JP2005111499A - Foundry, and plant layout system for foundry - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a foundry in which complicate physical distribution transporting process is simplified, the transport distance of tools, members or the like between respective processes are minimized, and the physical distribution system independently of an overhead crane or the like, and also the storing and supplying area of various kinds of materials, molds, tools or the like is directly connected to the working areas of melting, pouring, flask removal or the like, so that the productivitt per one worker and that per the area are drastically increased, working environment is improved, and the high-mix low-volume production is made efficient, and to provide a plant layout system therefor. <P>SOLUTION: A cubic storehouse 1 with stacker cranes 4, 4a having a storing part for master mold patterns, core patterns, cores and completed molds before pouring the molten metal and after pouring the molten metal, are disposed at the center part of the foundry, and the molding area is disposed along the one outer side of the cubic-storehouse and the casting process area of the melting, the pouring, the cooling, the flask removal, grinding, etc., is disposed along the reverse side outer side of the cubic-storehouse. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a plant layout method in a foundry and a foundry, that is, a jig such as a metal frame, a main model, a core model, and the like used for casting work in a casting machine or the like in a foundry that performs self-hardening casting, The present invention relates to a casting factory and a plant layout method in the casting factory for arranging the mold at an optimum position in consideration of convenience and efficiency of mold transfer.

  In a self-hardening foundry with a general configuration, during casting operations, production instructions for metal frames stored in a metal frame storage area installed outdoors, main models and core models stored in separate buildings, etc. In accordance with the above, it is carried into the factory by truck, forklift, overhead crane, etc., a metal frame is set on the main model, filled with self-hardening sand kneaded with a mixer, and after curing, lifted with an overhead crane, die-cut, painted After completion of operations such as mold, drying, core setting, and mold matching, a finished mold is prepared.

  In this case, the core is formed using a core model in another place, cured, coated, dried, and set in the main mold. The mold after pouring is allowed to cool as it is, and after the casting is cooled, the casting, metal frame, and foundry sand are separated by the operator using an overhead crane, and the casting is subjected to surface cleaning, maintenance, inspection, etc. After that, it is shipped as the final product. The used metal frame, the main model, and the core model are returned and returned to a predetermined place by a truck, a forklift, an overhead crane, or the like. The foundry sand is again conveyed to the mixer after the recovery and regeneration process.

Since a lot of man-hours are required for physical distribution conveyance between processes in such a conventional method, the production efficiency is extremely low. Such a production system uses a large planar work area and requires a large number of logistics transportation processes, so the worker production efficiency is only about 3 to 8 tons / person per month, and includes a metal frame and a model place. The contact area productivity is only about 50 kg / m ² . In addition, as the workplace expands, there is a problem that dust, hot air, and the like are dispersed and the working environment of the entire factory is impaired.

  From the above situation, simplify the complicated logistics transportation process in the foundry, minimize the transfer distance of jigs and members between each process, and build a logistics system that does not rely on overhead cranes etc. By doing so, the storage, supply, and storage areas for various materials, molds, jigs, etc. in the foundry are directly connected to the work areas such as the mold production site, melting, pouring, and demolition site, resulting in productivity per worker. However, there is a demand for a substantial increase in factory area productivity, improvement of work environment, efficiency of multi-product, multi-material, and small-volume production. It is an object to provide a plant layout method in a factory.

  The present invention provides a three-dimensional warehouse with a stacker crane having a main model, a core model and a core, a storage unit for finished molds before and after pouring, and the like in the center of the factory. A casting is characterized in that a mold manufacturing area is arranged along the side surface, and a casting process area such as melting, pouring, cooling, demolition, and polishing is arranged along the opposite outer surface of the three-dimensional warehouse. The above problems have been solved by a plant and a plant layout method in a foundry.

  Preferably, the mold manufacturing area and / or the casting process area has a two-layer structure, and the upper layer portion is a main model, core model, and core manufacturing area, and is directly from the upper part of the three-dimensional warehouse. The main model, the core model, and the core transfer pallet placed on the transfer pallet can be taken in and out.

  In the present invention, the main model and the storage of the main mold, the core model, and the core are integrated as a three-dimensional warehouse and arranged in the center of the factory, and the mold manufacturing site, the core manufacturing site, Arrangement of mold model and core model production place, melting, pouring, in-mold casting cooling, demolition site, etc., realized machine equipment arrangement as a comprehensive casting factory, especially in the self-hardening foundry Can increase productivity, improve production efficiency of castings of many types and materials and small lots, and can greatly reduce the production cost by increasing the factory area productivity. Is separated from the mold manufacturing area and the like, so that the working environment in the factory can be improved.

  Preferred embodiments of the present invention will be described with reference to the accompanying drawings. 1 to 3 are layout diagrams of a factory showing an example of a plant layout by the method according to the present invention. In the illustrated example, a part thereof has a two-layer structure. FIG. 1 shows an arrangement example of the first floor portion, and FIG. 2 shows an arrangement example of the second floor portion. In the foundry, all production commands are controlled by the factory computer production management system.

  The method according to the present invention is based on placing the three-dimensional warehouse 1 in the center of the factory floor. The three-dimensional warehouse 1 used here has two rows of storage shelves 2 and 3 in which storage units are arranged side by side, and is controlled by the computer to move vertically and horizontally along the storage shelves 2 and 3. It consists of stacker cranes 4 and 4a for taking in and out and transferring.

  Jigs, molds, and the like are stored in the storage portions of the storage shelves 2 and 3, and the storage locations are appropriately assigned according to the type of storage items. Typically, heavy objects such as finished molds and poured finished molds are placed on the lower layer of the shelf, and lightweight objects such as main model, core model, and core are placed on the upper layer of the shelf. The stacker crane 4 installed between the storage shelves 2 and 3 is used for a lightweight object, and the stacker crane 4a installed outside the storage rack 3 is used for a heavy object.

  In the illustrated example, the entire upper storage portion of one storage shelf 2 and the upper layer portion of the other storage shelf 3 are used as storage portions for lightweight main models, core models, cores, etc., and the lower layer portion of the other storage shelf 3 is weighted. It is the completed mold storage part 7 before and after pouring the hot water.

  The main model, the core model, the core, the completed mold, etc. are all stored on the storage shelves 2 and 3 while being placed on a dedicated transport pallet, and are transported while being placed on the transport pallet.

  The outside of one storage shelf 2 is a mold manufacturing area 10, and the outside of the other storage shelf 3 is a casting process area 11.

  The mold production area 10 has a two-layer structure, and on the first floor, in order along the storage shelf 2, an empty metal frame storage area 12, a main mold making place 13, a core setting place 14, and a mold setting place 15 are arranged. Is installed. In addition, a core molding field 16 and a main model / core model molding field 17 are installed on the upper layer (see FIG. 2).

  The main mold making place 13 is a work area in which a metal frame is placed on a main model and stuffed with sand to produce upper and lower main molds. For this work, the metal frame set compartments 20-22, the model preparation compartments 23-26, the sand-filled mold compartment 27, the curing compartments 28-30 for hardening the self-hardening sand, the die cutting compartment 31, the coating mold compartment 32 and drying. A partition 33 is disposed.

  In the main mold making place 13, the main model supplied from the main model storage unit 5 to the model preparation sections 23 to 26 is transferred to the metal frame setting sections 20 to 22 using a carriage 35 or the like. In the metal frame setting sections 20 to 22, a metal frame is set on the main model, and the main model on which the metal frame is set is sent to the sand-filled mold section 27.

  In the sand-filled molding section 27, self-hardening sand using a self-hardening resin as an adhesive is uniformly packed in the metal frame, and then transferred to the hardening sections 28 to 30 to wait for hardening. After curing, the mold is inverted and punched in the punching section 31, and the heat-resistant coating agent is applied in the coating section 32 and then dried in the drying section 33. Thus, the upper and lower main molds are manufactured.

  The inverted main mold model is transferred again to the metal frame setting sections 20 to 22, where the metal frame is set and sent to the sand-filled mold section 27. Alternatively, the metal frame is not set and returned to the model preparation sections 23 to 26 of the three-dimensional warehouse 1 and stored in the main model storage unit 5 of the three-dimensional warehouse 1.

  The core setting place 14 is a work area for setting the core in the main mold. For this operation, core supply stations 35 to 38 for receiving the core from the core storage section 6 of the three-dimensional warehouse 1 and core setting stations 39 to 42 for setting the core to the mold are provided. Arrange.

  In the core setting place 14, the core supply stations 35 to 38 prepare the upper mold and / or the lower mold sent from the drying section 33 via the carriage 43 in the core setting stations 39 to 42, respectively. Is set.

  The mold matching field 15 is provided adjacent to the core setting field 14, and an automatic mold covering machine is installed there. In this mold matching site 15, the automatic mold overlaying machine covers the lower mold with the main mold (upper mold) sent from the core set stations 39 to 42 via the carriage 43, thereby assembling the mold. And a finished mold is manufactured. At this time, the transfer mold pallet of the upper mold is conveyed by the conveyor 73 laid under the storage shelf 2 via the conveyor 62 and is supplied again to the die cutting section 31 by the carriage 35.

  An upper floor 44 in which the core molding field 16 and the main model / core model molding field 17 are arranged is provided on the mold manufacturing area 10 having the above layout, and the upper and lower layers of the storage shelf 2 corresponding to them. In the upper layer portion of the storage shelf 3, a core and core model storage unit 45 and a main model storage unit 47 are secured. As described above, the main model, the core model, and the core stored in these storage units are all stored on the transport pallet.

  In the core molding place 16, the core model placed on the transport pallet is taken out from the core model delivery section 46 of the three-dimensional warehouse 1 and supplied to the core model supply section 48. Then, the self-hardening sand is filled in the adjacent core sand containing molding section 49 and then transferred to the curing section 50 to wait for curing.

  After hardening, the core model is die-cut in the die-cutting section 51, and the used core model is returned from the delivery unit 52 of the three-dimensional warehouse 1 to the used model storage unit by the stacker crane 4. The core is placed on an empty transport pallet supplied from the transport pallet delivery unit 53, coated in the coating section 54, dried in the drying section 55, and then directly in the upper layers of the storage shelves 2 and 3. It is stored via the child delivery unit 56.

  In the casting process area 11, a pouring line 18 connected to the mold matching site 15 and a demolition site 19 are installed. The completed mold is sent to the completed mold storage section 7 in the lower layer of the storage shelf 3 through the roller 61 and the stacker crane 4a, etc., stored there, and waits for a call based on a production command.

  When there is a call for a finished mold that matches the melted material based on the production command, the corresponding finished mold is carried out and supplied from the finished mold storage section 7 to the pouring sections 63 to 64 by the stacker crane 4a. The molten metal supplied from the melting section 65 is injected. The mold after pouring is stored in the completed mold storage section 7 of the three-dimensional warehouse 1 for each in-mold cooling time and waits for cooling.

  After cooling, the mold is sent to the unpacking field 19 via the conveyor 57, where it is separated into a casting, a conveying pallet, a metal frame and foundry sand. The metal frame is conveyed to the metal frame storage place 12 by the conveyors 67 to 70 after cleaning, and is returned to a predetermined position for each type by an unmanned crane or the like. Further, the transport pallet returns to the conveyor 69 via the conveyors 67 and 68, and is transferred to the inverted die cutting section 31 by the carriage 35 via the conveyor 72 laid at the lower part of the storage shelf 3.

  On the other hand, the casting is subjected to surface grinding by shot blasting and the like, and after being subjected to care and inspection, it is shipped as a final product. The sand is regenerated in the sand processing section 71 and conveyed again to the main mixer and the core mixer. The return material is returned to the melting section 65.

  In the above embodiment, only the mold production area has a two-layer structure, but the casting process area may have a two-layer structure. In that case, the configuration of the upper layer portion of the storage shelf 2 is replaced with the configuration of the upper layer portion of the storage shelf 3. In addition, both the above areas can have a two-layer structure, and the configuration of the second floor portion can be appropriately distributed.

  In this way, diffusion of hot air and the like is prevented by arranging work areas for metal melting, pouring, solidification, in-mold casting cooling, and demolition on the opposite side of the mold manufacturing site across the three-dimensional warehouse 1. In addition, by collecting these work areas in a small space, it is possible to efficiently perform dust collection, thermal ventilation, and the like.

It is a top view which shows an example (1st floor part) of the plant layout by the method which concerns on this invention. It is a top view which shows an example (2nd floor part) of the plant layout by the method which concerns on this invention. It is a side view of the plant layout by the method concerning this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Three-dimensional warehouse 2, 3 Storage shelf 4, 4a Stacker crane 5, 6 Main model model and core storage part 7 Mold storage part 10 Mold production area 11 Mold process area 12 Metal frame place 13 Main mold shop 14 Core set Field 15 Mold matching field 16 Core molding field 17 Main model / core model molding field 18 Pouring line 19 Unloading field 20-22 Gold frame set section 23-26 Model preparation section 27 Sand-filled section 28-30 Curing section 31 Die-cut section 32 Coating section 33 Drying section 35-38 Core supply station 39-42 Core set station 43 Carriage 44 Upper floor 45 Core and core model storage section 46 Core model delivery section 47 Main model storage Section 48 Core model supply section 49 Core sand molding section 50 Core curing section 51 Die cutting section 52 Used model storage section 53 Transport pallet supply section 54 Coating section 5 5 Drying section 56 Core storage section 57 Conveyor 61 Rollers 63 to 64 Pouring line 65 Melting section 67 to 70 Conveyor 71 Sand processing section 72 Conveyor (for empty main mold transfer pallet)
73 Conveyor (for empty main mold transfer pallet)

Claims (6)

  A three-dimensional warehouse with a stacker crane having a main model, a core model and a core, a storage section for finished molds before and after pouring, etc. is installed in the center of the factory, along one outer surface of the three-dimensional warehouse. A plant layout in a foundry where a mold manufacturing area is arranged, and casting process areas such as melting, pouring, cooling, dismantling, and polishing are arranged along the opposite outer surface of the three-dimensional warehouse. Method.   The mold manufacturing area and / or the casting process area has a two-layer structure, and an upper layer portion thereof is a main model model, a core model, and a core manufacturing area. Plant layout method at a foundry in Japan.   3. The plant layout method in a foundry according to claim 2, wherein the first floor of the mold production area is a metal frame place, a main mold making place, a core setting place, and a mold matching place.   A three-dimensional warehouse with a stacker crane having a main model, a core model and a core, a storage section for finished molds before and after pouring, etc. is installed in the center of the factory, along one outer surface of the three-dimensional warehouse. A foundry where a mold manufacturing area is arranged, and a casting process area such as melting, pouring, cooling, dismantling, polishing, etc. is arranged along the opposite outer surface of the three-dimensional warehouse.   5. The mold manufacturing area and / or the casting process area has a two-layer structure, and an upper layer portion thereof is a main model model, a core model, and a core manufacturing area. Foundry.   The foundry according to claim 5, wherein the first floor of the mold production area is a metal frame place, a main mold making place, a core setting place, and a mold matching place.

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