JP2010234398A - Casting sand treatment method and casting sand treatment apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a casting sand treatment method and apparatus which effectively reconditions casting sand. <P>SOLUTION: The casting sand treatment method successively performs: an information acquiring step in which casting information INcast concerning a casting mold 13 for molten metal to be poured in and solidification part information INsolid concerning a solidification part 15 to be cast are acquired ; a dissipation estimating step in which dissipation moisture amount and dissipation additive amount are estimated for casting sand 14 based on the information; an additive amount estimating step in which a new moisture amount and a new additive amount to be newly added to the casting sand 14 are estimated on the basis of the dissipation moisture amount and the dissipation additive amount estimated by the dissipation estimating step; an adding step in which the new moisture amount and the new additive amount are added to the casting sand 14; a preliminary kneading step in which the casting sand 14 is preliminarily kneaded in a preliminary kneading section 6; an aging step in which the casting sand 14 is aged in an aging container 7; and a secondary kneading step in which the aged casting sand 14 is secondary-kneaded in the secondary kneading section 8. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a foundry sand treatment method and a foundry sand treatment apparatus for regenerating foundry sand.

  In Patent Document 1, each type of mold is separated into casting sand that is affected by the heat of the molten metal and casting sand that is not affected by the heat. Add the agent and adjust the moisture to make the adjusted sand, mix the casting sand that is not affected by the heat of the molten metal and the adjusted sand at a predetermined ratio, then perform the final moisture adjustment and final casting A method for obtaining sand is disclosed.

  Also in Patent Document 2, the foundry sand that is affected by the heat of the molten metal and the uncast sand that is not affected by the heat are recovered in a separated state. And adjusting the moisture to make the adjusted sand, blending the casting sand and the adjusted sand not affected by the heat of the molten metal at a predetermined ratio, and then adjusting the final moisture and final casting sand Is disclosed.

JP 2001-242745 A Japanese Patent Laid-Open No. 10-249482

  According to the technique described above, the foundry sand is not necessarily regenerated effectively. In the industry, there is a demand for the development of a foundry sand treatment method and a foundry sand treatment apparatus that can effectively regenerate the foundry sand.

  The present invention has been made in view of the above-described circumstances, and stores information on mold information related to a mold poured in a pouring part and solidification part information related to a solidified part solidified by the mold in an information acquisition unit. A casting that effectively regenerates the foundry sand by adding water and added amount to the pre-kneaded foundry sand based on the mold information and the solidified part information stored in the part, and further aging, followed by secondary kneading. It is an object to provide a sand treatment method and a foundry sand treatment apparatus.

  The casting sand treatment method according to the present invention separates a molding part for molding a mold from the casting sand and the solidified part solidified in the mold with respect to the mold into which molten metal is poured. A separation unit, a pre-kneading unit for adding water and additives to the foundry sand separated from the solidification unit and pre-kneading, a sand ripening container for storing and aging the pre-kneaded foundry sand, and aging In the foundry sand processing method using a secondary kneading part for adjusting the ingredients for the foundry sand, the mold information relating to the mold poured in the pouring part and the solidified part relating to the solidified part solidified in the mold Based on the information acquisition step of acquiring information to the information acquisition unit, and the mold information and the solidification unit information of the information acquisition unit, the amount of lost water and the amount of lost additive of the foundry sand before preliminary kneading are estimated. Disappearance estimation step and Based on the lost water amount and the lost additive amount estimated in the lost amount estimating step, an added amount estimating step for estimating a new water amount and a new additive amount to be newly added to the foundry sand to be pre-kneaded, A pre-kneading step of pre-kneading the foundry sand in the pre-kneading section with the new moisture content and the new additive amount added to the foundry sand, and the pre-kneaded foundry sand in the aging container An aging step for aging and a secondary kneading step for secondarily kneading the aged casting sand in the secondary kneading unit are performed in order.

  (2) The foundry sand processing apparatus according to the present invention includes a molding part for molding a mold with the foundry sand, and a solidified part solidified in the casting sand and the mold with respect to the mold into which molten metal is poured. A pre-kneading unit for pre-kneading by adding water and additives to the foundry sand separated from the solidifying unit, and a sand aging container for storing and aging the pre-kneaded foundry sand , A secondary kneading unit for adjusting the components of the aged casting sand, and a control unit having an information acquisition unit, wherein the control unit is a mold poured in the pouring unit Information acquisition step for acquiring information on the mold and solidified part information on the solidified part solidified by the mold in the information acquiring unit, and based on the mold information and the solidified part information of the information acquiring unit, before preliminary kneading Disappearance moisture content and disappearance addition of the foundry sand A new amount of water and a new additive newly added to the foundry sand to be pre-kneaded based on the amount of lost water and the amount of lost water estimated in the amount of lost water estimated step A pre-kneading step for pre-kneading the foundry sand in the pre-kneading section in a state where the new water content and the new additive amount are added to the foundry sand, and a pre-kneading step. An aging step of aging the cast sand that has been aged in the aging container, and a secondary kneading step of secondaryly kneading the aged casting sand in the secondary kneading unit are sequentially performed.

  (3) According to the method and apparatus of the present invention, in the information acquisition step, the mold information related to the mold poured in the pouring part and the solidified part information related to the solidified part solidified by the mold are acquired. In this case, the mold information and the solidification part information are stored in the information acquisition unit in advance, and a signal that detects a physical quantity related to the mold type for which molding has been completed or for which pouring has been completed is transmitted to at least sensors, auxiliary equipment, and workers. One may cause the control unit to acquire mold information and solidification unit information related to the mold poured by the pouring unit by causing the control unit to input one. In the lost amount estimation step, the lost water amount and the lost additive amount of the foundry sand before preliminary kneading are estimated based on the mold information and the solidified portion information acquired by the information acquisition unit.

  In the addition amount estimation step, a new water amount and a new additive amount to be newly added to the pre-kneaded foundry sand are estimated based on the lost water amount and the lost additive amount estimated in the lost amount estimation step. In the pre-kneading step, the foundry sand is pre-kneaded in the pre-kneading section in a state where a new water amount and a new additive amount are added to the foundry sand in which the mold is collapsed. In the aging step, the pre-kneaded foundry sand is aged in an aging container. In the secondary kneading step, the aging foundry sand is secondarily kneaded in the secondary kneading section.

  According to the present invention, in the information acquisition step, the information acquisition unit acquires the mold information related to the mold poured in the pouring part and the solidified part information related to the solidified part solidified by the mold. The foundry sand can be effectively regenerated based on the acquired mold information and solidified part information.

1 is a block diagram of an entire apparatus according to Embodiment 1. FIG. It is a figure which shows a part of area of an information acquisition part. It is sectional drawing which concerns on Example 1 and shows an example of the laminated structure of the foundry sand stored in the storage container. FIG. 6 is a diagram illustrating a part of a flowchart executed by a control unit according to the first embodiment. It is a figure which shows an example of the structure which concerns on another Example and is equipped with the some storage container and the some aging container.

  According to one aspect of the present invention, the foundry sand before preliminary kneading is stored in a storage container. Moreover, according to one viewpoint of this invention, the storage container which stores the casting sand before preliminary kneading | mixing is provided. According to one aspect of the present invention, the cooling unit includes a cooling unit that cools the foundry sand by adding a coolant to the foundry sand separated by the separating unit. An example of the coolant is water. In this case, the control unit performs a cooling step of estimating and adding the amount of coolant to be added to the foundry sand based on the mold information and the solidification unit information stored and acquired in the information acquisition unit. Is preferred.

  According to one aspect of the present invention, the mold information includes the weight and / or volume of the mold, the contact area where the solidified portion and the mold are in contact with each other, the amount of moisture contained in the foundry sand constituting the mold, and the mold. At least one of the amounts of additives contained in the foundry sand. Preferably, the solidified part information is at least one of a weight and / or volume of the solidified part, a surface area of the solidified part, and a pouring temperature.

  According to one aspect of the present invention, the information acquisition unit includes a foreign matter information acquisition unit that stores and acquires physical quantities related to the weight and / or volume of foreign matters other than the foundry sand and the solidified portion separated by the separation unit. In the disappearance amount estimation unit step, the control unit takes into account the physical quantity related to the weight and / or volume of the foreign material, that is, the lost water amount and the lost additive amount of the foundry sand that does not include the foreign material and is stored in the storage container. Is estimated.

  According to one aspect of the invention, preferably the amount M2 of additive added to the foundry sand in the pre-kneading step is greater than the amount M3 of additive added to the foundry sand in the secondary kneading step (M2 > M3). This is because, in the aging step performed after the preliminary kneading step, the aging effect of the foundry sand is enhanced to improve the quality of the foundry sand.

  Preferably, the amount of water W3 added to the foundry sand in the secondary kneading step is larger than the amount of water W2 added to the foundry sand in the preliminary kneading step (W3> W2). The reason why the amount of water W2 is relatively small is to allow the foundry sand aged in the aging container to be discharged well from the aging container.

  Embodiment 1 of the present invention will be specifically described below with reference to FIGS. The casting sand processing apparatus according to this embodiment includes (i) a molding part 1 for molding a mold 13 with casting sand, and (ii) a molten metal in the casting sand and the mold 13 with respect to the mold 13 into which the molten metal is poured. A separation part 2 that separates the solidified part 15 that has been solidified, (iii) a foreign substance removal part 3 that removes foreign substances such as metal and dust, and (iv) a casting that is separated from the solidified part 15 and from which foreign substances have been removed. A cooling unit 4 that cools the foundry sand 14 by adding cooling water that functions as a coolant to the sand 14, and (v) temporarily stores the foundry sand 14 cooled by the cooling unit 4 before the preliminary kneading step. A storage container 5 to be stored, (vi) a pre-kneading section 6 for adding and kneading both water and additives to the foundry sand 14 discharged from the storage container 5, and (vii) storing the pre-kneaded foundry sand 14 Aged in the aging container 7 and (viii) the aging container 7 A secondary kneading section 8 for the final component adjustment to Monosuna 14, and (ix) the control unit 9.

  The control unit 9 includes an input processing circuit 90, an output processing circuit 91, a CPU 93, and an information acquisition unit 94 (hereinafter also referred to as an acquisition unit) that functions as a storage unit that acquires data. The acquisition unit 94 is an internal storage medium such as a memory or a hard disk mounted on the control unit 9, but may be formed of an external storage medium such as a CDR, a memory card, or a USB memory. In the apparatus according to the present embodiment, N types of castings can be cast. Therefore, N types of molds 13 having different casting cavities can be molded by the molding machine of the molding unit 1.

  In the molding step, in the molding unit 1, the molding machine continuously molds the mold 13. The foundry sand 14 constituting the mold 13 is formed of fresh sand containing moisture and additives. A typical additive is bentonite. When the mold 13 is molded by the molding machine, an information acquisition step is executed, and the model information S1 of each molded mold 13 is input to the control unit 9 from the sensor 1s of the molding machine, Acquired by being stored in the area. Not limited to this, the operator may store the model information S1 of the molded mold 13 in a predetermined area of the acquisition unit 94 from a switch and / or a personal computer.

Here, the relationship between the type information S1 (S1 ₁ , S1 ₂ , S1 ₃ , S1 ₄ ...) Of the mold 13 and the mold information INcast regarding the mold 13 is stored in advance in the area of the acquisition unit 94 of the control unit 9. (See FIG. 2). Furthermore, the relationship between the type information S1 (S1 ₁ , S1 ₂ , S1 ₃ , S1 ₄ ...) Of the mold 13 and the solidified part information INsolid related to the solidified part 15 solidified by the mold 13 is obtained by the control unit 9. 94 are stored in advance (see FIG. 2). Therefore, when the model information S1 (S1 ₁ , S1 ₂ , S1 ₃ , S1 ₄ ...) Of the mold 13 is recognized by the control unit 9 and / or the operator, the control unit 9 and / or the operator 13 and the solidified part information INsolid relating to the solidified part 15 solidified by the mold 13 can be grasped. The model information S1 described above may be a physical quantity related to the mold 13 instead of the model itself.

  Here, the mold information INcast is information about the mold 13, and the weight and / or volume of the casting sand portion of the mold 13, the contact area where the solidified portion 15 where the molten metal solidifies in the mold 13 and the mold 13 contact each other (the mold 13 Corresponding to the area where moisture and additives are reduced by receiving the heat of the molten metal), the thickness of the mold 13 receiving the heat of the molten metal in the contact area (moisture and additives receiving the heat of the molten metal in the mold 13) Corresponding to the thickness of the foundry sand to be reduced), the amount of water contained in the foundry sand 14 constituting the mold 13 to be poured, and the foundry sand 14 constituting the mold 13 to be poured. The amount of the additive, the molten metal, the contact time between the solidified portion 15 and the mold 13 (related to the amount of water and additive in the foundry sand 14 are reduced) and the like are included. Note that the weight of the mold 13 can be obtained by multiplying the casting sand volume of the mold 13 by the specific gravity.

  The solidified part information INsolid includes the weight and / or volume of the solidified part 15, the surface area of the solidified part 15 (corresponding to the part of the mold 13 that is affected by the heat of the molten metal), and the pouring temperature (of the molten metal of the mold 13). Corresponding to the degree of thermal influence). The solidification part 15 is a site | part which solidified the molten metal, and contains the solidification site | part in a runner, a gate, and a dam other than the casting used as a product. The S / M ratio is the weight ratio of sand / metal, that is, the weight ratio of foundry sand 14 / solidified portion 15 per one mold 13. When the area of the runway, the gate, and the weir through which the molten metal flows increases, it affects the thermal deterioration of the foundry sand 14. The S / M ratio may be positioned as the mold information INcast. The mold information INcast and the solidified part information INsolid are unique to the mold 13 having the model.

Next, a pouring step is performed in the pouring unit 15. In the pouring part 15, a cast iron-based (for example, flake graphite cast iron and / or spheroidal graphite cast iron) high-temperature molten metal (for example, 1300 to 1600 ° C.) is placed in the casting cavity 13 x of the mold 13 molded by the molding machine of the molding unit 1. (Within range) is poured. When pouring is completed, the information acquisition step is executed again. In this information acquisition step, the type information S1 (S1 ₁ , S1 ₂ , S1 ₃ , S1 ₄ ...) Of the mold 13 relating to the mold 13 for which pouring has been completed by the pouring machine 15 of the pouring unit 15 is performed. .., Etc.) are stored in a predetermined area of the acquisition unit 94 of the control unit 9 and acquired. In this case, the operator may cause the mold information S1 of the mold 13 for which pouring has been completed to be acquired as mold information in the area of the acquisition unit 94 of the control unit 9 from a switch or a personal computer.

  In this embodiment, the molten metal is poured into the mold 13 by the pouring unit 15. The molten metal to be poured gradually solidifies in the cavity 13x of the mold 13 to become a solidified portion 15. A delivery sensor 15 s is provided for detecting that the mold 13 that has been poured is sent to a subsequent process. Input from the sending sensor 15s and / or the operator to the control unit 9 and acquired in a predetermined area of the acquisition unit 94. Thus, by the time when the predetermined time t1 has elapsed from the start time t0, the information Snum of the number of the molds 13 sent out from the pouring unit 15 to the subsequent process, the order thereof, and the type information S1 of the sent out molds 13 are sent to the control unit. 9 is stored as mold information in the area of the acquisition unit 94 and grasped.

  In addition, since moisture and additives are not basically consumed for the mold 13 that has not been poured, the signal for non-pouring is controlled by the feed sensor 15s, a switch operated by the operator, a personal computer, or the like. The data is input to the unit 9 and stored in a predetermined area of the acquisition unit 94 to be acquired. As a result, the information Sno-num of the number of unpoured molds 13, the order thereof, and the type information S1 of the molds 13 are transferred to the area of the acquisition unit 94 of the control unit 9, although they are transferred from the pouring unit 15 to the subsequent process. It is stored and grasped as mold information.

  Next, a separation step is performed in the separation unit 2. In this case, the collapsing device of the separation unit 2 collapses the mold 13 in which the solidification unit 15 is embedded. As a result, the casting sand 14 in which the mold 13 after the molten metal has solidified is separated into the solidified portion 15 in which the molten metal has solidified. As described above, the solidified portion 15 includes a cast iron solidified portion of a gate, a runner, and a weir in addition to the product casting. A signal of the weight Wsep of the foundry sand 14 existing in the separation unit 2 is input from the sensor 2s of the separation unit 2 to the control unit 9, and is stored and acquired as mold information in a predetermined area of the acquisition unit 94. In some cases, the operator may input a signal of the weight Wsep of the foundry sand 14 existing in the separation unit 2 from the switch and / or the personal computer to the control unit 9 and acquire it in a predetermined area of the acquisition unit 94. good.

  Next, the foreign matter removing unit 3 performs a foreign matter removing step. In this case, the foreign matter 14 y such as a bullion or a dama contained in the foundry sand 14 is separated from the foundry sand 14. As a result, the foreign matter 14 y is removed from the foundry sand 14. The weight Wf of the foreign matter 14y is detected by the foreign matter sensor 3s which is a weight sensor, and the signal from the foreign matter sensor 3s is input to the control unit 9 and acquired as mold information INcast and the weight of the foreign matter in a predetermined area of the acquisition unit 94. The The weight Wf of the foreign matter 14y is acquired as mold information INcast and the weight of the foreign matter in a predetermined area of the acquisition unit 94 of the control unit 9 so that it is not measured as the weight of the foundry sand 14. Thereby, the exact weight of the foundry sand 14 after collapsing the mold 13 is grasped in a state in which the foreign matter 14y is not included. The signal of the weight Wdiffe of the foundry sand 14 existing in the foreign matter removing unit 3 is input from the sensor 30s of the foreign matter removing unit 3 to the control unit 9, and stored and acquired as mold information INcast in a predetermined area of the obtaining unit 94. Is done. In some cases, the operator inputs a signal of the weight Wdiffe of the foundry sand 14 existing in the foreign substance removing unit 3 to the control unit 9 from a switch and / or a personal computer, and as mold information in a predetermined area of the acquisition unit 94 It may be stored and acquired.

  Next, a cooling step is performed in the cooling unit 4. In this case, in the cooling unit 4, water (coolant) is added as a water amount W <b> 4 to the foundry sand 14 separated by the separating unit 2 and from which the foreign matter 14 y has been removed, thereby cooling the foundry sand 14. Here, the cooling unit 4 promotes the vaporization of water by reducing the atmosphere containing the cooling container 41 by adding water to the foundry sand 14 and the mixture, and the latent heat due to the vaporization of water. A decompressor 42 that generates an endothermic effect and lowers the temperature of the foundry sand 14. The signal of the weight Wcool of the foundry sand 14 existing in the cooling unit 4 is input from the sensor 4s of the cooling unit 4 to the control unit 9 and acquired as mold information INcast in a predetermined area of the acquisition unit 94. In some cases, the operator inputs a signal of the weight Wcool of the foundry sand 14 existing in the cooling unit 4 from the switch and / or the personal computer to the control unit 9, and as mold information INcast in a predetermined area of the acquisition unit 94. You may get it.

  According to the present embodiment, the control unit 9 performs the coolant estimation step, and based on the mold information INcast and the solidification unit information INsolid stored in the acquisition unit 94 by the previous information storage step, the control unit 9 or An operator calculates | requires the quantity W4 of the water (coolant) which should be added to the foundry sand 14 in a cooling step.

  In such a coolant estimation step, a map and / or calculation that defines the relationship between the mold information INcast and the solidified portion information INsolid described above and the amount of water (coolant) W4 to be added to the foundry sand 14 in the cooling step. The expression is acquired in advance in a predetermined area of the acquisition unit 94 of the control unit 9. Based on the mold information INcast and the solidification part information INsolid acquired as described above, the control unit 9 particularly contacts the contact area Scontact where the molten metal and the mold 13 are in heat transfer contact with the mold 13 and the molten metal information. Based on the data such as the casting sand thickness Tcontact, the pouring temperature, etc. that heat affects the mold 13 from the map and / or the calculation formula, the amount W4 of water (coolant) to be added to the casting sand 14 in the cooling step is determined. Ask. This is because the contact area Scontact, the foundry sand thickness Tcontact, and the pouring temperature are basically considered to have a great influence on the amount of water lost in the mold 13 during pouring. In some cases, the operator measures the moisture content of the foundry sand immediately before being supplied to the cooling unit 4 with a moisture sensor, determines the amount of water W4 according to the result of the moisture sensor, and the operator uses it to make a personal computer, a switch, etc. May be input to the control unit 9 and stored in a predetermined area of the acquisition unit 94 for acquisition.

  The control unit 9 or the operator adds an amount of water W4 corresponding to the water W4 from the water supply device 43 to the foundry sand 14 of the cooling unit 4. The signal S4 of the amount of water W4 added to the foundry sand 14 in the cooling step is stored in a predetermined area of the acquisition unit 94 of the control unit 9 by the control unit 9 or the operator as having been added with water.

  Next, a storage step is performed in the storage container 5 prior to pre-kneading. The purpose of the storage step is to increase the water absorption rate of the additive contained in the foundry sand. In this case, the foundry sand 14 cooled in the cooling step is charged into the storage chamber of the storage container 5 from the inlet 5 i at the upper end of the storage container 5 and temporarily stored in the storage chamber of the storage container 5. Note that the number of storage containers 5 is much smaller than the number of molds 13 formed by the molding unit 1. The number of storage containers 5 may be singular or plural. In a plurality of cases, the order in which the storage containers 5 are stored is specified in advance, and it is specified in advance that the plurality of storage containers 5 are stored so as to be filled in order. The data such as the flow path cross-sectional area and the height of the storage container 5 are stored in a predetermined area of the acquisition unit 94 in advance.

  Here, for example, from the start time to the time when the predetermined time t1 elapses, the number of molds 13f is N1, the number of molds 13s is N2, the number of molds 13t is N3, and in that order. It is assumed that the water has been heated and sent to the subsequent process. The molds 13f, 13s, and 13t are identified by signals stored in the acquisition unit 94 of the control unit 9 by the sensor 1s, the sensor 15s, or the operator.

  In this case, the total weight Wtotal of the cast sand 14 after pouring that is conveyed from the pouring unit 15 to the subsequent process is basically obtained by calculation as follows. That is, the weight W100 of one mold 13f and the number N1 of molds 13f supplied to the subsequent process from the pouring unit 15 are known and acquired by the acquisition unit 94. Furthermore, the weight W200 of one mold 13s and the number N2 of molds 13f supplied from the pouring unit 15 to the subsequent process are known and acquired in a predetermined area of the acquisition unit 94. Furthermore, the weight W300 of one mold 13t and the number N3 of molds 13t supplied to the subsequent process from the pouring part 15 are known. As described above, these pieces of information are acquired in the area of the acquisition unit 94 by signals from the sensors 1s and 15s and / or input by the operator. The foreign matter weight Wf is preferably subtracted from the weight of the foundry sand 14 conveyed from the pouring part 15 to the subsequent process so as not to be measured as the foundry sand 14. f represents a function. α1 represents a correction coefficient.

Wtotal = f [(W100 × N1 + W200 × N2 + W300 × N3−Wf) × α1]
Here, a storage amount sensor 5 s for detecting the stored weight of the foundry sand 14 stored in the storage container 5 is disposed at the bottom of the storage container 5. A storage weight signal W5 of the foundry sand 14 detected by the storage amount sensor 5s is input to the control unit 9 and acquired by the acquisition unit 94. Here, the discharge amount Wdischarge of the foundry sand 14 discharged from the outlet 5p of the storage container 5 is obtained based on a signal from the storage amount sensor 5s. Specifically, the storage amount sensor 5s detects the weight of the foundry sand 14 stored in the storage container 5 with the outlet 5p closed. Let this be Wbefore. After the outlet 5p is opened once and the foundry sand 14 stored in the storage container 5 is discharged from the outlet 5p, the weight of the foundry sand 14 stored in the storage container 5 is reduced with the outlet 5p closed again. This is detected by the storage amount sensor 5s. This is assumed to be Wafter (Wbefore> Wafter). At this time, the discharge weight Wdischarge of the foundry sand 14 discharged from the outlet 5p of the storage container 5 to the outside of the storage container 5 in one discharge from the storage container 5 is basically calculated as follows. Desired. f represents a function. α2 represents a correction coefficient. Wdischarge = f [(Wbefore−Wafter) × α2]
Whenever the outlet 5p of the storage container 5 is opened and the foundry sand 14 in the storage container 5 is discharged from the outlet 5p, the discharge weight Wdischarge of the foundry sand 14 discharged from the storage container 5 is obtained by the control unit 9. Regarding the number of discharges NA at which the foundry sand is discharged from the storage container 5, a signal of the lid opening switch 5c for detecting the opening of the lid 5m that opens the outlet 5p provided in the storage container 5 is input to the control unit 9, By being acquired in a predetermined area of the acquisition unit 94, it is detected by the control unit 9.

  Accordingly, considering the number of times the cover 5m of the outlet 5p of the storage container 5 is opened and the outlet 5p is opened, the casting sand 14 in the storage container 5 is discharged at the time when the predetermined time t1 has elapsed from the start time t0. The total discharge weight Wd-total discharged from 5p is obtained. As a result, Wtotal and Wd-total are known by the control unit 9.

  Further, the weight Wsep of the foundry sand 14 present in the separation unit 2 is known by the sensor 2s and is detected by the control unit 9. The weight Wdiffe of the foundry sand 14 present in the foreign matter removing unit 3 is known by the sensor 30s and is detected by the control unit 9. The weight Wcool of the foundry sand 14 present in the cooling unit 4 is known by the sensor 4s and is detected by the control unit 9. For this reason, the estimated weight Win for estimating the weight of the foundry sand currently stored in the storage chamber of the storage container 5 is basically estimated as follows. f represents a function. αin represents a correction coefficient. The correction coefficient αin can be appropriately set according to the structure of the sand treatment apparatus.

Win = f [(Wtotal−Wd−total−Wsep−Wdiffe−Wcool) × αin]
Here, the actual weight of the foundry sand stored in the storage chamber of the storage container 5 is always detected as Win-sensing by the storage amount sensor 5 s of the storage container 5 and is always input to the control unit 9. A ratio (Win / Win-sensing) between the estimated weight Win and the detected weight Win-sensing is β. When β is within a predetermined range (β1 <β <β2), the above estimation is considered correct. When β is outside the predetermined range (β1 <β <β2), the above-described estimation issues a warning to the warning unit 200, assuming that errors may be accumulated. Β1 and β2 can be set as appropriate according to factors such as the type and season of the foundry sand 14 by trial and error.

  For this reason, the control part 9 can grasp | ascertain the lamination | stacking state and lamination | stacking height of the foundry sand 14 in the inside of the present storage container 5 based on above-described information. Alternatively, the operator may estimate the lamination state and the lamination height of the foundry sand 14 in the current storage container 5, input the signal to the control unit 9, and store the signal in the acquisition unit 94. Here, when the foundry sand 14 is not discharged from the storage container 5, the laminated state of the foundry sand 14 in the storage container 5 is as shown in FIG. Is the order of the collapsed foundry sand 14. Based on the above example, from the outlet 5p of the storage container 5 toward the inlet 5i, the casting sand layer 13fo corresponding to the N1 molds 13f, the casting sand layer 13so corresponding to the N2 molds 13s, and the N3 molds 13t. Corresponding casting sand layers 13to are sequentially laminated.

  For example, the weight of the foundry sand 14 put into the preliminary kneading unit 6 once is defined as Wset (Wset> cast sand layer 13fo). The foundry sand having a weight Wset exists on the outlet 5p side of the storage container 5. In this case, when the foundry sand existing on the outlet 5p side of the storage container 5 is introduced into the preliminary kneading unit 6 once, as shown in FIG. 3B, the laminated state of the foundry sand 14 in the storage container 5 is The casting sand layer 13soa, which is a part of the casting sand layer 13so, and the casting sand layer 13to corresponding to the N3 molds 13t are sequentially laminated from the outlet 5p of the storage container 5 to the inlet 5i. In addition, the foundry sand newly thrown into the storage container 5 is laminated | stacked on the foundry sand layer 13to.

  As described above, every time pre-kneading is performed in the pre-kneading section 6, a part of the foundry sand 14 corresponding to the weight Wset of the foundry sand 14 existing in the vicinity of the outlet 5 p in the storage container 5 becomes the outlet 5 p of the storage container 5. Deducted from. The control unit 9 or the operator can recognize which type of casting sand of the casting mold 13 of the casting mold 13 is charged into the preliminary kneading unit 6 at one time (step S100). According to the present embodiment, prior to such preliminary kneading, the foundry sand 14 stored in the storage container 5 is introduced into the preliminary kneader. A lost amount estimation step is performed on the foundry sand 14 put into the preliminary kneader. In this case, based on the mold information INcast and the solidified part information INsolid acquired in the area of the acquisition unit 94, the control unit 9 determines the amount of lost water Wremoval from which water has been removed from the foundry sand 14 due to the high heat of the molten metal, and the molten metal. The amount of disappeared additive Mremoval that has disappeared due to the burning of the additive in the foundry sand 14 due to the high heat is estimated (step S200).

  In this case, the laminated state of the foundry sand 14 inside the storage container 5 is estimated by the control unit 9. For this reason, it is determined whether the foundry sand 14 introduced into the preliminary kneading unit 6 from the outlet 5p of the storage container 5 is derived from the mold 13f, the mold 13s, or the mold 13t. Furthermore, the amount W4 of water added to the foundry sand 14 by the cooling unit 4 and the amount of water reduced by vaporization from the foundry sand 14 in the cooling unit 4 are also known from the map and / or the arithmetic expression, and the obtaining unit 94 Have been acquired in a certain area.

  Therefore, the control unit 9 estimates the lost water amount Wremoval from which the moisture has been removed from the foundry sand 14 put into the preliminary kneading unit 6 by the high heat of the molten metal. Further, the control unit 9 estimates the disappearance additive amount Mremoval from which the additive has been removed from the foundry sand 14 put into the preliminary kneading unit 6 by the high heat of the molten metal. Here, in the mold 13 into which the high-temperature molten metal is poured, the contact area Scontact where the molten metal and the mold 13 are in heat transfer contact and the casting sand thickness Tcontact where the heat of the molten metal thermally affects the mold 13 are as follows. It is an eigenvalue in the mold 13. Therefore, the lost water amount Wremoval is basically estimated as follows. Here, the lost water amount Wremoval and the lost additive amount Mremoval are basically estimated as follows. f represents a function. αwr-contac and αmr-contact indicate correction values. The correction value αwr-contac and the correction value αmr-contact can be changed according to the structure of the sand treatment device, the mold, the season, the humidity of the outside air, and the like.

Wremoval = f (Scontact × Tcontact × αwr-contact)
Mrmoval = f (Scontact × Tcontact × αmr-contact)
For the lost water amount Wremoval, the moisture content contained in the foundry sand 14 immediately before being preliminarily kneaded and discharged from the outlet 5p of the storage container 5 is actually measured by a moisture sensor, and the measured value From this, the lost water amount Wremoval may be obtained.

  Next, an addition amount estimation step is performed. In this case, based on the lost water amount Wremoval and the lost additive amount Mremoval estimated in the lost amount estimation step, the insufficient moisture amount Wshortage and the insufficient additive amount Mshortage deficient in the foundry sand 14 constituting the mold 13 are estimated ( Step S300). It can be considered that the deficient moisture amount Wshortage substantially corresponds to the lost moisture amount Wremoval. It can be considered that the shortage additive amount Mshortage substantially corresponds to the disappearance additive amount Mremoval. For this reason, the deficient moisture amount Wshortage and the deficient additive amount Mshortage deficient in the foundry sand 14 are estimated as follows. Here, f represents a function. α4 and α5 indicate correction coefficients. The correction coefficients α4 and α5 can be changed according to the structure of the sand treatment device, the mold, the season, the humidity of the outside air, and the like.

Wshortage = f (Wremoval × α4)
Mshortage = f (Mremoval × α5)
In this case, a moisture amount W2 corresponding to the insufficient moisture amount Wshortage and an additive amount M2 corresponding to the insufficient additive amount Mshortage are estimated (step S400), and the moisture amount W2 and the additive amount M2 are obtained by the preliminary kneading unit 6. Each is added to the pre-kneaded foundry sand 14 (step S500). In this state, the pre-kneading unit 6 stirs the foundry sand 14 with a stirrer and pre-kneads it (pre-kneading step). Thereby, the water content and additive amount of the foundry sand 14 affected by the heat of the molten metal are adjusted.

  Next, an aging step is performed in the aging container 7. In this case, the casting sand 14 preliminarily kneaded in the preliminary kneading step is charged into the aging container 7. In that state, the foundry sand 14 is held for a predetermined time (for example, within a range of 1 to 4 hours), and the foundry sand 14 is aged in the aging container 7. Since bentonite which is a typical example of the additive is blended in the foundry sand 14 and stored and aged while absorbing water, the caking property of the foundry sand 14 gradually increases as the aging time elapses. The fluidity of the sand 14 decreases.

  When the aging step is completed, the secondary kneading step is then performed in the secondary kneading unit 8. In this case, the casting sand 14 after aging discharged from the outlet 7p of the aging container 7 is put into a secondary kneader and secondarily kneaded. In this state, water is added to the foundry sand 14 in the secondary kneading unit 8. Here, the amount of water added to the foundry sand 14 in the secondary kneading step is defined as W3. The amount of water W3 added in the secondary kneading step is larger than the amount of water W2 added in the preliminary kneading step (W3> W2). If it is necessary to add an additive in the secondary kneading step, the additive is added to the foundry sand 14. Let M3 be the amount of additive added in the secondary kneading step. Since the foundry sand after the secondary kneading step has been regenerated well, it is supplied to the molding unit 1 and the mold 13 is molded by the molding machine in the molding unit 1. The mold 13 may be framed or unframed.

  Here, with respect to the water added to the foundry sand 14, the amount of water W2 added in the preliminary kneading step may be larger than the amount of water W3 added in the secondary kneading step (W2> W3). However, in this case, the amount of water contained in the foundry sand 14 that is aged in the aging container 7 becomes larger. As a result, the caking property of the foundry sand 14 aged in the aging container 7 becomes excessive, and the fluidity of the foundry sand 14 aged in the aging container 7 may be lowered. In this case, when the aging step is completed, there is a problem that the aged casting sand 14 is difficult to be discharged from the outlet 7p of the aging container 7. Considering this, W3> W2, and water is added to the foundry sand 14 in the secondary kneading step.

  Further, regarding the amount of additive added to the foundry sand 14, the amount M3 of additive added in the secondary kneading step is made larger than the amount M2 of additive added in the preliminary kneading step (M3). > M2) is also conceivable. However, in this case, the amount of additive in the foundry sand 14 aged in the aging container 7 is small. As a result, the aging effect of the foundry sand 14 is not sufficiently obtained in the aging step, and the caking property of the aged foundry sand 14 may not be sufficiently obtained. Here, the caking property of the foundry sand 14 to which the additive is added has a property of gradually increasing as time passes. Therefore, even if a large amount of additive is added to the foundry sand 14 in the secondary kneading step after the ripening step, the caking property of the foundry sand 14 may not be sufficiently obtained because the aging time is short. . In this regard, according to the present embodiment, the amount of the additive added to the foundry sand 14 is in a relationship of M2> M3. For this reason, the required amount of additive is mostly added and kneaded in the preliminary kneading step. Therefore, the aging time of the foundry sand 14 containing the additive is sufficiently secured, the caking property of the foundry sand 14 for forming the mold 13 is sufficiently obtained, and it can contribute to increasing the strength of the mold 13.

  The present embodiment basically has the same configuration and the same function and effect as the first embodiment. When the molten metal held in the ladle poured into the cavity of the mold 13 by the pouring part 15 becomes empty, the pouring step is stopped for a predetermined time. For this reason, conveying the casting mold 13 for which pouring has been completed to the subsequent process is interrupted. Even in this case, the foreign matter removing step in the foreign matter removing unit 3, the cooling step in the cooling unit 4, the storing step in the storage container 5, the preliminary kneading step in the preliminary kneading unit 6, and the secondary kneading step in the secondary kneading unit 8 are performed. Each has been implemented. Therefore, when the interruption time exceeds a predetermined time, the foundry sand existing in the foreign matter removing unit 3, the foundry sand present in the cooling unit 4, the foundry sand present in the storage container 5, and the foundry sand present in the preliminary kneading unit 6 The foundry sand present in the secondary kneading part 8 is once emptied. This can be reset. If the reset is performed in this way, it is possible to suppress accumulation of errors of each physical quantity over a long period of time. Therefore, the foundry sand present in the foreign matter removing unit 3, the foundry sand present in the cooling unit 4, the foundry sand present in the storage container 5, the foundry sand present in the preliminary kneading unit 6, and present in the secondary kneading unit 8. It is preferable that the reset step for emptying the foundry sand is appropriately performed as necessary.

  The present embodiment basically has the same configuration and the same function and effect as the first and second embodiments. However, the amount of water W3 added to the foundry sand 14 in the secondary kneading step is approximately the same as the amount of water W2 added to the foundry sand 14 in the preliminary kneading step (W3≈W2, W3 = W2). Thereby, the foundry sand 14 can be sufficiently absorbed. However, since the caking property of the foundry sand aged in the aging container 7 is improved and the fluidity of the foundry sand 14 is lowered, the opening area of the outlet 7p of the aging container 7 is preferably increased.

  FIG. 5 shows a part of the fourth embodiment. The present embodiment basically has the same configuration and the same function and effect as the first and second embodiments. In the following, different parts will be mainly described. According to the present embodiment, the number of storage containers 5 is much smaller than the number of molds 13 formed by the molding unit 1. As shown in FIG. 5, the storage container 5 is made into a plurality (three in this example), and has a first storage container 5a, a second storage container 5b, and a third storage container 5c. The foundry sand 14 cooled in the cooling step is sequentially charged from the storage chamber of the first storage container 5a, and when the storage chamber of the first storage container 5a is full, it is inserted into the storage chamber of the second storage container 5b. When the storage chamber of the second storage container 5s is full, the storage chamber of the third storage container 5c is charged.

  The number of aging containers 7 is much smaller than the number of molds 13 formed by the molding unit 1. A plurality of aging containers 7 are provided (three in this example), and each has a first aging container 7a, a second aging container 7b, and a third aging container 7c. The foundry sand 14 cooled in the cooling step is sequentially charged from the aging room of the first aging container 7a, and when the aging room of the first aging container 7a is full, it is charged into the aging room of the second aging container 7b. When the aging chamber of the second aging container 7s is full, the aging chamber of the third aging container 7c is charged.

  This embodiment basically has the same configuration and the same function and effect as those of the first to fourth embodiments. In the following, different parts will be mainly described. According to the present embodiment, the cooling unit 4 shown in FIG. 1 is not provided. The foundry sand that has passed through the foreign matter removing section 3 is left for a predetermined time and then stored in the storage container 5.

  This embodiment basically has the same configuration and the same function and effect as those of the first to fourth embodiments. In the following, different parts will be mainly described. According to the present embodiment, the foreign matter removing unit 3 shown in FIG. 1 is not provided. The foundry sand that has passed through the separation unit 2 is cooled in the cooling unit 4 and then stored in the storage container 5.

  (Others) The present invention is not limited to the embodiments and examples described above and shown in the drawings, and can be implemented with appropriate modifications within a range not departing from the gist. The following technical idea can also be grasped from the description of this specification.

  (Additional Item 1) A molding part for molding a mold with foundry sand, a separating part for separating the foundry sand and a solidified part solidified in the mold from the mold into which molten metal is poured, A pre-kneading part for adding water and additives to the foundry sand separated from the solidification part and pre-kneading, an aging container for storing and aging the pre-kneaded foundry sand, and the aged casting sand A foundry sand treatment method using a secondary kneading part for adjusting the components.

  (Additional Item 2) A molding part for molding a mold with foundry sand, a separation part for separating the foundry sand and a solidified part solidified in the mold with respect to the mold into which molten metal is poured, A pre-kneading part for adding and kneading water and additives to the foundry sand separated from the solidification part, an aging container for storing and aging the pre-kneaded foundry sand, and the aged casting sand A foundry sand treatment apparatus comprising a secondary kneading unit for adjusting components and a control unit.

  1 is a molding part, 2 is a separation part, 3 is a foreign matter removal part, 4 is a cooling part, 5 is a storage container, 6 is a preliminary kneading part, 7 is an aging container, 8 is a secondary kneading part, 9 is a control part, 94 Indicates an information acquisition unit.

Claims (7)

A molding part for molding a mold with foundry sand, a separation part for separating the casting sand and the solidified part solidified in the mold from the mold into which molten metal is poured, and a separation part separated from the solidified part. A pre-kneading part for pre-kneading by adding water and additives to the foundry sand, an aging container for storing and aging the pre-kneaded foundry sand, and adjusting the ingredients for the aged cast sand In the casting sand processing method using the secondary kneading part of
An information acquisition step of acquiring, in an information acquisition unit, mold information related to the mold poured by the pouring part and solidified part information related to the solidified part solidified by the mold, and the mold information and the solidification of the information acquisition unit Based on part information, the disappearance amount estimation step for estimating the disappearance moisture amount and the disappearance additive amount of the foundry sand before preliminary kneading, and the disappearance moisture amount and the disappearance additive amount estimated in the disappearance amount estimation step And an addition amount estimating step for estimating a new water amount and a new additive amount to be newly added to the pre-kneaded casting sand, and adding the new water amount and the new additive amount to the foundry sand. A pre-kneading step in which the foundry sand is pre-kneaded in the pre-kneading section, an aging step in which the pre-kneaded foundry sand is aged in the aging container, and before aging Molding sand processing method which comprises carrying out a secondary kneading step of secondary kneading molding sand in the secondary kneading section in order.   2. The foundry sand processing method according to claim 1, wherein the foundry sand before preliminary kneading is stored in a storage container. A molding part for molding a mold with foundry sand, a separation part for separating the casting sand and the solidified part solidified in the mold from the mold into which molten metal is poured, and a separation part separated from the solidified part. A pre-kneading part for pre-kneading by adding water and additives to the foundry sand, an aging container for storing and aging the pre-kneaded foundry sand, and adjusting the ingredients for the aged cast sand A secondary kneading unit, and a control unit having an information acquisition unit,
The controller is
An information acquisition step of acquiring, in an information acquisition unit, mold information related to the mold poured by the pouring part and solidified part information related to the solidified part solidified by the mold, and the mold information and the solidification of the information acquisition unit Based on the part information, the disappearance amount estimation step for estimating the disappearance moisture amount and the disappearance additive amount of the foundry sand before preliminary kneading, and the disappearance moisture amount and the disappearance additive amount estimated in the disappearance amount estimation step An addition amount estimation step for estimating a new water amount and a new additive amount to be newly added to the foundry sand to be pre-kneaded, and a state in which the new water amount and the new additive amount are added to the foundry sand A pre-kneading step for pre-kneading the foundry sand in the pre-kneading section, an aging step for aging the pre-kneaded foundry sand in the aging container, and the aged casting sand Sand processing apparatus characterized by carrying out a secondary kneading step of secondarily kneaded in the secondary kneading section in order.   4. The foundry sand processing apparatus according to claim 3, wherein a storage container for storing the foundry sand before preliminary kneading is provided.   The cooling unit according to claim 4, further comprising a cooling unit that cools the foundry sand by adding a coolant to the foundry sand separated by the separation unit, and before storing the foundry sand in the storage container, The control unit executes a coolant amount estimation step of estimating a coolant amount to be added to the foundry sand based on the mold information and the solidified portion information of the information acquisition unit. Processing equipment. 6. The mold information according to claim 3, wherein the mold information includes a weight and / or volume of the mold, a contact area where the solidified portion and the mold are in contact with each other, and the foundry sand constituting the mold. At least one of the amount of moisture and the amount of additive contained in the foundry sand constituting the mold,
The foundry sand processing apparatus, wherein the solidified part information is at least one of a weight and / or volume of the solidified part, a surface area of the solidified part, and a pouring temperature. 7. The foreign matter information acquisition unit according to claim 3, wherein the information acquisition unit stores a physical quantity related to the weight and / or volume of foreign matter other than the foundry sand and the solidified portion separated by the separation unit. Have
The controller estimates a lost water amount and a lost additive amount of the foundry sand stored in the storage container in consideration of a physical quantity related to the weight and / or volume of the foreign matter in the lost amount estimation step. A foundry sand processing apparatus.

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