17 CN CNA2004800199043A patent/CN1822912A/en active Pending
- 2004-12-17 WO PCT/EP2004/014388 patent/WO2005061156A1/en active Application Filing
- 2004-12-17 CA CA002528474A patent/CA2528474A1/en not_active Abandoned
- 2004-12-17 BR BRPI0414936-0A patent/BRPI0414936A/en not_active Application Discontinuation
- 2004-12-17 AU AU2004305239A patent/AU2004305239A1/en not_active Abandoned
- 2004-12-17 AT AT04820597T patent/ATE331582T1/en active
- 2004-12-17 JP JP2006544351A patent/JP2007514549A/en active Pending
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- 2005-12-12 ZA ZA200510103A patent/ZA200510103B/en unknown
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2911522A1 (en) * | 2007-01-22 | 2008-07-25 | Cinetic Linking Sa | AUTOMATED PRODUCTION CHAIN OF METAL PARTS AND MOLDING METHOD |
FR2911521A1 (en) * | 2007-01-22 | 2008-07-25 | Cinetic Linking Sa | Arrangement for automated production of metallic parts, comprises equipments for the preparation of molten metal, die casting, core preparation and for finishing, three poly-articulated robots, and three implantation areas |
WO2008107558A1 (en) * | 2007-01-22 | 2008-09-12 | Cinetic Automation Sa | Static carousel |
DE102019134739B3 (en) * | 2019-12-17 | 2021-04-01 | Meissner Ag Modell- Und Werkzeugfabrik | Core shooting process and core shooting device for the production of cores with simultaneous hardening process |
Also Published As
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ZA200510103B (en) | 2006-12-27 |
BRPI0414936A (en) | 2006-11-07 |
DE10360694B3 (en) | 2005-06-30 |
PL1626830T3 (en) | 2006-11-30 |
DE502004000896D1 (en) | 2006-08-10 |
US7588070B2 (en) | 2009-09-15 |
ATE331582T1 (en) | 2006-07-15 |
EP1626830A1 (en) | 2006-02-22 |
CA2528474A1 (en) | 2005-07-07 |
US20070169912A1 (en) | 2007-07-26 |
DE20320923U1 (en) | 2005-06-09 |
MXPA06000096A (en) | 2006-04-07 |
AU2004305239A1 (en) | 2005-07-07 |
WO2005061156A8 (en) | 2005-09-22 |
JP2007514549A (en) | 2007-06-07 |
WO2005061156A1 (en) | 2005-07-07 |
ES2268667T3 (en) | 2007-03-16 |
CN1822912A (en) | 2006-08-23 |
RU2006104714A (en) | 2007-09-10 |
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